Welding is an intense task done in mostly harsh conditions. Since more than 50% of products in the U.S require some form of welding, welding equipment and machines are prone to occasional wear after long periods of use.
Troubleshooting problems with your welding machine as they occur could save you a lot of time and money on repair costs. Finding and fixing a problem on-site is much cheaper, easier, and more convenient than replacing an entire unit. You can always get an expert to help you out, in case you’re stuck. Finding the root cause of the problem first is imperative.
This piece will highlight some essential troubleshooting tips to help you pinpoint any issues with your welding machine so that you save time and money on your repairs.
Welding machines are very complicated pieces of machinery, and some issues may require a great deal of skill and expertise to tackle. There are, however, a few troubleshooting tips to help you check for problems during your welding machine repair.
1. Wire Feeding Problem
First things first, you’ll want to check if the wire is feeding correctly. A major problem likely to occur in many welding machines is a worn-out drive roller. Having a worn driver roller may affect how your wire is fed and may even cause a slip. Check the liner for any dirt or debris; these are sure indicators of a worn-out roller. Sometimes a simple welding machine cleaning can free up your wire and solve the problem instantly.
2. Inspect the Machine Tip
On your welding gun, you’ll find a tip near the wire exit. Examine this part for any wear just like the drive roller. A worn tip won’t allow the electricity your machine creates to hit the surface effectively. This wear on the tip makes the welding gun very inefficient meaning you’ll have to work a lot harder to get little work done. A worn tip may also cause back burn, which is very disruptive. You may want to replace the tip of your welding gun as soon as you can to prevent these problems.
3. Check the Welding Cup
Your welding cup should always be free of splatter. Though it seems unnecessary, having a clean welding machine is imperative to conducting proper welding machine repair. A clean welding cup, and a clean machine, in general, makes it easier for you to identify problems with your welding machine. A clean welding cup also makes for better propane gas coverage, which significantly increases the efficiency of your machine.
4. Asses the Ground Clamp
Most welders overlook the ground clamp during routine welding machine repair and maintenance. But when the ground clamp gets coated with oxides, electrons could easily transfer which beats the logic of having a ground clamp. A heavily coated ground clamp can change the way the current flows back to the machine because of the heavy resistance. This could not only raise energy costs significantly but could also make your welding very difficult.
5. Examine the Welding Cable
Closely inspect the welding cable for any wear or frays. A damaged cable is the root cause of many machine problems that you can easily fix with a soldering gun and insulating tape. You should also adjust the brake on the spool. Anything too high or too low could make welding very difficult.
6. Ask a Professional
Welding machine repair is never easy. It might be best to get a professional if you fail to pinpoint the exact problem. Experts can help identify the exact problem and carry out the necessary repairs, including welding regulator repair and air tool repair, to name a few.
This post gives only a few tips to help you diagnose problems with your welding machine. Remember to have your safety glasses and gloves on, even when carrying out simple repairs, just like when you weld. Hopefully, this piece has been of great help to you.