-14-
H8153 DC Stick/TIG Pulse Welder
Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem devel-
ops. If you need replacement parts or you are unsure of your repair skills, then feel free to call our Technical
Support at (570) 546-9663.
SECTION 6: SERVICE
Troubleshooting
Symptom
Possible Cause
Possible Solution
Welder does not
power up or the
breaker trips.
1. Plug/receptacle is at fault or wired incor-
rectly.
2. Wiring is open/has high resistance.
3. ON/OFF switch is at fault.
4. Duty cycle has been exceeded.
1. Test for good contacts; correct the wiring.
2. Check for broken wires or disconnected/corroded
connections, and repair/replace as necessary.
3. Replace faulty ON/OFF switch.
4. Let the fan cool the welder.
Porosity (small cavi-
ties or holes caused
from gas pockets
in weld); poor weld
bead color.
1. Arc length is too long.
2. Workpiece is dirty or damp.
3. Damp electrodes.
4. Inadequate gas flow (TIG).
5. Incorrect electrode/filler metal used.
6. Loose fittings in torch/gas hoses (TIG).
1. Reduce length of arc.
2. Remove all grease, oil, moisture, coatings, rust, and
dirt from workpiece before welding; blow out all air
and moisture from gas lines.
3. Use dry electrodes.
4. Adjust gas flow rate as necessary.
5. Use correct type and size of electrode/filler metal.
6. Tighten torch/gas hose fittings; check gas hoses and
connections for leaks; replace if necessary.
Excessive spatter.
1. Amperage too high for electrode.
2. Voltage too high; arc length too long.
3. Incorrect electrode/tungsten rod used.
4. Incorrect gas or gas settings (TIG).
1. Select large electrode or decrease amperage.
2. Reduce voltage or arc length.
3. Use correct type and size of electrode/tungsten rod.
4. Use the correct gas for the welding operation; adjust
the gas flow as necessary.
Distortion of base
metal.
1. Excessive heat applied to base metal.
1. Make tack welds along joint before starting opera-
tion; select lower amperage for electrode; increase
travel speed; weld in small segments and allow cool-
ing between welds.
Burn through or
excessive penetra-
tion of base metal.
1. Excessive heat applied to base metal.
1. Select lower amperage; use smaller electrode;
increase and/or maintain steady travel speed.
Lack of penetration. 1. Improper joint preparation.
2. Improper weld technique.
3. Insufficient heat applied to weld.
4. Incorrect gas or gas settings (TIG).
1. Material too thick; joint preparation must provide
access to bottom of groove.
2. Keep arc on leading edge of weld puddle; reduce
travel speed.
3. Increase amperage; select larger electrode.
4. Use the correct gas for the welding operation; adjust
the gas flow as necessary.
Troubleshooting
