Lincoln Electric IM666 TANDEM MIG Torch G3494-2A, 3A, 4A, 5A, 6A - Manual (Page 21)

E-3 TROUBLESHOOTING E-3
TANDEM MIG TORCH
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
(SYMPTOMS)
PPOSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Porosity in the weld. (Continued)
The arc length is inconsistent.
There is arcing to the nozzle.
There is arcing between the contact tips
or arc flaring.
g. Wrong shielding gas composition.
h. Lead arc length too short.
i. Water is leaking into the arc.
j. Air is being drafted through the barrel.
k. Weld is too large.
l. Excessive anti-spatter fluid.
m. For installations with an anti-spatter
system, the anti-spatter solenoid may
not be closing completely.
n. For installations without an anti-spat-
ter system, the line may not be
plugged.
a. The contact tip is worn.
b. The liner and/or conduit are dirty or
worn.
c. The drive rolls and guide tubes on the
wire feeder are not properly assem-
bled.
d. The variation in the joint is too large.
e. The electrode or work lead connec-
tions are loose.
f. Only one ground lead is being used.
g. The wrong weld program has been
selected.
a. Spatter build-up is bridging between
the nozzle and contact tips or diffusers
b. The nozzle is too narrow for the appli-
cation.
c. The torch is not insulated from the fix-
ture.
a. Spatter build-up is creating a bridge
between the contact tips.
b. The wire size selection is wrong.
g. Make sure the shielding gas is appro-
priate for the weld procedure.
h. The lead arc should be in the spray or
pulse mode and not in globular or
short arc transfer.
i. Verify that nozzle to torch o-rings are
sealing properly.
j. Check that the o-rings to seal the bar-
rel to the over molded assembly are
sealing properly.
k. Use a trailing gas shield or a nozzle
that supplies a wider coverage of gas
shielding.
l. Use only a minimal amount of anti-
spatter fluid.
m. Verify that the solenoid closes com-
pletely.
n. Make sure the anti-spatter line is
plugged and sealed.
a. The wire should slide freely through
the contact tip. Replace if necessary.
b. Clean the liners and conduit. Replace
if necessary.
c. Make sure the correct size drive rolls
and guide tubes are in the feeder the
wire feeds through without distortion.
d. Improve fixturing and part forming if
necessary, or add seam tracking.
e. Verify that all the connections are tight
and are not overheating.
f. Use an individual ground lead from the
work stud of each power source to the
fixture.
g. Make sure the welding program on the
power source matches the wire size
and gas actually being run.
a. Remove spatter build-up on a regular
basis. Adjust weld procedure to
reduce spatter.
b. Switch to a wider nozzle.
c. Make sure the torch is on an insulated
mount. Use M19190 insulator if neces-
sary.
a. Remove spatter build-up on a regular
basis. Adjust procedure to reduce
spatter.
b. Switch to a larger diameter lead and
trail wire.