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Operating Instructions and Parts Manual
Troubleshooting Chart - Welder
Symptom Possible Cause(s) Corrective Action
No output
Wire tangles at drive roller
Gun nozzle arcs to work surface
Work clamp and/or cable gets
hot
Wire does not feed
1. Duty cycle exceeded
2. Poor work clamp
connection
3. Defective ON/OFF
switch
4. Blown breaker or fuse
1. Wrong size gun tip
2. Gun liner clogged or
damaged
3. Gun tip clogged or
damaged
4. Feed roller worn
5. Not enough tension
Slag inside gun nozzle
Poor contact
1. Wire jammed
2. Out of wire
3. Not enough tension
4. Wire liner worn
1. Allow welder to cool until ON/OFF Switch lamp goes out
2. Be sure all connections are secure, and attaching surface is
clean
3. Replace switch
4. Reduce circuit load, reset breaker or replace fuse
1. Use proper size gun tip
2. Clean or replace gun liner
3. Clean or replace gun tip
4. Replace
5. Tighten tensioning screw
Clean slag from gun nozzle
Be sure all connections are secure, and attaching surface is
clean
1. Reload wire
2. Replace wire spool
3. Tighten tensioning screws if wire is slipping
4. Replace liner
For Information About This Product Call 1-800-746-5641
Troubleshooting Chart - Welds
Symptom Possible Cause(s) Corrective Action
Bead is intermittently too thin
Bead is intermittently too thick
Ragged depressions at edge of
weld
Weld bead does not penetrate
base metal
Wire sputters and sticks
1. Inconsistent travel speed
2. Output heat setting too low
1. Slow and/or inconsistent
travel speed
2. Output heat setting too high
1. Travel speed too fast
2. Wire speed too fast
3. Output heat setting too high
1. Inconsistent travel speed
2. Output heat setting too low
3. Excessive extension cord length
1. Damp wire
2. Wire speed too fast
3. Wrong type of wire
1. Decrease and maintain constant travel speed
2. Increase output heat setting
1. Increase and maintain travel speed
2. Reduce output heat setting
1. Decrease travel speed
2. Decrease wire speed (WF2000)
3. Reduce output heat setting
1. Decrease and maintain constant travel speed
2. Increase output heat setting
3. Use an extension cord no longer than 20 ft.
1. Use dry wire and store in dry location
2. Reduce wire speed
3. Use flux core wire only (Do not use MIG or copper
color wire)
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