8
LIGHTNING
®
941-753-7557 • FAX:941-753-6917 • 800 342-8477 • [email protected] • www.AmericanTorchTip.com
8
A. Wire not feeding or bumpy feeding
Possible Cause
Possible Solution
1. Feeder relay / malfunction
Consult feeder manufacturer.
2. Broken control lead
Connect spare control leads.
3. Poor adaptor connection
Test and replace leads and/or contact pins.
4. Incorrect type of drive roll
Use manufacturers recommended drive rolls
5. Improper drive rolls size
Replace with proper size.
6. Drive roll tension misadjusted
Adjust tension at feeder.
7. Burn back to contact tip
See “E.
Contact tip burn back
.”
8. Wrong size liner
Replace with correct size.
9. Buildup inside of liner
Replace liner, check condition of electrode.
10. Worn drive roll
Replace with new drive roll.
11. Improper guide tube relationship
Eliminate all gaps in electrode path.
12. Improper wire guide diameter
Replace with proper guide diameter.
13. Gaps at liner into gas diffuser
Reset liner and lock or replace with new liner
B. Premature contact tip failure
Possible Cause
Possible Solution
1. Improper voltage or wire feed speed
Set parameters.
2. Erratic wire feeding
See “G.
Erratic arc
.”
3. Improper tip stickout
Adjust nozzle/tip relationship.
4. Improper electrode stickout
Change length of wire stickout.
C. MIG Gun running hot
Possible Cause
Possible Solution
1. Exceeding duty cycle
Replace with properly rated duty cycle MIG Gun.
Decrease parameters to within Gun rating.
2.
Loose or poor power connection
Clean and retighten all electrical connection.
Check rating and condition of ground clamp.
D. Porosity in weld
Possible Cause
Possible Solution
1. Nozzle/Insulator/O-rings worn
Replace.
2. Retaining head spring/band
Replace retaining head.
3. Extreme heat or duty cycle
Use X-heavy-duty consumables.
4. Gas not getting to the weld
Check gas regulator/flowmeter/cylinder
5. Gas ports plugged
Clean or replace gas diffuser/nozzle.
6. Loose fittings or cut gas hose
Tighten or repair hose lines.
Lightning® Troubleshooting
