Operating Instructions and Parts Manual
12
www.campbellhausfeld.com
For Information About This Product Call 1-800-746-5641
Troubleshooting Chart - Welder
Symptom
Possible Cause(s)
Corrective Action
No output
1. Duty cycle exceeded
1. Allow welder to cool until lamp goes out
2. Poor work clamp connection
2. Be sure all connections are secure, and attaching
surface is clean
3. Tripped circuit breaker
3. Reset by pushing button on back of unit
4. Blown breaker or fuse
4. Reduce circuit load, reset breaker or replace fuse
Wire tangles at drive roller
1. Wrong size contact tip
1. Use proper size contact tip
2. Torch liner clogged or damaged
2. Clean or replace wire liner
3. Contact tip clogged or damaged
3. Clean or replace contact tip
4. Drive roller worn
4. Replace
5. Not enough tension
5. Tighten tension knob
Gun nozzle arcs to work surface
1. Slag inside gun nozzle
1. Clean slag from gun nozzle
2. Insulation ring melted/expired
2. Replace nozzle
Work clamp and/or cable gets hot
1. Poor contact
1. Be sure all connections are secure, and attaching
surface is clean
2. Using an extension cord with
excessive length
2. Never use an extension cord longer than 20 ft
Wire does not feed
1. Wire jammed
1. Reload wire
2. Out of wire
2. Replace wire spool
3. Not enough tension
3. Tighten tension knob if wire is slipping
4. Wire liner worn
4. Replace liner
5. Wire disconnected internally
5. Call 1-800-746-5641 for assistance
6. Contact tip clogged
6. Replace contact tip
(Aluminum) Wire burns back into
tip or (Aluminum) Metal bubbles or
burns through
1. Wire speed too slow
1. Run speed in 7 - 10 range
2. Travel speed too slow or heat is
too high
2. Increase the travel speed or reduce heat settings
Weld pops and sputters
1. Wire speed setting
1. Tune in correct setting (1-5 mild steel; 5-10
aluminum)
2. Contact tip size too large
2. Replace contact tip
3. Polarity set incorrectly
3. Reverse polarity
4. Drive roller slipping
4. Increase tension
5. Gas bottle empty
5. Replace gas bottle
Bead is intermittently too thin
1. Inconsistent travel speed
1. Decrease and maintain constant travel speed
2. Output heat setting too low
2. Increase output heat setting
Bead is intermittently too thick
1. Slow and/or inconsistent travel
speed
1. Increase and maintain travel speed
2. Output heat setting too high
2. Reduce output heat setting
Ragged depressions at edge of
weld
1. Travel speed too fast
1. Decrease travel speed
2. Wire speed too fast
2. Decrease wire speed
3. Output heat setting too high
3. Reduce output heat setting
Weld bead does not penetrate base
metal
1. Inconsistent travel speed
1. Decrease and maintain constant travel speed
2. Output heat setting too low
2. Increase output heat setting
3. No or low shielding gas
3. Use gas for MIG process or refill bottle
4. Wrong shielding gas (aluminum)
4. Use only 100% Argon gas
5. Extension cord is too long
5. Never use an extension cord longer than 20 ft
6. (Aluminum) Possible oxide buid-
up on surface
6. Clean surface thoroughly with a stainless steel
brush only
Wire sputters and sticks
1. Damp wire
1. Use dry wire and store in dry location
2. Wire speed too fast
2. Reduce wire speed
3. Wrong type of wire
3. Use flux-cored wire when not using gas
4. No or low shielding gas
4. Use gas for MIG process or refill bottle
