8
Wire Feed Arc Welder
Troubleshooting Chart - Welder
Symptom
Possible Cause(s)
Corrective Action
1. Duty cycle exceeded
2. Poor work clamp connection
3. Defective power switch
4. Blown breaker or fuse
1. Wrong size gun tip
2. Gun liner clogged or
damaged
3. Gun tip clogged or damaged
4. Feed roller worn
5. Not enough tension
Slag inside gun nozzle
Poor contact
1. Wire jammed
2. Out of wire
3. Not enough tension
4. Wire liner worn
5. Fuse blown
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Bead is intermittently too
thin
Bead is intermittently too
thick
Ragged depressions at
edge of weld
Weld bead does not
penetrate base metal
Wire sputters and sticks
1. Inconsistent travel speed
2. Output heat setting too low
1. Slow and/or inconsistent travel
speed
2. Output heat setting too high
1. Travel speed too fast
2. Wire speed too fast
3. Output heat setting too high
1. Inconsistent travel speed
2. Output heat setting too low
1. Damp wire
2. Wire speed too fast
1. Allow welder to cool until ON/OFF Switch lamp goes out
2. Be sure all connections are secure, and attaching surface is
clean
3. Replace switch
4. Reduce circuit load, reset breaker or replace fuse
1. Use proper size gun tip
2. Clean or replace gun liner
3. Clean or replace gun tip
4. Replace
5. Tighten tensioning screw
Clean slag from gun nozzle
Be sure all connections are secure, and attaching surface is
clean
1. Reload wire
2. Replace wire spool
3. Tighten tensioning screws if wire is slipping
4. Replace liner
5. Replace fuse on wire feed control board inside welder,
(1.6 amp time delay)
No output
Wire tangles at drive roller
Gun nozzle arcs to work
surface
Work clamp and/or cable
gets hot
Wire does not feed
Troubleshooting Chart - Welds
Symptom
Possible Cause(s)
Corrective Action
1. Decrease and maintain constant travel speed
2. Increase output heat setting
1. Increase and maintain travel speed
2. Reduce output heat setting
1. Decrease travel speed
2. Decrease wire speed
3. Reduce output heat setting
1. Decrease and maintain constant travel speed
2. Increase output heat setting
1. Use dry wire and store in dry location
2. Reduce wire speed
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