I've had this welder for about 3 years now. Its starting to surge when it warms up. Its like the wire pulsates. Makes for a terrible looking weld with lots of air pockets. Any one ever heard of one doing this?? Any ideas??? I am not a welder by any means. Just try to fix my own stuff and do small projects.
Hobart Handler 125 EZ
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deereman75
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I am not much of a mig guy, so take this for what it's worth. It sounds like your drive rolls might be slipping. I think that could either be bad adjustment, badly dirty liner, or worn out/plugged rollers. Are you running coated wire? Are you running knurled/serated drive rolls?
Ed of all trades
Elite Member
Replace the liner and you should be good, if you are cheep pull the liner out and clean it in a pan of nafta. I know I can't spell, it is a paint thinner. Cleaning works most of the time.
Thanks for the input guys. This one is flux core wire, no gas. Don't think its coated wire. I'll look at the rolls. that could be an issue since its adjusted all the way. No more room to tighten.
As far as the liner. Is this what the wire rides in inside the rubber going to the gun?? I'm not much for spelling either. I know what you're talking about though. I have some here.
If I need to replace the rollers, where is a good place to get them that won't cost an arm and a leg. Guess the cheap comment fit pretty good, eh???
As far as the liner. Is this what the wire rides in inside the rubber going to the gun?? I'm not much for spelling either. I know what you're talking about though. I have some here.
If I need to replace the rollers, where is a good place to get them that won't cost an arm and a leg. Guess the cheap comment fit pretty good, eh???
rankrank1
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Flux core wire usually makes a liner dirty the fastest as flux core is not as clean and pure as the wire that is used with gas mode. So that is likely your trouble if problem returns since you have been using it 3+ years.
The liner looks like an old time throttle or choke cable on a tractor or mower. The liner runs the entire length of your lead hose (ie. from the machine to the gun).
Usually costs around $17 - $22 or so to buy a new liner. Or sometimes, as has been pointed out, you can get lucky and soak the liner in solvent like Naptha and clean them to remove the dirty residue. Often though a kink or deformation of the liner has occurred (e.g someone stepping on it or laying heavy object on it). If the liner is deformed, then replacement is the only fix.
The liner looks like an old time throttle or choke cable on a tractor or mower. The liner runs the entire length of your lead hose (ie. from the machine to the gun).
Usually costs around $17 - $22 or so to buy a new liner. Or sometimes, as has been pointed out, you can get lucky and soak the liner in solvent like Naptha and clean them to remove the dirty residue. Often though a kink or deformation of the liner has occurred (e.g someone stepping on it or laying heavy object on it). If the liner is deformed, then replacement is the only fix.
Arc weld
Veteran Member
Are you using the right size and type drive rolls for the wire? You shouldn't have to tighten the drive rolls all the way. That could be causing the problem and deforming the wire so it binds in the liner and/or contact tip. It would also cause little bits of wire to flake off and plug the liner. Flux-core should use a knurled drive roll and need very little tension since the knurled part will grab the wire a lot easier than a smooth drive roll.
Robert_in_NY
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Out of curiosity but did you happen to kink the hose to the gun while you were welding? On my handler if you get a tight bend in the hose it causes the wire to slip on the rollers because of the added tension from the tight bend. Straighten the hose and it works fine.
Can't say that it ever got kinked. The way we have it set up in the shed it would be kind of hard to have that happen, though anything is possible. Might have happened to one of the boys and didn't cause an issue at that time so nothing was mentioned.
Going to be using it again hopefully in the first few days of the week if I have spare time. We'll see if its still working ok or back to causing an issue.
Thanks for all the comments and suggestions. Much appreciated.
Going to be using it again hopefully in the first few days of the week if I have spare time. We'll see if its still working ok or back to causing an issue.
Thanks for all the comments and suggestions. Much appreciated.
