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

9-15. Troubleshooting − Distortion
Possible Causes
Excessive heat input.

9-16. 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.
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.
Select lower voltage range and/or reduce wire feed speed.
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.
Gun end not inserted into drive housing properly.
Dirty or damaged (kinked) liner.
Wire slipping in drive rolls.
Wrong size gun liner or contact tip.
Incorrect voltage setting for selected wire feed speed 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.
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.
Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
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.
Readjust welding parameters.
Repair or replace gun as necessary.
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OM-923 Page 35