Sealey MIGHTYMIG170 - Manual (Page 7)

6 . TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE REMEDY
1. Power source stops Overheating protection activated due to overload Protection automatically resets when transformer has cooled (about 15 min)
2. No weld current Rectifier blown Replace rectifier
3. No weld current Bad connection between clamp & workpiece Clean or grind contact surface and weld area
Break in earth lead Repair or replace earth lead.
Break in torch lead Repair or replace torch
4. Feed motor not working, lamp is on
Gear damaged or worn Replace gears. (Contact service agent)
Motor defective Replace motor (Contact service agent)
5. Wire does not feed, feed roller rotates Pressure roller improperly adjusted Adjust tension
dirt, copper, dust, etc, has collected in torch liner Clean the liner from the machine forward. Use compressed air. If too much dirt,
replace the liner.
Gas cup (Nozzle) or tip defective Replace gas cup (nozzle) and/or tip. (Section 3.9.4 to 3.9.7)
deformed wire Check roller tension and adjust it if necessary (Section 3.10)
6. Wire feeds unevenly dirt, etc, in liner Clean the liner from the machine forward. Use compressed air
Gas cup (Nozzle) or Tip defective Replace gas cup (nozzle) and/or tip. (Section 3.9.4 to 3.9.7)
Gas cup (Nozzle) spattered Clean or replace gas cup (nozzle) (Section 3.9.4 to 3.9.7)
Feed roller groove clogged Clean feed roller. (Section 3.12).
Feed roller groove deformed Replace feed roller. (Section 3.12)
Pressure roller tension improper Adjust tension. (Section 3.10)
7. Unstable arc Incorrect settings Check settings. (Section 4)
Impurities in weld area Clean and/or grind workpiece. (Section 4.1.1)
Worn or defective gas cup (nozzle) Replace gas cup (nozzle). (Section 3.9.4 to 3.9.7)
8. Porous weld No gas Open gas cylinder, regulate gas flow
Gas cup clogged Clean or replace cup. (nozzle) (Section 3.9.4 to 3.9.7)
draft blowing away shielding gas Screen off welding site or increase gas flow
Rusty or dirty joints Clean and/or grind workpiece. (Section 4.1.1)
Torch too far from or at wrong angle to work The distance from gas cup to workpiece should be 8 to 10mm
Gas leak Check hoses, connections and torch assembly. (Section 3.5, 3.5). Press the gas
cup in correction position
Faulty electrovalve Clean out or replace
9. electrode sticking in gas cup (nozzle) Worn or defective gas cup (nozzle) Replace gas cup (nozzle). (Section 3.9.4 to 3.9.7)
electrode deformed Check roller tension. (Section 3.10)
Wire speed too slow See recommendations for wire speed
10. Irregular weld head Torch incorrectly held Use correct torch angle
Wire weaving in weld pool Check roller tension and adjust as needed. (Section 3.10)
11. Weld bead too narrow and raised Weld current too low Increase power and wire speed. (Section 4)
Weld speed too high Move torch slower and weave a little more
12. Weld bead too wide Weld current too high decrease power and wire speed. (Section 4)
Weld speed too low Move torch faster and weave less
Arc too long Bring torch closer to workpiece
13. Poor penetration Weld current too low Increase power and wire speed. (Section 4)
Arc too long Bring torch closer to workpiece
14. excessive penetration Weld current too high decrease power and wire speed. (Section 4)
Weld speed too slow Move torch faster
incorrect distance of torch to workpiece Torch distance should be 8-10mm
5.1. WIRE FEED UNIT Check the wire feed unit at regular intervals. The feed roller wire guide plays an important part in obtaining consistent results. Poor
wire feed affects welding. Clean the rollers weekly, especially the feed roller groove, removing all dust deposits.
5.2. TORCH Protect the torch cable assembly from mechanical wear. Clean the liner from the machine forwards by using compressed air. If the liner is
clogged it must be replaced.
5.3. CHANGING FEED ROLLER (See Section 3.12)
5.4. CONTACT TIP The contact tip is a consumable item and must be replaced when the hole becomes enlarged or oval. The contact tip MUST be kept free
from spatter to ensure an unimpeded flow of gas. Refer to fig.12 and section 3.9 for removal and replacement.
5.5. GAS CUP The gas cup must also be kept clean and free from spatter. Build up of spatter inside the gas cup can cause a short circuit at the contact tip
which will result in either the fuse blowing on the printed circuit card, or expensive machine repairs. To keep the contact tip free from spatter, we
recommend the use of Sealey anti-spatter spray (MIG/722308) available from your Sealey dealer. Refer to fig.12 and section 3.9 for removal and
replacement.
5.6. REPLACING THE LINER Wind the wire back on to the spool and secure it. Unscrew the torch from the machine and undo the brass nut. The liner should
now be visible. Pull it out and replace with a new one.
5. MAINTENANCE
Original Language Version MIGHTYMIG170, MIGHTYMIG190, MIGHTMIG210 Issue: 2 - 26/02/10