IMA 603
REDI-MIG 455 Remote
Page 21
Section 9 - TROUBLESHOOTING
Problem
Rough wire feeding or
wire not feeding but
drive rolls turning.
Variable or “hunting”
arc.
Poor arc striking with
sticking or “blast offs”,
weld porosity, narrow
and ropey looking bead,
or electrode stubbing
into plate while welding.
Tip seizes in diffuser.
Possible Cause
Gun cable kinked and/or twisted.
Wire jammed in gun and cable.
Incorrectly fitted drive roll.
Drive roll loose.
Gun cable dirty.
Worn drive roll.
Electrode rusty and/or dirty.
Worn nozzle or cable liner.
Partially flashed or melted contact tip.
Incorrect idle roll pressure.
Wrong size, worn and/or melted contact
tip.
Worn work cable or poor work
connection.
Loose electrode connections.
Wrong polarity.
Improper procedures or techniques.
Improper gas shielding.
Tip overheating due to prolonged or
excessive high current and/or duty cycle
welding.
What To Do
Inspect gun cable and replace if necessary.
Remove wire from gun and cable - feed in new
wire. Note any obstructions in gun and cable.
Replace gun and cable if necessary.
See Wire Drive Roll Section in this manual for
proper installation of drive roll.
Remove, clean, install and tighten.
Clean cable or replace liner.
Replace.
Replace.
Replace.
Replace contact tip.
Set idle roll pressure.
Replace tip - remove any spatter on end of tip.
Inspect - repair or replace as necessary.
Be sure electrode lead is tight, gun cable tight in
wire feeder contact block, gun nozzle and gun tip
tight. All work lead connections must be tight.
Check connection at output studs for polarity
required by welding process.
See “Gas Metal Arc Welding Guide” (GS100).
Clean gas nozzle. Make certain that gas diffuser
is not restricted. Make certain that gas cylinder is
not empty or turned off. Make certain gas
solenoid valve is operating and gas flow rate is
correct.
Remove gun liner and check rubber seal for any
sign of deterioration or damage. Be sure set
screw in brass connector is in place and
tightened against the liner bushing.
Do not exceed current and duty cycle rating of
gun.
A light application of high temperature antiseize
lubricant may be applied to tip threads.
• Have an electrician install and
service this equipment.
• Turn the input power off at the fuse
box, or unplug input lead before
working on equipment.
• Do not touch electrically hot parts.
ELECTRIC
SHOCK
can kill
WARNING
