Possible Causes:

• Power cord not properly connected
• Incorrect voltage setting (110V vs 220V)
• Thermal overload protection activated
• Faulty power outlet

Solutions:

1. Check power cord connections at both ends
2. Verify voltage selector switch matches your power supply
3. Allow machine to cool for 15-20 minutes if overheated
4. Test outlet with another device
5. Check circuit breaker/fuse

Possible Causes:

• Incorrect amperage setting
• Poor ground connection
• Dirty or contaminated metal
• Worn electrode or contact tip

Solutions:

1. Increase amperage setting gradually
2. Clean and tighten ground clamp connection
3. Remove rust, paint, and oil from workpiece
4. Replace contact tip or electrode
5. Check for loose cable connections

Possible Causes:

• Voltage too high
• Wire feed speed too fast
• Incorrect gas flow (MIG)
• Dirty base metal

Solutions:

1. Reduce voltage setting
2. Decrease wire feed speed
3. Adjust gas flow to 15-20 CFH
4. Clean workpiece thoroughly
5. Use anti-spatter spray

Possible Causes:

• Contaminated shielding gas
• Insufficient gas coverage
• Windy conditions (outdoor welding)
• Dirty base metal or filler

Solutions:

1. Check gas cylinder pressure and connections
2. Increase gas flow rate
3. Use windshield for outdoor welding
4. Clean metal with wire brush
5. Replace gas cylinder if contaminated

Possible Causes:

• Incorrect drive roll tension
• Kinked or tangled wire
• Worn liner or contact tip
• Wrong size drive rolls

Solutions:

1. Adjust drive roll tension (not too tight)
2. Check wire spool for kinks
3. Replace liner and contact tip
4. Ensure drive rolls match wire diameter
5. Clean wire feed path

Possible Causes:

• Exceeding duty cycle
• Blocked cooling vents
• High ambient temperature
• Continuous high-amperage welding

Solutions:

1. Allow cooling periods between welds
2. Clean cooling vents and fan
3. Improve workshop ventilation
4. Reduce amperage or weld time
5. Wait for thermal protection to reset (15-20 min)