Troubleshooting − Waviness Of Bead; Troubleshooting − Distortion; Troubleshooting Guide For Semiautomatic Welding Equipment - Hobart Handler 125 EZ Owner's Manual

8-14. Troubleshooting − Waviness Of Bead
Possible Causes
Welding wire extends too far out of nozzle.
Unsteady hand.
8-15. Troubleshooting − Distortion
Possible Causes
Excessive heat input.

8-16. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem
Wire feed motor operates, but
wire does not feed.
Wire curling up in front of the
wire feed rolls (bird nesting).
Welding arc not stable.
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Support hand on solid surface or use two hands.
Distortion − contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Set Metal Thickness Selector switch to a lower selection.
Increase travel speed.
Weld in small segments and allow cooling between welds.
Probable Cause
Too little pressure on wire feed rolls.
Incorrect wire feed rolls.
Wire spool brake pressure too high.
Restriction in the gun and/or assembly.
Too much pressure on wire feed rolls.
Incorrect cable liner or gun contact tip size.
Dirty or damaged (kinked) liner.
Wire slipping in drive rolls.
Wrong size gun liner or contact tip.
Incorrect Metal Thickness Selector switch setting on
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun.
Feed motor bogging down.
Corrective Actions
Corrective Actions
Remedy
Increase pressure setting on wire feed rolls.
Check size stamped on wire feed rolls, replace to match
wire size and type if necessary.
Decrease brake pressure on wire spool.
Check and replace cable, gun, tip adapter, and contact
tip if damaged. Check size of contact tip and cable liner,
replace if necessary.
Decrease pressure setting on wire feed rolls.
Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Replace liner.
Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.
Match liner and contact tip to wire size and type.
Change Metal Thickness Selector switch setting.
Repair or replace gun as necessary.
Too much feed roll pressure. Loosen tension knob.
S-0641
S-0642
OM-923 Page 35