Full Product Manual

98
NO. Trouble Possible Cause Solution
1
Unit is switched on, but the power light
isn’t on
Switch damaged. Replace.
Unit Fuse damaged. Replace.
Power breaker tripped. Reset.
2
After welding machine is overheating and
the fan does not work
Fan damaged. Check fan housing and fan. Replace if necessary.
Fan power connector is loose. Tighten wires, check for dislodged connectors.
3
When torch switch is pressed, no gas
flows
No gas in the gas cylinder. Replace.
Gas pipe leaks gas. Resolve .
Gas solenoid valve damaged. Check and clean/replace.
Torch switch damaged. Repair or Replace.
Control board damaged. Inspect the circuit.
4
Wire-feeder does
not work
Wire reel does
not turn
Motor damaged/Fuse blown. Check and Replace.
Control circuit damaged. Check the board.
Wire reel turns
The tensioner is loose or wire slips on
rollers. Wrong size drive roll. Wire is not
mated in drive groove.
Increase tension. Check for proper drive roll size/type. Make
sure wire is in groove not riding on top of the drive roller shoul-
der.
The drive roller doesn’t t the diameter
of weld wire.
Change roller or wire size to match.
Wire Spool is damaged. Change out wire spool.
Gun liner is jammed.
Repair or change it, clear wire from liner/clean liner with com-
pressed air.
Contact Tip is jammed because of slag
or burn back.
Clean or replace. If with Aluminum, increase tip size to next
size.
5 No arc, or no output voltage
Work clamp engaged in wrong connect-
or.
Change polarity.
Control circuit damaged. Check the circuit.
6
Welding stops and warning light is on,
Wire continues feeding but no arc is
present.
Self-protection has engaged.
Check over-voltage, over-current, over-temperature, lower-
voltage and over-temperature. Allow unit to cool if over heated.
If an OC, use a shorter wire stick out or smaller diameter wire or
reduce power settings with large diameter wires. Check power
plug for problems. If easily tripped the Resistor value too low.
(Contact Everlast if OC is tripping regularly with normal set-
tings.)
7
Welding Voltage/Current is uncontrolla-
ble
Potentiometer damaged. Repair or Replace it.
Control board damaged. Check the circuit.
9 Intermittent Arc/ Wandering arc
Work Clamp is not secure or it is dam-
aged. Too windy/breezy.
Check and/or Work Clamp, change position of clamp and attach
direct to the work. Move out of wind.
10 Excessive spatter
Voltage too high too high arc force/ Too
high wire speed. Too much torch angle.
Wrong size nozzle
Lower voltage or increase wire speed. Check torch angle for
less than 15° push or pull. Change arc force settings to reduce
spatter. Change nozzle size.
11 Weld sooty or oxidized looking
Poor metal prep, poor gas flow, too much
torch angle, wrong gas type, windy or
breezy. Plugged nozzle
Thoroughly clean metal, check gas flow and reposition gun so
gas flow is not creating turbulence. Move indoors if necessary.
Reposition the welder so its fan will not blow on the weld area.
Clean nozzle.
12
Bird nesting of the wire around the drive
roll
Jammed gun liner, wire too soft
(aluminum), gun hose is kinked or coiled
too tightly. Too much tension / pressure
on wire feeder .
Reduce wire feed tension so that drive will slip if it encounters
too much resistance Check Gun and liner and replace if neces-
sary. Straighten cable.
13 Wire feeds irregularly
Wrong drive roller or wrong size drive
roller, too little tension on wire, wire in
wrong groove.
Check and match wire size to groove size, increase tension on
drive rollers. Check to make sure the wire is not riding on the
shoulder of the drive roller.
14 Wire burns back and seizes in tip
Wrong contact Tip size or too much burn
back time set.
Match tip size for wire diameter. Reduce burn back time. If
using with aluminum, use tip designed for aluminum or use one
size larger tip than the wire.
15 Nozzle arcs to work piece welding Nozzle plugged with spatter Check/clean nozzle and use a nozzle dip.
16 In Stick mode will not arc Cables not connected, inverter issue Check connections.
17 In Stick mode, the rod sticks
Arc force/Hot Start is set too low, arc
striking method is poor, wrong polarity,
too low of amperage. Wet welding rods or
wrong kind.
Check polarity. Check Hot Start settings. Increase arc force
control/Hot Start. Change arc striking method. Increase amper-
age. Use fresh welding rods when possible.
Section 4 Trouble Shooting