®
www.harger.com
UltraShot Troubleshooting
Tips
P
r
oblem
P
ossible
C
a
use
Sug
gested Cor
rections
W
eld not sticking
to steel or cast iron
surface
Surface not prepared properly
Clean surface down to bright metal by either grinding or using tools suggested in the instructions.
Cable not placed in mold according to instructions
Be sure to follow the mold instruction on the placement of the conductors in the mold to make sure
sufficient
heat
is
transferred
to
the
steel
surface
to
make
the
weld.
Not using cast iron powder when
welding to cast iron surface
Order cast iron powder
.
Problems
welding
to
ground rod
Surface not prepared properly
Clean and prepare surfaces according to instructions.
Mold not supported during welding
Place
vice
grips
or
clamp
under
mold
to
support
it
during
welding
process.
Cable not placed in mold according to
instructions
Be sure to follow the mold instructions on the placement of the conductors in the mold to make sure
sufficient
heat
is
transferred
to
the
ground
rod
to
make
the
weld.
Mold does not close all the way or handle clamps won’t lock
Handle
clamp
is
not
adjusted
properly
Follow
instructions
on
adjusting
handle
clamp
to
adjust
them
properly
.
Dirt,
slag
or
other
material
stuck
in
the
parting line or on the dowel pins
Clean of
f all material to get a good seal.
Bent or out of round conductors
Straighten conductors or cut out bad sections and retry
.
Mold gets stuck on
weld
Mold left on weld too long
Remove
mold
from
weld
within
about
30
seconds
to
weld
being
made,
especially
on
welds
to
steel.
15
®
www.harger.com
®
www.harger.com
P
r
oblem
P
ossible
C
a
use
Sug
gested Cor
rections
Excessively high weld or excessive gas in
weld
Moisture or foreign substance on the
mold or conducturs
Preheat
molds
and
conductors
with
a
torch
to
a
temperature
that
will
burn
of
f any
water
or
organic
material.
Use
steel
brush
to
remove
any
residual
material
from
conductors.
Do
not
use
steel
brush
on
graphite mold.
W
rong
size
cartridge
used
Double
check
the
mold
ID
plate
to
make
sure
the
proper
weld
cartridge
is
being
used.
Moisture in weld metal
Replace
with
new
weld
metal.
Duct
seal
in
weld
cavity
Duct
seal
is
to
be
used
on
the
outside
portion
of
the
mold
only
as
a
last
resort.
If
it
has
to
be
used
do
not let it migrate into the weld cavity
.
Conductors pull out of mold during process
Conductors are under tension
Remove
tension
from
conductors
or
use
wire
clamp
GRCC
to
remove
tension
from
conductors.
Mold wearing out
too fast
Improper cleaning of molds
Only use soft bristle brush or cotton rag to clean out the mold. Use of metal brushes, screw
driver
, or
other
metal
objects
will
scratch
the
mold.
Also,
do
not
use
plastic
on
the
mold
as
it
will melt and cause gassy welds.
Bent, burred, or out of round
conductors
Closing the mold on conductors that are bent, burred, or out of round will crack and chip the molds.
Try removing the damaged sections if possible.
Inserting conductors after mold is
closed
Try to close the mold with the conductors already inserted.
This will reduce the wear on the
conductor openings.
UltraShot Troubleshooting
Tips
16
