DCM00003 REV. 07 31
Overloads when welding.
Stack not tuned properly.
Tooling not set up properly.
Crash gap not set properly.
Tip nut cracked, replace if needed.
Check weld parameters.
Check stack interfaces for fretting.
Check for loose or failed horn or booster,
tighten or replace as necessary.
When touching the system you get a slight
electrical shock.
Inspect power cord, replace if needed.
Inspect system ground, repair if needed.
Tooling heats up after machine runs a
while.
Cooling air is not turned on or is not on
long enough.
Cooling air is not directed at tooling.
Low weld strength.
Check weld parameters.
Check tooling gaps.
Check knurl on tooling. If worn replace
tooling.
Increase Energy.
Check the Down stop adjustment.
Check for part contamination.
Ensure all hardware is tight.
Excessive welding.
Reset parameters.
Reset amplitude.
Reset pressure.
Measure and re-calibrate amplitude
display.
Time limit error or peak power error
displayed after weld cycle.
Reset limits.
Check tip, rotate or replace if worn.
Check anvil for wear, rotate or replace if
worn.
Check air pressure setting.
Check up stop for proper adjustment.
Process settings have to be opened up due
to part variance or limits should be
adjusted according to the part/wire being
run.
Check anvil clamp for proper torque.
Table 4.1 Troubleshooting Guide
Problem Solution
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