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I have hobart handler with a spool runner 100 when trying to weld withit it burns thru like a plsma cutter on settings 3 thru 8 and on 1 and 2 it wont penetrate ibought this machine new in augest it has been at repair shop for 90 days tech dont no how to fix it any idea
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This happens to me all the time. Wear and tear has taken its toll and everything has to be maintained for it to work. Most likely the welding tip is worn and should be replaced. Lincoln electric tips work well and I will replace mine several times during the day. Also check your tension and make sure the wire will uncoil freely from the spool. You can remove the tip and make sure the wire will feed without it. If not, your liner may be worn out. Also a welding Jell will help keep the tip from cloging. It will still happen, but hopefully not on your first weld of the day.
Check the two main diodes. These units have a light duty cycle. About 20% if I remember correctly. I have one that I was welding with for a considerable amount of time, and burned up the diodes. You can test them by disconnecting the wires (with unit disconnected) and use a ohm meter. You should get a reading in one direction, but not the other. If no reading, then the diode is blown. You can order new ones from your local welding shop. Also check all conections on the secondary for any signs of overheating and loose connections.
your hobart machine it's not suit up for standard aluminum welding, the lenght of the gun it's too long therefore the wire will nest at the drive rolls. You need to buy a spool gun. Or change gun liner for a teflon one (instead of metal one), then change the drive roll for knurled ones and finally oversize your tip if you can. No need to do ALL this if you buy a spool gun.
Check your input line voltage. 115 volt Mig welders / plasma cutters need stable voltage / current. Test to see if the voltage drops to below 100 volts when welding. If so, find a more stable power supply.
When you pull the trigger the entire spool of wire and anything metal that touches it becomes electrically hot. If the tail end of the spool is hanging loose and touches something on or connected to the chassis it will do that, and could have welded the connection so it's solid.
lets go over the basics 1 do you have it set up ,the wire feader turned up at least to see if it sparks 2 do you have itset up at least to see if the amps are on enough to get a spark? try thoughs and see where you are,then turn those up enough to weld with . (make sure your wearing a good helmut .please you only get one pair of eyes!!!!!!!!! )hope this helps jojogunn.
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