Hey guys,I'm a mechanical engineer that's been working for a pressure vessel manufacturer for a few years and I got really interested in hobby welding about a year ago. I have a question about some wire feed issues that I haven't been able to figure out, so I'm hoping some input from the more experienced than me will help.I have a Hobart Auto Arc 130 that I've been using with flux core to weld things on a ranch mostly (fences, etc.). Lately, it has been having trouble feeding the wire consistently. It seems to feed very weak and at times and almost in an oscillating pattern. To me, it almost seems like the motor shaft is bent or something.I am using only Lincoln Innershield NR-211.So far I have tried the following:-Thought liner was clogged or kinked - replaced with no change at all.-Adjusted drive roll tension - less and more.-Changed from .035" wire size to .030" - helped a little.-Inspected spool - added washer to spool assembly, it seems to rotate consistently.-Not a ground issue - happens when feeding only.-Not a contact tip issue - happens without contact tip.-If I line up the gun straight, it helps a lot. But it's a pain to only be able to weld with the gun cable straight.Are there any other troubleshooting steps I can try?
Reply:I once had a Century MIG welder that would give me fits sometimes and I tried everything. Then I put a grade 8 washer under the spool tension nut and never had a problem again. The softer regular washer was catching every once in a while and changing the spool tension, but only for a partial turn of the spool. At it's worse, it would catch on the wing nut and turn it a quarter to half turn at a time, increasing the spool tension as I welded. Using the grade 8 washer under the spool tension wing nut solved all of my feeding problems. The point that I'm getting to is that even though you checked everything, have you really checked them? Sometimes it's easy to miss something that's kind of intermittent. Drive rollers that are the wrong size or tension can slip part of the revolution, but feed fine the other part of the revolution. Take them off and look carefully at them for signs of wear, dirt, etc. and then make certain that they are placed back on the shafts correctly and the wire is in the correct groove for flux core wire. With a new liner and still getting feeding problems I'm betting that you either have a reel tension problem or a drive roller or roller tension problem.If you have access to a tachometer you might also try watching the roller speed to see if it is constant. Problems with the motor can cause this symptom, but it's very rare. They usually just stop altogether. Make absolutely certain that the problem is in one of the other places before attacking the motor.CharleyMiller MM252Miller Bobcat 225NTMiller DialArc HF / DIY Cooler2 Victor O/A TorchsetsMilwaukee 8" Metal SawMilwaukee Dry Cut "Chop" Saw 5 Ton Wallace Gantry Various Grinders, Benders, etc.
Reply:You can get weird feeding issues with small rolls of wire sometimes. As the wire runs out, the inner part of the spool is so tight it doesn't feed properly. You can try switching to larger rolls of wire. They're cheaper by the pound anyways.Make sure your groove in the roller isn't worn. Watch it feed as you point the gun towards a block of wood at an angle, if the rollers start slipping, and the wire doesn't advance, it might be wear issues (although I doubt it, I have run many pounds of wire thru my Hobart with no real wear issues)I will occasionally have feed issues when the machine gets hot, it's not mechanical but electrical in nature. The wire will stub as if the ground is intermittent. This usually occurs when I push the duty cycle. Shortening the stickout while welding usually solves the problem."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Thanks for the great replies. I will make sure to check everything in more detail. CharleyL: I am definitely going to replace the washer, since it can't hurt, and mine is a cheap soft one right now.How can you visually tell if the drive roll is worn? I am using the knurled flux core side. It looks the same to me as a new one that I saw in a store Saturday as far as wear. How often are drive rolls usually replaced?Also, something else I've wondered, what are the negative effects of increasing the tension? I used to be able to feed it at a block of wood until it doesn't get stopped by the wood, set it and I'd be good. Now, it seems like I have to crank down on the tension pretty hard. Maybe this is a normal amount of tension...Farmersamm, now that you mention it, yesterday I used up a whole 1 lb spool. Everything was fine until about 1/4-1/8 of the wire was left and that's when this problem was the worst. Finally, I almost gave up, but noticed I was out of wire. I will go ahead and only use 10 lb spools, since they're cheaper anyways. I will reply back after checking these things.
Reply:Originally Posted by 81CamaroDudeAlso, something else I've wondered, what are the negative effects of increasing the tension? I used to be able to feed it at a block of wood until it doesn't get stopped by the wood, set it and I'd be good. Now, it seems like I have to crank down on the tension pretty hard. Maybe this is a normal amount of tension...
Reply:So, after the many great replies, I've tried just about everything mentioned and without luck, I'm afraid. I tried a grade 8 washer with a 1lb spool, which did not seem to help much. I then bought the Hobart 10lb spool kit and a 10lb spool and the issue is still present. I did notice though at some points even with the contact tip completely off, the wire has trouble feeding. At this point, I can weld about 24" until I need another contact tip. I took the drive roller off and cleaned it with some gun solvent. I'm not sure what they look like when they are worn and need to be replaced, but here are some photos
o you think my next step should be to replace the roller? Should I stick with a Hobart roller or is there a better alternative?Right now I am using the standard .030" / .035" flux core roller and a (relatively new) .030" / .035" liner. Would switching to a .045" liner be worth trying?
Reply:Really doubt you wore out the roller. I've got countless 10 pound roles through mine....plus yours looks good. Try it with gun off to eliminate gun/liner.Last edited by farmer2; 10-01-2014 at 10:58 PM.
Reply:Is the wire feeding off the roll on the top or bottom side, makes a difference.REAL TRUCKS DON'T HAVE SPARK PLUGS
Reply:It is feeding off the bottom side of the roll.
Reply:Originally Posted by 81CamaroDudeThanks for the great replies. I will make sure to check everything in more detail. CharleyL: I am definitely going to replace the washer, since it can't hurt, and mine is a cheap soft one right now.How can you visually tell if the drive roll is worn? I am using the knurled flux core side. It looks the same to me as a new one that I saw in a store Saturday as far as wear. How often are drive rolls usually replaced?Also, something else I've wondered, what are the negative effects of increasing the tension? I used to be able to feed it at a block of wood until it doesn't get stopped by the wood, set it and I'd be good. Now, it seems like I have to crank down on the tension pretty hard. Maybe this is a normal amount of tension...Farmersamm, now that you mention it, yesterday I used up a whole 1 lb spool. Everything was fine until about 1/4-1/8 of the wire was left and that's when this problem was the worst. Finally, I almost gave up, but noticed I was out of wire. I will go ahead and only use 10 lb spools, since they're cheaper anyways. I will reply back after checking these things.
Reply:Check your gun liner for a kink.
Reply:If it worked good, then I wold say it is likely your liner. To trouble shoot: Remove tension from the drives and see how hard it is to pull wire through the line. If it is hung up, you may have instaled the liner incorrectly. The length is very critical to wire feed transfer, and must be correct. If the wire flows good by hand, you could have more complicated problems.Constant Current Weldor.
Reply:Hi 81 Camaro Dude, My name is Brian , I bought the Hobart 130 4 years ago and it's have the wire feed problem at first minute of day 1! !! and I put it away in far far away corner of my oldest shed. Today I have some free time and sit down to fix it... ( warranty is over long ago ) after 40 minute look at the wire feed component running, working …..….I found down the bottom wheel is slide 1.3mm to the out side cage. In this case because the design don't have the stopper for the bottom roller, and the black cover plastic cage is 1.3 to 1.4 mm width wider and the bottom wheel is free to slide 1.3 mm to the out side when it turn... cause the wire roll out of the deep grove line. Now take the plastic cage cover out, I'm then took the 1.3 mm washer and place into the shaft[ maybe your machine plastic cage is little bit different with mine, you need to measure the gap] ( just outside next to the bottom wheel) and put the plastic cover back( press it in and turn it in)….. Problem SOLVED. The wire is back into the deep grove line 100% Work like King, feeding sound is nice. Sorry about my English , I'm tried my best to explained . Today is 9-15-2018 . Hopefully any one still have 130+135 Hobart got a chance to read this reply...., on the last picture you will see the very light dark line just 1.3 mm below the deep grove line. the first is show how the washer sit into the plastic cage... and the second pict. is show the wheel and washer and plastic cage put into order,just 5 second repair and you have a nice welder machine. Cheer. Attached ImagesLast edited by Brian M; 09-16-2018 at 12:24 AM.
