SECTION 10 — TROUBLESHOOTING
10-1 Troubleshooting Table
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
1. Electrode does not feed.
1. Feeder relay.
2. Broken control lead.
3. Poor adaptor connection.
4. Improper / worn drive roll.
5. Drive roll tension misadjusted.
6. Burn back to contact tip.
7. Wrong size liner.
8. Buildup inside of liner.
1. Consult feeder manufacturer.
2.
a.
Test and connect spare control lead.
b.
Install new cable.
3. Test and replace leads and/or contact pins.
4. Replace drive roll.
5. Adjust tension at feeder.
6. See ‘
Contact tip burn back
’.
7. Replace with correct size.
8. Replace liner or clean out with compressed air, check
condition of electrode.
2. Contact tip burn back.
1. Improper voltage and/or wire feed
speed.
2. Erratic wire feeding.
3. Improper tip stickout.
4. Improper electrode stickout.
5. Faulty ground.
1. Adjust parameters.
2. See ‘
Erratic wire feeding
’.
3. Adjust nozzle / tip relationship.
4. Adjust wire stickout.
5. Replace cables and/or connections.
3. Tip disengages from the
gas diffuser.
1. Worn gas diffuser/retaining head.
2. Improper tip installation.
3. Extreme heat or duty cycle.
1. Replace tip and/or gas diffuser / retaining head.
2. Install as per section 7-1 Changing Consumables on page
3. Replace with heavy duty consumables. See appropriate
Spec Sheet for details.
4. Short contact tip life.
1. Contact tip size
2. Electrode eroding contact tip.
3. Exceeding duty cycle.
1. Replace with proper size.
2. Inspect and/or change drive rolls.
3. Replace with properly rated Bernard MIG Gun.
5. Erratic arc.
1. Worn contact tip.
2. Buildup inside of liner.
3. Wrong tip size.
4. Not enough bend in neck.
1. Replace contact tip.
2. Replace liner, check condition of electrode.
3. Replace with correct tip size.
4. Replace with 45° or 60° neck.
6. Erratic wire feeding.
1. Buildup inside of liner.
2. Wrong size liner.
3. Improper drive roll size.
4. Worn drive roll.
5. Improper guide tube relationship.
6. Improper wire guide diameter.
7. Gaps at liner junctions.
8. Feeder malfunction.
9. Worn contact tip.
1. Replace liner, check condition of electrode.
2. Replace with new liner of proper size.
3. Replace with proper size drive roll.
4.
a.
Replace with new drive roll.
b.
Repair worn drive roll.
5. a. Adjust / replace guide as close to drive rolls as
possible.
b. Eliminate all gaps in electrode path.
6. Replace with proper guide diameter.
7.
a.
Replace with new liner trimmed as per section 7-4
Changing the Liner on page 18.
b.
Replace guide tube / liner trimming as close to mating
component as possible.
8. Consult feeder manufacturer.
9. Inspect and replace.*
7. Extreme spatter.
1. Improper machine parameters.
2. Improper tip installation.
3. Improper shielding gas coverage.
4. Contaminated wire or workpiece.
1. Adjust parameters.
2. Adjust nozzle / tip relationship.
3.
a.
Verify shielding gas coverage.
b.
Verify gas mixture.
4. Clean wire and workpiece.
TG408-1.2
23
Summary of Contents for T-Gun 445-45
Page 29: ...NOTES TG408 1 2 25...
