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Item 63621
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Troubleshooting – MIG / Flux-Cored Welding
IMpORTANT!
Be cERTAIN to shut off the Welder, disconnect it from power, and discharge the MIg gun to
ground before adjusting, cleaning, or repairing the unit.
problem
possible causes
Likely Solutions
Wire Feed Motor
Runs but Wire Does
Not Feed Properly
1. Insufficient wire feed pressure.
2. Incorrect wire feed roller size.
3. Damaged MIG Gun, cable, or liner assembly.
4. Feed Tensioner is too tight.
1. Increase wire feed pressure properly.
Follow step 27 on page 17.
2. Flip roll to correct size. Follow the Feed
Roller instructions on page 12.
3. Have a qualified technician inspect these
parts and replace as necessary.
4. Loosen Feed Tensioner so it applies only
enough pressure to prevent continued
spinning after the Gun Trigger is released.
Wire Creates a
Bird’s Nest During
Operation
1. Excess wire feed pressure.
2. Incorrect Contact Tip size.
3. MIG Gun Cable Connector not fully
inserted into Wire Feed mechanism.
4. Damaged liner.
1. Adjust wire feed pressure properly.
Follow step 27 on page 17.
2. Replace with the proper tip for wire used.
3. Insert Gun Cable Connector properly.
Follow steps 13 and 14 on page 13.
4. Have a qualified technician inspect
and repair/replace as necessary.
Wire Stops
During Welding
1. Gun cable is severely bent and Wire
Feed mechanism cannot feed wire.
2. Gun liner is clogged or worn.
3. Gun liner is too small for
welding wire being used.
4. Wire is tangled on the spool.
5. Wire is not making contact with Feed Rollers.
6. Feed Roller is not making enough contact
with wire or is crushing flux-cored wire.
1. Straighten Gun cable.
2. Check gun liner for obstruction.
Replace if necessary.
3. Check that gun liner is correct size for wire.
4. Check wire for cross winding or tangled spool.
5. Check Feed Rollers and ensure correct
groove for wire diameter is being used.
6. Check Feed Tensioner and ensure it is set properly.
Welding Arc
Not Stable
1. Wire not feeding properly.
2. Incorrect Contact Tip or liner
size or excessive wear.
3. Incorrect wire feed speed.
4. Loose MIG Gun cable or ground cable.
5. Damaged MIG Gun or loose
connection within Gun.
6. Incorrect polarity for process being run.
7. Gas coverage may be insufficient or too high.
8. Poor connection with workpiece.
1. See first Troubleshooting section above.
2. Replace with the proper tip or
liner size for wire used.
3. Adjust wire feed speed to achieve
a more stable arc.
4. Check to ensure that all connections are tight.
5. Have a qualified technician inspect
and repair/replace as necessary.
6. Ensure polarity is correct for operation:
DCEP for MIG welding and DCEN for
Flux-Cored self-shielded welding.
7. Ensure gas flow rate is set according to
Settings Chart. Make sure MIG Gun Cable
Connector is fully inserted into Wire Feed
mechanism with no O-Rings exposed.
8. Check the ground clamp connection to
the workpiece and machine. Ensure
the MIG Gun is properly secured.
Weak Arc Strength
1. Incorrect line voltage.
2. Improper gauge or length of cord.
3. Not enough current.
1. Check the line voltage and, if insufficient, have
a licensed electrician remedy the situation.
2. Do not use an extension cord on this Welder.
Use only one of the supplied power cords for
this Welder or an identical replacement cord.
3. Switch current to proper setting for metal thickness.
Follow all safety precautions whenever diagnosing or servicing the equipment.