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E-4
TROUBLESHOOTING
E-4
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Wire feed speed consistently oper-
ates at the wrong value. The speed
changes when the wire feed speed
knob is adjusted.
The wire feed speed is fast (maxi-
mum) and there is no change when
the wire feed speed knob is adjust-
ed.
Variable or "hunting" arc.
(Digital display models)
When the trigger is pulled, the wire
feeds slowly.
(Digital display models)
The preset voltage does not match
the power source voltage.
Poor arc starts with sticking or
"blast-offs", weld porosity, narrow
and ropy looking bead.
1. The jumper lead for normal
speed/extra torque is connected
improperly.
2. The wrong gear is installed in the
wire drive.
3. The brushes on the motor are
worn.
1. The tachometer is connected
improperly.
2. The tachometer has failed.
1. Wrong size, worn and/or melted
contact tip.
2. Worn work cable or poor work
connection.
3. Wrong polarity.
4. The gas nozzle is extended
beyond the contact tip or the wire
stickout is too long.
5. Poor gas shielding on processes
requiring gas.
1. The Run-In switch is "ON"
1. The preset voltage calibration in
the feeder has been selected for a
different power source.
1. Improper procedures or tech-
niques.
1. Properly connect the normal
speed/extra torque jumper.
2. Install the proper pinion gear in
the wire drive.
3. Replace the motor/gearbox
assembly.
1. Verify all of the tachometer leads
are properly connected.
2. Replace the motor and tachome-
ter assembly.
1. Replace the contact tip.
2. Verify all work and electrode con-
nections are tight and that the
cables are in good condition.
Clean/replace as necessary.
3. Adjust polarity to the recommend-
ed procedure.
4. Adjust the gas nozzle and shorten
the stickout to 3/8 to 1/2 inches.
5. Check gas flow and mixture.
Remove or block sources of
drafts.
1. Place the Run-In switch to the
"OFF" position.
1. Use the set-up menu to change
the preset voltage calibration in
the feeder to match the power
source.
1. See "Gas Metal Arc Welding
Guide" (GS-100)
LN-25 PRO EXTREME
Output Problems