E-5
TROUBLESHOOTING
WIRE FEED MODULE™
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility
for technical troubleshooting assistance before you proceed.
CAUTION
3. Check to see that leads 2 and 4 are connected. Put a
voltmeter across these leads and the meter should read
close to zero volts. If voltage reads approximately 15
volts, then the trigger circuit (leads 2-4) is open. Check
the wiring from the WFM control box to the WFM control
panel for loose or broken connections. Turn machine
off and check the operation of the “LOCAL/REMOTE”
switch by connecting an ohmmeter across leads 2 and
4 at the switch with switch positioned in “LOCAL”
mode, if resistance is high or open replace the switch.
4. Check for coil voltage across leads 633 and 634 at
P2 plug to the P.C. Board. If voltage is present,
check for loose or broken leads from the plug to
the contactor coil. If connections are good and
voltage correct, replace contactor CR4.
5. If no voltage is present at CR4 contactor coil, see
Procedure for Replacing P.C. Boards.
5. Procedure for Checking the Capacitor Bank Contactor
(CR3)
1. Verify machine is in CV (wire) mode. Measure volt-
age across leads 630 and 631 at the contactor.
The voltage should be approximately 120 +/- 15V
DC with engine set on high idle. If voltage is not
present, go to step 3 of this procedure.
2. If the proper voltage is present at leads 630 - 631,
measure the voltage between L2 terminal and ter-
minal opposite L2. If the voltage is equal to the
output voltage across the positive and negative
output terminals, replace the contactor CR3.
3. If the proper voltage is not present at leads 630 -
631, check the wiring to CR3 coil for loose or bro-
ken connections. If connections are good, see
Procedure for Replacing P.C. Boards.
6. Checking Voltage Control Potentiometer on Machine
1. Turn machine off.
2. Remove the control panel screws and open the
front cover. Turn the “LOCAL/REMOTE” switch
(S2) to “REMOTE”.
3. Disconnect P.C. Board harness plug P2 from the
P.C. Board.
4. With an ohmmeter on X1K, connect it to lead 76A
and 77A on S2. Rotate the voltage control poten-
tiometer. The resistance reading should be from
approximately zero to 10K ohms. Check the resis-
tance reading between lead 75 on potentiometer
and 77A on switch S2. The reading must be 10K
ohms. No reading will indicate an open poten-
tiometer and a low reading will indicate a shorted
or partially shorted potentiometer; in either case,
replace. Reconnect P.C. Board plug P2.
7. Remote Control Check
1. The remote control connector pin assignments are:
pin G-75A, pin F-76B, pin E-77B. Make sure
remote control connections are tight and check for
any physical damage to the control cable. Connect
an ohmmeter across lead 75 and 76B on switch
S2. With S2 in remote mode, rotate the poten-
tiometer in the remote control. The resistance
reading should vary from zero to 10K ohms.
Repeat with ohmmeter across 77B and 76B with
the same results. Connect an ohmmeter across 75
and 77B. The reading should be 10K ohms. If an
open or short is measured replace the potentiome-
ter.
