Product manual

Page 13For technical questions, please call 1-800-444-3353.Item 61206
Troubleshooting
Problem Possible Causes Likely Solutions
No Weld Output 1. Unit not plugged into
electrical outlet.
2. Building’s fuse or
circuit breaker blown.
3. Power Switch
damaged or worn.
1. Plug Power Cord into electrical outlet.
2. Replace building’s fuse or reset circuit breaker.
3. Have a qualified technician inspect Power
Switch and replace if necessary.
Poor Welding Occurs 1. Electrode Tips deformed,
dirty, oxidized, or pitted.
2. Tongs dirty or oxidized.
3. Poor contact with
workpieces.
4. Coatings on workpieces
inhibiting good contact.
5. Material too thick
for Spot Welder.
1. Dress or replace Electrode Tips. Refer to
Dressing Electrode Tips on page 9 or
Replacing Electrode Tips on page 12.
2. Clean or replace Tongs.
3. Adjust Tong pressure. Refer to Adjusting Tong
and Operating Lever Pressure on page 10.
4. Remove paint, oxides, chemical compounds
including galvanized coating.
5. Ensure that workpiece thickness is within capacity of
Spot Welder. Refer to Specifications on page 7.
Longer Than Normal
Weld Time Required
1. Electrode Tips deformed,
dirty, oxidized, or pitted.
2. Metals to be
welded are dirty.
3. Tongs dirty or oxidized.
4. Facility line voltage low.
1. Dress or replace Electrode Tips. Refer to
Dressing Electrode Tips on page 9 or
Replacing Electrode Tips on page 12.
2. Clean metals with fine wet-dry sandpaper.
3. Clean or replace Tongs.
4. Check input line voltage with voltmeter.
Burn Through
at Weld Point
1. Weld time too long.
2. Tongs out of alignment.
3. Electrode Tips deformed,
dirty, oxidized, or pitted.
1. Shorten weld time.
2. Realign Tongs. Refer to Tong and Electrode
Tip Alignment on page 9.
3. Dress or replace Electrode Tips. Refer to
Dressing Electrode Tips on page 9 or
Replacing Electrode Tips on page 12.
Electrode Tips
Overheating
1. Not enough Tong
pressure.
2. Weld time too long.
3. Material too thick
for Spot Welder.
1. Increase Tong pressure. Refer to Adjusting Tong
and Operating Lever Pressure on page 10.
2. Shorten weld time.
3. Ensure that workpiece thickness is within capacity of
Spot Welder. Refer to Specifications on page 7.
Electrode Tips Arcing
on Workpieces
1. Not enough Tong
pressure.
2. Electrode Tips
misaligned.
3. Workpiece material has
become welded to Tips.
1. Increase Tong pressure. Refer to Adjusting Tong
and Operating Lever Pressure on page 10.
2. Realign Tips or dress Tips to correct diameter. Refer
to Tong and Electrode Tip Alignment and/or Dressing
Electrode Tips on page 9.
3. Dress or replace Electrode Tips. Refer to Dressing
Electrode Tips on page 9 or Replacing Electrode
Tips on page 12.
Hole in Weld Contact area of Electrode
Tips too large.
Dress Electrode Tips to restore spot diameter and
face angle to approximate that of new tip. Refer
to Dressing Electrode Tips on page 9.
Molten Material
Forced Out Around
the Weld Point
1. Electrode Tips
misaligned.
2. Weld time too long.
3. Too much Tong pressure.
1. Dress Electrode Tips so they align correctly and lie flat
on the workpiece. Refer to Dressing Electrode Tips
and/or Tong and Electrode Tip Alignment on page 9.
2. Shorten weld time.
3. Decrease Tong pressure. Refer to Adjusting Tong
and Operating Lever Pressure on page 10.
Follow all safety precautions whenever diagnosing or servicing
the tool. Disconnect power supply before service.
SAFETYOPERATIONMAINTENANCE SETUP