No.	Problem	Location	Cause	Checks & Corrective Action
1	Wire Break	1. Near the feeder plate	Feeder Panel is worn	Check feeder plate & replace if necessary. Replace during each Preventive Maintenance rebuild/overhaul.
			Water from the feeder plate nozzle does not hit the feeder plate	Clean the feeder plate nozzle and check for proper water pressure.
		2. Near the wire guide	Wire guide is dirty	Check guide and clean; normal maintenance
			Wire is dragging in the guide	Check for alignment and make adjustments
			Wire guide is not in the proper location	Reset the guide accurately
		3. During initial string up	Wrong wire setting	Check for proper setting according to manufacturing practice
			Wire tangles or cross overs	Exchange the spool of wire; untangle the problem wires, if possible
		4. Immediately after start up and within about 5 mm	Air trapped in processing fluid Work is not square w/wire	Processing conditions are not correct. Degrease the work piece. Check process fluid water pressure. Verify the alignment and restart.
		5. After start up & more than about 5mm	Low pressure of process fluid	Check the process fluid nozzle for position and wear
			Inconsistent processing conditions	Check the suction port of the process fluid tank for dirt
			Foreign matter or pinhole inside the work	When processing a complicated shape, check ease of flow/discharge/removal of the fluid
			Defective wire	Change the wire
			Defective guiding of the wire	Check the urethane rubber rollers for proper friction, cuts or dirt
				Adjust wire tension to the correct setting
2	Poor Accuracy	1. Defective shape	Low wire guide pressure, not maintaining location	Adjust the wire guide, reset the wire guide
			Low wire tension	Set the wire tension correctly, according to your best manufacturing practice
			Large change in ambient temperature	Remove stress/strain in the work
			Non-uniform workpiece	Check vertical alignment of the wire
			Incorrect offset	Clean and maintain guide/dies, etc.
3	Poor finish or surface accuracy	1. Rough surface 2. Longitudinal streaks occur on the processed surface.	Inconsistent processing conditions, nonuniform electrical discharge. Low wire tension Incorrect process parameters Slow processing speeds	Increase wire feed rate Increase the processing speed
4	Poor processing speed	1. No increase in processing speed	Inconsistent processing conditions (incorrect quality of material, plate thickness and size)	Set according to conditions in your best manufacturing practice.
5	Curling	1. Wire not settling & storing easily in the scrap box	Nonuniform residual stress in the wire	Increase applied current by one tap (for increased processing speed).
			Partial wear of transfer roller belt	Replace belts when wear exceeds one third the diameter of the wire.
			Misalignment of transfer roller belt	Consult the equipment manufacturer/dealer
			Incorrect pressure of transfer roller belt	Run at a belt pressure suitable for the wire
			Wire is not straight.	Replace the wire with wire from a Lot with proper straightness
6	Poor automatic threading because of poor insertion	1. Impossible to thread into guide and workpiece hole	The guide is dirty or clogged up. Too small a diameter in the work hole. Low waterjet pressure & flow rate. Misalignment between the upper head and the work hole.	Complete cleaning and regular maintenance. Check the machine practices for minimum diameter of the workpiece hole. Manually adjust the water pressure valve.
	Poor automatic threading because of poor cutting	Cutting w/cutter 1. Cutting is not performing well 2. Unable to insert into the prepared hole.	Partial wear of the cutter and low cutting power. Cutting burrs occur at the end of the wire. Wire is not straight.	Replace the cutter if blades show dents or wear. Check for proper cutting force and pressure Replace the cutter. Replace the wire with a new Lot of straight wi
	Poor automatic threading because of poor cutting	Cutting w/annealer 1. Poor Cutting quality 2. Cutting location varies	Incorrect wire diameter data input Poor quality wire Different quality of wire	Adjust cutting to the quality and characteristics of the wire. Check data input regarding wire diameter.

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