ESAB Fabricator 181i, Service Manual

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ESAB FABRICATOR 181i
Manual 0-5449 6-1 TROUBLESHOOTING
6.01 Basic Troubleshooting-Power Source Faults
The following table is a guide for analysing problems and making repairs to the Power Source.
FAULT CAUSE REMEDY
1 Electricity Supply is
ON, power indicator is
illuminated however the
Power Source will not
commence welding.
A Power Source is not in the
correct mode of operation.
A Set the Power Source to the
correct mode of operation with the
process selection switch.
B Faulty torch trigger. B Repair or replace torch trigger
switch/lead.
2 Fault Indicator is
illuminated and the Power
Source will not commence
welding.
Duty cycle of Power Source
has been exceeded.
Leave the Power Source
switched ON and allow it to
cool. Note that fault indicator
must be extinguished prior to
commencement of welding.
3 The Power Source will not
feed wire in MIG mode.
A Electrode wire stuck in conduit
liner or contact tip (burn-back
jam).
A Check for clogged / kinked MIG
Gun conduit liner or worn contact
tip. Replace faulty components.
B MIG GUN/SPOOL GUN switch
is switched to SPOOL GUN.
B Switch the MIG GUN/SPOOL GUN
switch to MIG GUN.
4 Welding wire continues to
feed when torch trigger is
released.
A Trigger mode selection switch
is in 4T latch mode.
A Change the trigger mode selection
switch from 4T latch mode to 2T
normal mode.
B Torch trigger leads shorted. B Repair or replace torch trigger
switch/lead.
5 Welding arc cannot be
established in MIG mode.
A MIG Gun polarity lead is not
connected into a welding
output terminal.
A Connect the MIG Gun polarity
lead to either the positive welding
output terminal or the negative
welding output terminal as
required.
B Poor or no work lead contact. B Clean work clamp area and ensure
good electrical contact.
6 Inconsistent wire feed. A Worn or dirty contact tip. A Replace if necessary.
B Worn feed roll. B Replace.
C Excessive brake tension on
wire reel hub.
C Reduce brake tension on spool
hub
D Worn, kinked or dirty conduit
liner
D Clean or replace conduit liner
7 No gas flow in MIG mode. A Gas hose is damaged. A Replace or repair.
B Gas passage contains
impurities.
B Disconnect gas hose from the rear
of Power Source and blow out
impurities.
C Gas regulator turned off. C Turn on regulator.
D Empty gas cylinder. D Replace gas cylinder.
SECTION 6:
TROUBLESHOOTING