I've been playing around with my brothers Hobart Handler 140, and the problem is that the wire comes out so curved it's hard to aim and stay consistent because it jumps all over the place.

Does anybody else have this problem?

What can I do to rectify the situation?

 

Whats making it come out curved?

 

I guess it's curved from being tightly wound on the wire roll.

It's so curved that as it's feeding out it's touching the bottom of the tip and it keeps fusing onto it.

 

thats not right. either the tip is too small for your wire, or its clogged with a chunk of slag. Replace the tip.

 

It has been doing this since it was brand new.

I think the problem may be the tip is too large for the wire? And it's not holding it tight and kind of letting it bounce around as it leaves the tip?

I just gave up using it and am using my Hobart 200 instead. No problems there. It welds so much nicer!

 

Could be the tip, are you sure the slack on the wire is good ? I have seen wire that was on there to tight, and the wire itself would jump a little .

 

I'll check that.

My brother was having pretty good luck with this Handler to do his turbo piping...maybe I'll ask him when he gets home if he had it setup differently than me.

 

make sure your gun cord is straight as possible and doesn't have any tight turns.. i only have the problem when i don't stretch out my cord before i weld...

 

If the tip was too small the wire would start to back up and youd eventually geta birds nest in the feeder. If the tip is too big it wouldnt curve out...it would jump around all over the place. I think its the wire tension. Go reset the tension and check deflection. Im almost positive that this is the problem. Hope this helps

 

How can that change the curvature of the wire as it leaves the tip?

The wire is jumping around because the wire comes out with such an extreme curve.

I've checked everything else...the problem has to be with the wire spool. It's so tightly wound that even away from the actual spool it's still very curved.

I'm pretty sure if i switch to a larger spool I won't have this problem.

 

It could have a damaged liner in it that is kinked and causing the wire to get this way.

Also try swapping spools of wire. I have seen some cheaper wires that seemed to do some crazy ****....maybe due to shitty equipment that rolled it on or something....I dunno for sure.

Or try swapping the entire leads from one machine to the other if they will.

 

could it bee the rollers being tightened too much?

i've never had that problem with my lincoln; and i've used some of the cheapest wire you can get

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Jonathan_ED3 &raquo;</TD></TR><TR><TD CLASS="quote">How can that change the curvature of the wire as it leaves the tip?

The wire is jumping around because the wire comes out with such an extreme curve.

I've checked everything else...the problem has to be with the wire spool. It's so tightly wound that even away from the actual spool it's still very curved.

I'm pretty sure if i switch to a larger spool I won't have this problem.</TD></TR></TABLE>

The wire is supposed to "curve" when it leaves the tip. Not instantly...but when it gets out a few inches it should curve. Thats called deflection. If it curves too much or too soon then you most likely have too much tension on the wire. If the wire is jumping around then you most likely have too big of a contact tip or you have an ovalized tip. It is impossible for the wire to "jump around" if youve got the correct tip on it. If you look at the tip where the wire comes out youll be able to see if its ovalized or not. As i said before...check the wire tension.

Also...i agree with Engloid. Ive seen cheap wire have too much deflection for the amount of tension it has. If the tip is good and the tension is good then a new spool should be the next thing you check.

Once again...Good Luck

 

This often happens from the drive roller tension being to tight.