General
OM-244 814 Page 45
9-9. Basic Welding Troubleshooting
Listed below are some problems, causes and remedies related to welding operations; however, this list does not contain every possible condition that
could be encountered in welding.
Trouble Probable Cause Remedy
No weld output; unit completely
inoperative
Line disconnect switch in Off position Place switch in On position
Power source switch in Off position Place switch in On position
Primary power fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker and check in-
put voltage
Weld output is present, but wire stops
feeding while welding
Wire feeder protective fuse blown or circuit breaker
tripped
Replace fuse or reset circuit breaker and find over-
load condition
No start input signal to weld control Check external start, PLC, or robot signal to weld
control
Wire feeder drive rolls misaligned Align drive rolls
Wrong size drive rolls Replace with proper size drive rolls
Too much or too little drive roll pressure Adjust drive roll pressure
Too much tension set at wire spool Reduce wire spool tension
Restriction in unspooler or drum adapter Replace unspooler or repair restriction
Feeder motor burnt out Test motor and replace if necessary
Gun liner dirty or restricted Remove gun liner and clean or replace
Wrong type or size of liner Install proper size liner
Broken or damaged gun or torch Replace faulty parts
Contact tip opening restricted Replace contact tip
Wrong size or type of contact tip Replace with proper size and type contact tip
Sharp bends or kinks in gun cable or liner Straighten gun cable and/or replace liner
Inlet cable too long Reduce distance to shorten inlet cable or use an in-
termediate drive
Gun overheating Use gun with proper amperage rating
Wrong size wire Match wire size to liner and contact tip
Guides rubbing on drive rolls Adjust or position guides properly
Drive rolls jammed Remove foreign object from gears
Motor cable disconnected or damaged Connect, repair or replace motor cable
Porosity in weld
Dirty base metal, heavy oxides, mill scale, oil, etc Clean base metal by brushing, grinding or use
chemical cleansing before welding
Regulator/flowmeter faulty Adjust or replace regulator/flowmeter
Gas cylinder valve closed Open gas cylinder valve
Gas regulator diaphragm defective Replace regulator
Flowmeter cracked or broken Repair or replace flowmeter
Gas hose disconnected or leaking Connect or replace gas hose
Too much or too little gas flow Adjust for proper gas flow
Moisture in shielding gas Replace gas cylinder or supply
Wrong gas for wire type or transfer mode Use correct shielding gas
Feeder gas solenoid faulty Replace solenoid
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