Troubleshoot Welding Machines

Troubleshooting welding machines is painful – you have a stack of work, the client is screaming and of course the welding machine picks that instant to stop – whether you are just starting out or have years of experience it’s stressful to have machine problems especially if you can’t fix it quickly. It’s a waste of time and money, right? Learning to quickly fix a welding machine is more convenient, less stress, and gets you back working.

7 Easy Ways to Troubleshoot Welding Machines

1. Machine Doesn’t Start – There are 4 things to check with this problem: a blown fuse, dead power circuit or wrong voltage input, and overloading.

  • First, check the fuse and replace if it has blown.
  • Next, check the circuit and the voltage input and correct if necessary following the instruction manual.
  • If it’s overloading just let it cool down before using.

    • 2. Welding Machine Suddenly Stops – This issue is usually due to: overloading, obstruction of ventilation outlet, or dysfunction internal cooling fan.

  • To avoid overloading remember to always follow the recommended machine cycle.
  • Check the ventilation outlet for any obstruction and clean.
  • Check the fan to see if it needs repair or replacement.

    • 3. Machine Doesn’t Switch Off – This happens when the on/off switch failed or the feedback line is worn out. Check whether it needs repair or replacement.


    4. Polarity Switch Problems – Using the polarity switch whilst the machine is under load can cause damage. Replacing the switch is necessary for this problem.

    5. Electrical Shocks – This happens when the welding machine frame is not grounded properly. Review the manual and follow the instructions on how to ground the frame of the machine and its cover.

    6. Damaged Cables – Long term use of welder cables causes them to worn out. Continuing to use damaged cables is dangerous and may cause more problems. Be sure to check your cables from time to time to avoid the issue and replace when damaged.

    7. Bad Ground Clamp – This occurs when the ground clamp gets coated with oxidants. Because of this, the electrons cannot transfer easily which alters the flow of the current and create resistance to the current flow. Check and clean your ground clamp regularly to avoid oxidants coating on the ground clamp.

    I have listed 7 easy ways to troubleshoot a welding machine and extend its working life. We can all get attached to a favorite old friend that has served us well for years but there comes a time when you seems to spend as much time repairing as doing and sad though it is, you need to think of retiring the old faithful to build a relationship with a new welding machine and concentrate on doing and building happy clients.