Troubleshooting Guide For Semiautomatic Welding Equipment - Hobart Welding Products Handler 125 Owner's Manual

9-17. 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).
Wire feeds, but no gas flows
(GMAW).
Welding arc not stable.
OM-283007 Page 34
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.
Gas cylinder empty.
Gas nozzle plugged.
Gas cylinder valve not open or flowmeter not adjusted.
Restriction in gas line.
Loose or broken wires to gas solenoid.
Gas solenoid valve not operating.
Incorrect primary voltage connected to welding power
source.
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.
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, 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.
Replace empty gas cylinder.
Clean or replace gas nozzle.
Open gas valve at cylinder and adjust flow rate.
Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Have Factory Authorized Service Agent repair wiring.
Have Factory Authorized Service Agent replace gas
solenoid valve.
Check primary voltage and relink welding power source
for correct voltage.
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.