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
opposite polarity (para 39).
49. Welding Arc Sluggish
Probable cause
Possible remedy
Current too low ..........................................................................................Check output and current recommended for electrode
being used (para 28).
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.
51. Generator Control Fails To Vary Current
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