46. Welder Generating but Current Falls Off
Probable cause
Possible remedy
Electrode or ground connections loose.......................................................Clean and tighten all connections.
Poor ground...............................................................................................Check ground-return circuit.
Brushes worn off ........................................................................................Replace brushes (para 56).
Weak brush spring pressure .....................................................................Replace brush springs (para 57).
Brush not properly fitted . ...........................................................................Sand brushes to fit (para 56).
Brushes in backwards ................................................................................Reverse, sand to fit (para 56).
Wrong brushes used..................................................................................Replace with correct brushes (para 56).
Brush pigtails damaged .............................................................................Replace brushes (para 56).
Motor connection single phased .................................................................Check all connections against wiring diagram (fig. 4).
Insufficient cooling air ................................................................................Remove obstructions that may block ventilating air or
cause the exhaust air to recirculate.
47. Welder Runs but Soon Stops
Probable cause
Possible remedy
Wrong overload relay.................................................................................Check rating of starter overload relay (para 92).
Welder overloaded.....................................................................................Check control settings (para 28).
Duty cycle too high ....................................................................................Do not operate continuously at overload currents.
Line leads too long or too small in cross section.........................................Lines should be large enough to carry welding current
requirement without excessive voltage drop. Report to
proper authority.
Power circuit single phased........................................................................Check for one dead fuse at power source or line.
Ambient temperature too high
Operate at reduced loads when temperatures exceed
100F.
Ventilation blocked.....................................................................................Check air inlet and exhaust openings.
48. Welding Arc Is Loud and Spatters Excessively
Probable cause
Possible remedy
Polarity wrong............................................................................................Check polarity, try reversing, or using an electrode of
49. Welding Arc Sluggish
Probable cause
Possible remedy
Current too low ..........................................................................................Check output and current recommended for electrode
Poor connections .......................................................................................Check electrode holder, cable, and ground connections
Cable too long or too small ........................................................................Check cable voltage drop and change cable (paras 26 and
50. Touching Machine Gives Shock
Probable cause
Possible remedy
Frame not grounded ..................................................................................Ground solidly.
Internal components grounded...................................................................Report to proper authority.
Probable cause
Possible remedy
Any part of field circuit may be short circuited ............................................Report to proper authority.
Faulty rheostat ..........................................................................................Replace rheostat (para 65).
52. Excessive Brush Sparking
Probable cause
Possible remedy
Faulty brush spring (broken or worn)..........................................................Replace springs (para 57).
Incorrect, broken or chipped brushes..........................................................Replace brushes (para 56).
Contaminated atmosphere, such as carbontetrachloride.............................Remove contaminant and improve ventilation.
fumes.
AGO 8244A
22