Section 5:service, 01 cleaning of the unit, 02 cleaning of the feed rolls – Tweco FP-165 Mini MIG User Manual

Page 45: 03 basic troubleshooting, 04 solving problems beyond the welding terminals, Section 5:service -1, Cleaning of the unit -1, Cleaning of the feed rolls -1, Basic troubleshooting -1, Solving problems beyond the welding terminals -1

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FIREpOwER Fp-125, 135, 165



Manual 0-5123

5.01 Cleaning of the Unit

Periodically remove the right side panel (after disconnect-

ing the supply cord from the receptacle) and blow out the

interior with clean, dry, compressed air of not more than

25 PSI air pressure. Do not strike any components with

the air hose nozzle.

5.02 Cleaning of the Feed Rolls

Clean the wire groove on the feed roll at frequent intervals.

This cleaning operation can be done by using a small

wire brush. To clean the wire groove, loosen the pressure

device and lift the feedroll pressure arm. Remove all wire

from the feedhead. Wipe off the bearing roll (the “top” roll

in the feedhead).

5.03 Basic Troubleshooting

The basic level of troubleshooting is that which can be

performed without special equipment or knowledge, and

without removing the covers from the Power Source.
If major components are faulty, then the Power Source

should be returned to an Accredited THERMAL ARC Ser-

vice Agent for repair.

5.04 Solving Problems Beyond the

Welding Terminals

The general approach to fix Gas Metal Arc

Welding (GMAW) problems is to start at the

wire spool then work through to the MIG torch.

There are two main areas where problems oc-

cur with GMAW:

1. Porosity
When there is a gas problem the result is usually porosity

within the weld metal. Porosity always stems from some

contaminant within the molten weld pool which is in the

process of escaping during solidification of the molten

Contaminants range from no gas around the welding arc

to dirt on the work piece surface. Porosity can be reduced

by checking the following points:



1. Gas cylinder contents and flow meter.

a. Ensure that the gas cylinder is not empty and

the flow meter is correctly adjusted to 20CFM

(15 liters per minute).

2. Gas leaks

a. Check for gas leaks between the regulator/cyl-

inder connection and in the gas hose to the

Power Source.

3. Internal gas hose in the Power Source.

a. Ensure the hose from the solenoid valve to the

MIG torch adaptor has not fractured and that it

is connected to the MIG torch adaptor.

4. Welding in a windy environment.

a. Shield the weld area from the wind or increase

the gas flow.

5. Welding dirty, oily, painted, oxidized or greasy


a. Clean contaminates off the plate.

6. Distance between the MIG torch nozzle and the

work piece.

a. Keep the distance between the MIG torch nozzle

and the work piece to a minimum.

7. Maintain the MIG torch in good working order.

a. Ensure that the gas holes are not blocked and

gas is exiting out of the torch nozzle. Refer to

WARNING below.

b. Do not restrict gas flow by allowing spatter to

build up inside the MIG torch nozzle.


Disengage the drive roll when testing for gas

flow by ear.

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