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OM-478 Page 39
8-10. Troubleshooting
A. Welding
Trouble Remedy
No weld output. Check position of Ampere Range and Output Selector switches.
Place Output/Contactor Control switch in On position, or place switch in Remote position and connect
remote contactor to optional Remote 14 receptacle RC3 or terminal strip 3T (see Sections 4-8 and 4-9).
Disconnect equipment from auxiliary power receptacles during start-up.
Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-8 and 4-9).
Reset circuit breaker CB3 and/or CB4 (see Section 8-7).
Check fuse F6, and replace if necessary (see Section 8-7).
Have Factory Authorized Service Agent check brushes and slip rings, and circuit boards PC1 and
PC2.
Erratic weld output. Check and tighten connections both inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Tighten lead connections to Ampere Range switch.
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
High or low weld output. Check engine speed, and adjust if necessary (see Section 8-6).
Check CC/CV switch position.
If low weld output, check fuse F6, and replace if necessary (see Section 8-7).
Low open-circuit voltage. Check engine speed, and adjust if necessary (see Section 8-6).
Check CC/CV switch position.
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
Maximum weld output only in each
ampere range.
Have Factory Authorized Service Agent check Amperage/Voltage control R1, capacitor C8, diode D8,
integrated rectifier SR5, control relay CR8, and CV regulator board PC2.
Wire feeder does not work. Reset circuit breaker CB3 and/or CB4 (see Section 8-7).
Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-8 and 4-9).
Repair or replace wire feeder.
No amperage control. Place Amperage/Voltage Control switch in correct position.
Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-8 and 4-9).
Repair or replace remote control device.
Have Factory Authorized Service Agent check controls.
No CV weld output. Check and secure connections to optional Remote 14 receptacle RC3 or terminal strip 2T (see Section
4-8 or 4-9).
Repair or replace remote control device.
Have Factory Authorized Service Agent check CV regulator board PC2 and connector board PC30 and
connections, and replace if necessary.
Low CV weld output. Set Ampere Range switch to highest range.