Replacement Part List

GEN4000DF-STW 4000 Surge Watt / 3500 Running Watt Portable Dual Fuel Generator + Welder

Welder Troubleshooting:

The following operation requires sufficient professional knowledge on electric aspect and comprehensive safety

knowledge. Make sure the input cable of the machine is cut off from the electricity utility before uncovering the

welding machine.

Malfunction

Cause and Solution

Turn on the machine, the power LED is off, the fan

doesn't work, and no welding output.

(1) Check if the power switch is closed.

(2) No input power.

Turn on the machine, the fan works, but the output

current is unstable and can't be controlled by

potentiometer when welding.

(1) The current potentiometer fails. Replace it.

(2) Check if any loose contact exists inside the machine. If

any, reconnect.

Turn on the machine, the power LED is on, the fan

works, but no welding output.

(1) Check if any loose contact exists inside the machine.

(2) Open circuit or loose contact occurs at the joint of

output terminal.

(3) The overheating LED is on.

a) The machine is under over-heating protection

status. It can recover automatically after the

welding machine is cooled.

b) Check if the thermal switch is ok. Replace it if

damaged.

The electrode holder becomes very hot.

The rated current of the electrode holder is smaller than its

actual working current. Replace it with a bigger rated current.

Excessive spatter in MMA welding.

The output polarity connection is incorrect. Exchange the

polarity.