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REDI-MIG
®
Plus 215C, 255C, 255S
IM6016
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 exces-
sive 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.
WARNING
ELECTRIC
SHOCK
can kill
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box and unplug the ma-
chine before working on equip-
ment.
• Do not touch electrically hot
parts.
Section 9 - TROUBLESHOOTING
