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OM-1581 Page 36
5-13. Troubleshooting
A. Wire Feeder Trouble
Trouble Remedy
Pressing gun trigger does not energize
feeder. Welding wire is not energized.
Shielding gas flows.
Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 3-6).
Secure 115 VAC input plug connection (see Section 3-12).
Check fuse F1 (see Section 5-11).
Check water connection to feeder or gun (see Sections 3-6 and 3-8).
Check for kinks in water hose.
Be sure coolant supply is turned On (see Section 4-14).
Have nearest Factory Authorized Service Station/Service Distributor check optional water flow switch,
if applicable (see Section 5-12).
Wire feeds, shielding gas flows, but
welding wire is not energized.
Secure 115 VAC/contactor control plug connection (see Section 3-12).
See Troubleshooting section in welding power source manual.
Check plug PLG50, PLG51 and PLG52 connections (see Section 3-13).
Wire feeds erratically. Check position of Motor Torque switch (see Section 4-11).
Adjust drive roll pressure if necessary (see Section 3-15).
Replace or clean drive rolls as necessary (see Sections 5-2 and 5-3).
Align drive roll with opening in gun conduit fitting and groove in bearing (see Section 5-3).
Arc varies and welding wire is kinked
when feeding out gun.
Place Motor Torque switch in low torque position if welding with .030 (0.8 mm) aluminum welding wire (see
Section 4-11).
Pressing gun trigger will not feed wire,
wire is not energized, shielding gas
flows, and Jog switch activates motor.
Reset circuit breaker CB1 (see Section 5-11).
Feeder feeds wire but remains in run-in
mode after arc initiation.
Route weld cable through current sensing relay (see Section 3-8).
If constant current (CC) welding, be sure PLG5 is in EXT. position on PC1, and voltage sensing lead is
connected (see Section 3-11).
If constant voltage (CV) welding, be sure PLG5 is in INT. position on PC1, and that voltage sensing lead
is not connected (see Section 3-11).
Feeder feeds wire, but switches from
weld mode to run-in mode while CV
welding with voltage sensing lead
installed.
Be sure PLG5 is in INT. position on PC1. Disconnect voltage sensing clamp from workpiece (see Section
3-11).
Shielding gas leak through gas valve in
gun.
Reduce shielding gas pressure at regulator flowmeter. Do not exceed 50 psi (345 kPa).