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A Working Welding Machine That Needed Some Tweaking Done. Model: Zika

By on October 23, 2021
welding machine repair








A Welding technician came to my shop; he said that he machine is vibrating when powered on and was wondering what the cause was. While the customer awaits, I powered the machine on and soon enough, it started to make a loud noise and it was vibrating which gave me an indication where the fault is. Let’s get started.

how to fix welding machine

After dusting the whole machine off (it was really nasty) I proceeded to the area that needed attention.

how to repair welding machine

The previous photo should give you a hint where the problem is and yes it was the fan.

a broken fan blade

As you can see, some of the fins on this fan were broken which caused an unbalanced spin when power was applied to the machine.

The only answer to this problem is changing the fan.

welding fan replaced

According to the customer, this machine has not been maintained for the past seven years which makes this fan an original one from the factory.

welding machine fix

I have almost the same fan (the Amp rating is less but workable).

I went ahead and installed the fan but I almost powered on the machine when I noticed this problem.

how to fix a welding machine

The DC power polarity was not correct on the new fan so I cut the wires off and did what was needed to be done and powered on the machine.

The Machine was running fine, no vibrations and the voltages were according to specifications but the customer asked me to do another task for him.

how to fix a broken welding machine

The negative and the positive outputs of the machine pins needed replacement. The customer provided these parts for me so I can replace for him.

how to repair a broken welding machine zika

I did an overall check on the machine and I could not find anything that needed my attention. The customer liked what has been done to his machine and was very generous.

Mission Accomplished.

This article was prepared for you by Waleed Rishmawi, one of our ‘Master Authors’ and currently working in the Bethlehem area of Palestine repairing electrical and electronic equipment.

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Note: You can check his previous article on A Shorted Surround Sound Amplifier Repaired




  1. Parasuraman S

    October 23, 2021 at 1:26 pm

    Yes, yet another mission accomplished with the usual professional touch!

    • Waleed Rishmawi

      October 23, 2021 at 4:39 pm

      Parasuraman: I appreciate the comment my friend. have a blessed day

  2. Yogesh Panchal

    October 23, 2021 at 2:03 pm

    well done! waleed.

    • Waleed Rishmawi

      October 23, 2021 at 4:40 pm

      Yogesh: thanks man. have a blessed day

  3. Albert van Bemmelen

    October 23, 2021 at 3:27 pm

    Fan with 24VDC 0.36A or one with 0.35A indeed won't make that much of a difference at all. Provided that the new Fan blades produce the same flow of air. It is still strange that we never just can replace those Fan blades by new good blades from these brushless ball bearing motors. That sure would improve these repairs because the motor often never needs replacing.

    • Waleed Rishmawi

      October 23, 2021 at 4:45 pm

      Albert: yes, that is the idea. enough air rushing through to keep the machine cool is the objective here. i wish I could find just the blades and replace them. it would be faster and cheaper but there are not available at all. have a blessed day

    • abdellah kamli

      October 24, 2021 at 12:57 am

      Hi Albert,this is a good note that would be the best desired solution especially while preserving the original motor, I am thinking of the 3D printer which can reproduce the deteriorated fan, also all types of electrical plugs or other plastic tools come to mind.

  4. Babu M S

    October 23, 2021 at 10:37 pm

    It is understood your having all spares in stock, that makes you to repair the machines in no time. Thank you very much for sharing.

    • Waleed Rishmawi

      October 25, 2021 at 2:56 pm

      Babu: you are most welcome and yes I do my best to get the right part for the right job but sometime ordering these parts take forever to get so I order a head of time but that need know what parts are needed in the shop and that comes from experience. have a blessed day


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