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Wire is jamming
or 'bird nesting'
at the drive
roller.
Wire burns back
to contact tip.
Ground clamp
and/or ground
cable gets hot.
Dirty, porous or
brittle weld.
Torch nozzle arcs
to work surface.
Welding unit
gives trickle
shocks.
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90A Flux Core Welder
1. Too much tension on
drive roller.
2. Torch liner worn or
damaged.
3. Contact tip is clogged or
damaged.
4. Liner stretched or is too
long.
1. Torch liner worn or
damaged.
2. Liner stretched or is too
long.
3. Wrong size contact tip.
4. Contact tip is clogged or
damaged.
5. Wire feed speed is too
slow.
Bad connection from cable
to clamp.
1. Plugged welding nozzle.
2. Dirty or rusty welding
wire.
Slag buildup inside nozzle
or nozzle is shorted.
1. Accidental contact with
workpiece.
2. Current leakage caused
by moist clothing or
work area,
1. Adjust drive tension. (See
Install the Welding Wire).
2. Replace torch liner.
3. Replace contact tip.
4. Trim liner to proper length.
1. Replace torch liner.
2. Trim liner to proper length.
3. Use correct size contact tip.
4. Replace contact tip.
5. Increase wire feed speed
Tighten connection or replace
cable.
1. Clean or replace nozzle.
2. Replace spool of wire.
Clean or replace nozzle as needed
(see Maintaining Nozzle).
1. Avoid contact with workpiece.
2. Make sure clothing and work
area are dry.
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