Tweco Max 300 w-Merlin 6000GST - Manual (Page 34)

SERVICE 5-4 Manual 0-2642
5.05 Troubleshooting Guide
A. Troubleshooting
This Sub-Section covers troubleshooting that requires
dissasembly and electronic measurements. It is helpful
for solving many of the common problems that can arise
with this torch assembly.
B. How to use this Guide
The following information is a guide to help the Cus-
tomer/Operator determine the most likely causes for
various symptoms.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions (Text Type)
1. Cause (Italic Type)
a. Check/Remedy (Text Type)
Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
the unit is fully operational after any repairs.
A. Torch will not pilot when torch switch is activated
1. Gas Control Module MODE switch in SET position
a. Place MODE switch to RUN position.
2. Torch switch activated during power on purge
a. Release torch switch and wait at least 20 sec-
onds before activating switch again
3. Faulty torch parts
a. Inspect torch parts and replace if necessary. Re-
fer to Section 5.04, Inspection and Replacement
Consumable Torch Parts
4. Gas pressure or flow too high
a. Refer to Gas Control Module Manual 0-2641
for making settings.
5. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if neces-
sary. Refer to Section 5.07, Torch and Leads
Troubleshooting.
6. Faulty components in power supply system components
a. Return for repair or have qualified technician
repair per Service Manual.
B. No cutting output
1. Torch not properly connected to power supply
a. Check that torch leads are properly attached
to power supply and work cable is attached to
workpiece
2. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if neces-
sary. Refer to Section 5.07, Torch and Leads
Troubleshooting.
3. Faulty components in power supply system components
a. Return for repair or have qualified technician
repair per Service Manual.
C. Low cutting output with no control
1. Incorrect setting of AMPERAGE control on power sup-
ply
a. Check and adjust to proper setting.
2. Torch tip contacting workpiece
a. Increase standoff distance
3. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if neces-
sary. Refer to Section 5.07, Torch and Leads
Troubleshooting.
4. Faulty components in power supply system components
a. Return for repair or have qualified technician
repair per Service Manual.
D. Limited output with no control
1. Poor input or output connections to power supply
a. Check all input and output connections.
2. Incorrect setting of AMPERAGE control on power sup-
ply
a. Check and adjust to proper setting.
3. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if neces-
sary. Refer to Section 5.07, Torch and Leads
Troubleshooting.
4. Faulty components in power supply system components
a. Return for repair or have qualified technician
repair per Service Manual.
E. Erractic or improper cutting output
1. Poor input or output connections to power supply
a. Check all input and output connections.