In daily welding operations, the stable performance of the wire feeder is crucial. To help engineers and operators quickly locate and resolve issues, we have compiled the common faults, causes, and corresponding troubleshooting methods for the OTC Daihen CM6201, CM6202, and CM6402 wire feeders.
1. Common Troubleshooting & Solutions Quick Reference
When your equipment experiences abnormalities, please check against the “Phenomenon” in the table below and follow the “Solutions” for maintenance or part replacement:
| No. | Phenomenon | Cause of Fault / Abnormality | Solutions |
|---|---|---|---|
| 1 | Wire Deformation / Crushing | Excessive pressure | Adjust according to the wire pressure adjustment value. |
| Wire diameter does not match the engraved value on the roll | Replace with a wire feed roll that matches the wire diameter. | ||
| Wire feed roll and pressure roll are worn out | Replace with new parts. | ||
| 2 | Wire Feed Failure | Control cable has poor contact or is broken | Check the socket connection; inspect or replace the cable. |
| Motor failure | Replace with a new motor. | ||
| Insufficient pressure | Adjust according to the wire pressure adjustment value. | ||
| Inlet of the guide tube or area around the feed roll is clogged with chips and debris | Clean out the chips and debris. | ||
| 3 | Pressure Roll Rotates Unsmoothly | Defective bearing | Replace with a new bearing. |
| 4 | No Shielding Gas When Torch Switch is Pressed | Gas cylinder valve is closed | Open the valve. |
| Insufficient gas cylinder pressure | Check the gas pressure. | ||
| Solenoid gas valve (SOL) failure | Check the operation of the solenoid gas valve (SOL) and replace if necessary. | ||
| 5 | Shielding Gas Will Not Shut Off | Solenoid gas valve failure | Check the operation of the solenoid gas valve (SOL) and replace if necessary. |
| 6 | Gas Hose Cracks | Hose aging or physical damage | Replace with a new gas hose. |
2. Purchasing Original Parts & Technical Support
If you confirm the need to replace components (such as wire feed rolls, motors, solenoid gas valves, etc.) after troubleshooting, please directly provide us with the equipment nameplate or photos of the parts. As an authorized distributor, we promise to provide 100% genuine original parts with professional technical guidance from our maintenance engineers.
Contact Us for Inquiries & Support
- Global Sales & Tech Support: International Sales Team
- 24/7 Service Hotline (WhatsApp & WeChat Same No.): +86-180-9663-1656
- Official Email: ahojotc@gmail.com
Encounter an unsolvable fault? Please take a video or photo of the equipment's abnormality and send it to us via WhatsApp or Email. We will provide maintenance advice as quickly as possible!