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Part VI Troubleshooting Guide
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
1. Electrode does not feed. 1. Feeder relay.
2. Broken control lead.
3. Poor adaptor connection.
4. Worn or broken switch.
5. Improper drive roll size.
6. Drive roll tension misadjusted.
7. Burn back to contact tip.
8. Wrong size liner.
9. Buildup inside of liner.
1. Consult feeder manufacturer.
2 a. Test & connect spare control lead.
b. Install new cable.
3. Test & replace leads and/or contact pins.
4. Replace.
5. Replace with proper size.
6. Adjust tension at feeder.
7. See ‘Contact Tip Burn Back’.
8. Replace with correct size.
9. Replace liner, check condition of electrode.
2. Contact Tip burn back. 1. Improper voltage and/or wire feed speed.
2. Erratic wire feeding.
3. Improper contact tip stickout.
4. Improper electrode stickout.
5. Faulty ground.
1. Set parameters.
2. See ‘Erratic Wire Feeding’.
3. Adjust nozzle/contact tip relationship.
4. Adjust gun to base metal relationship.
5. Repair all cables & connections.
3. Contact Tip disengages from head. 1. Worn gas diffuser.
2. Improper contact tip installation.
3. Extreme heat or duty cycle.
1. Replace contact tip and/or gas diffuser.
2. Install as per ‘Maintenance & Repair’ (Section
2).
3. Replace with heavy duty consumables as per
‘Accessories’ Section.
5. Erratic arc. 1. Worn contact tip.
2. Buildup inside of liner.
3. Wrong contact tip size.
4. Not enough bend in neck.
1. Replace.
2. Replace liner, check condition of electrode.
3. Replace with correct size contact tip.
4. Replace with 45º or 60º neck.
4. Short contact tip life. 1. Contact tip size.
2. Electrode eroding contact tip.
3. Exceeding duty cycle.
1. Replace with proper size.
2. Inspect and/or change drive rolls.
3. Replace with properly rated Bernard MIG Gun.
6. Erratic wire feeding. 1. Buildup inside of liner.
2. Wrong size liner.
3. Improper drive roll size.
4. Worn drive roll.
5. Improper guide tube relationship.
6. Improper wire guide diameter.
7. Gaps at liner junctions.
8. Feeder malfunction.
9. Contact tip.
1. Replace liner, check condition of electrode.
2. Replace with new liner of proper size.
3. Replace with proper size drive roll.
4 a. Replace with new drive roll.
b. Stone edge of groove on drive roll.
5 a. Adjust/replace guide as close to drive rolls
as possible.
b. Eliminate all gaps in electrode path.
6. Replace with proper guide diameter.
7 a. Replace with new liner trimming as per
‘Maintenance & Repair’ (Section 5 & 8).
b. Replace guide tube/liner, trim as close to
mating component as possible.
8. Consult feeder manufacturer.
9. Inspect and replace.*
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