17
Power source
Component
Fault symptom
Cause
Primary cable
No or low welding output
Bad or incorrect primary
connection, lost phase
Earth cable and clamp
Arc will not initiate
Damaged, loose or undersized
cables and clamps
Connectors and lugs
Overheating of connectors
and lugs
Loose or badly crimped
connectors
Switches
Erratic or no output control
Switches damaged or incorrectly
set for the application
Wire feeder
Component
Fault symptom
Cause
Gas solenoid valve
No gas flow or gas flows
continuously
Gas valve faulty or sticking in open
position
Wire feed rolls
Wire slippage, wire deformation
Incorrect feed roll size, incorrect
tension adjustment, misalignment
Inlet, outlet guides
Wire shaving or snarling
Incorrect wire guide sizes,
misalignment
Universal adaptor
Wire restriction, gas leaks, no
trigger control
Universal adaptor not correctly
mounted or secured, incorrect size
of internal guide, bent contact pins
Wire feed speed control
No control over wire feed speed,
no amperage control
Faulty wire speed feed
potentiometer, wire feed motor in
overload or trip condition
Wire inch switch
Wire live when feeding through
cable and gun before welding
Faulty wire inch switch,
inappropriate use of gun trigger
switch
Spindle
Wire spool drags or overruns
Spindle brake set too tight or too
loose, spool not properly located
on spindle
5.0 Troubleshooting and Fault Finding
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