Hobart 210 “shaving” .035 wire…. Why?

Jeffncs

Jeffncs

Well-Known Member
Joined
Apr 4, 2017
Location
Wake Forest
My Hobart has been spinning .035 Vulcan (HF) solid wire for a few years without issue. Today the machine started off fine then it wouldn’t hold a smooth bead to save its life. Sputtering and popping.

Plenty of gas and it’s “on”.
Metal is clean.

Opened the side door found a big ball of wire shaved off. Cleaned it out and finished without too much trouble.

I opened the side hatch again just now and the wire is getting “shaved” as it enters the little metal tube that leads to the gun. Why would this happen?

Wire still feeds fine. Just leaving super fine, shaving behind which clogs and stops the feed wheel. What’s causing this and how do I fix it?

Thanks!

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mbalbritton said:
I’d be looking at alignment of the tube opening to the groove on the feed wheels. And also for any debris or scratches/burs on the tube opening.

It looks like it’s clearly coming for the tube entrance.
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I was thinking the same. Thought about pulling it off to check for sharp edges. Odd since it just randomly started.
 
Tom@Hilltop_Machine said:
When was the last time the liner was changed? If it is constricting the wire as it goes thru the lead I could see the rollers struggling and causing this issue.
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I’ve had the machine a few years and never changed the liner. Quick google search says I should have replaced it long ago! Amazon has a new liner coming to me next week.
 
Good thought…. But the roller was in the correct slot for .030/.035.

Explanation: The roller has multiple wire diameters on the roller. The roller has 2 spots for .030/.035 and 1 spot for .024. The wire gauge is set based on where the spring-loaded pin is set (each spot is a different depth to align the wire on the roller to the sheath.
 

Looks like its in the Standard 030/035 slot thats just out of frame at the bottom of the picture.

With that said, the alignment looks a little off, not much, but maybe enough to cause it to shave some material:
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I'd pull that 3 groove roller out and make sure there isn't some junk on it down in the pocket. It almost looks like its not springing out far enough. Also, make sure the upper roller spins freely, even with some pressure on it.
 
The wire isn't aligned with the liner. Liner is a hardened spring type steel coil with a nylon liner. A feed roller would never have a sharp edge that would shave the wire while rolling.
Some rollers float a little to align, some don't.
V-groove hard wire, U-groove shielded or flux cored, Knurled aluminum.
How high do you have to set the compression of the rollers to feed? If your having to crank it down alignment and liner issues is the result.

Edit...the leading black nipple can wear a groove in them causing drag or alignment issues. Some units have them fore and aft. Also for anyone running bare steel wires, not copper coated the factory corrosion inhibitor clogs all of the above. Little cleaner wipes can be attached but i find them less than effective and just another consumable.
 
Took some more pics and measured the wore (.036”). The roller groove is the correct one. It’s possible the tension was too high. I’ll drop that down.

Looks like the wire may be feeding low into the coiled spring guide.

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It looks like the end of that liner is bent/curved upward.
 
Liner should be delivered today. I should have ordered a 2nd at same time.

I may need some garage time to clear my head of the work day so perhaps a good excuse to tinker out there.
 
I noticed when the lead was pulled that the liner feed section was indeed bent.

I ordered and received the replacement liner. Somehow I measured once and cut twice???? ($&@!!!)

I got lucky Tractor Supply had them in stock so I ran over. Last one and was branded Hobart so legit….bonus it was on clearance. I would have bought 3 at that price but I got the last one.

I’m going to scour local TS stores for clearance welding stuff. Not sure if they’re turning over stock or changing brands but Hobart parts and rods were deeply discounted. (I also snagged a 5# box of 7018 for $12 - may go get another tomorrow!)
 
Jeffncs said:
I noticed when the lead was pulled that the liner feed section was indeed bent.

I ordered and received the replacement liner. Somehow I measured once and cut twice???? ($&@!!!)

I got lucky Tractor Supply had them in stock so I ran over. Last one and was branded Hobart so legit….bonus it was on clearance. I would have bought 3 at that price but I got the last one.

I’m going to scour local TS stores for clearance welding stuff. Not sure if they’re turning over stock or changing brands but Hobart parts and rods were deeply discounted. (I also snagged a 5# box of 7018 for $12 - may go get another tomorrow!)
Click to expand...
I've noticed our local stock is way down I hope they don't switch to some other brand like Forney.
 
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