Question about Hobart Handler 140 Mig Welder

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Welding aluminum and wire keepscoming out of rollers

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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.

Posted on Jan 12, 2011

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Posted on Jan 02, 2017

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1 Answer

I have a Lincoln wirematic 250 when I weld it will run fine but once in a while it will pulse the ark in the weld. And is doing it more often. Stoping me from running a continuous bead.


indicates the following problems
rusty wire in use-- the rust builds up in the inner wire and will not allow free movement
the inner cable is worn and is grabbing the wire in a groove -- the inner cable will wear a groove and that catches the wire in certain situations --
the feed rollers are worn or the wire in use is not correct for the groove in use
most feed rollers have 2 grooves and each one is for set dia wire there are different rollers if gasless wire is in use to prevent the wire from deforming as it passes through the rollers

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I have a lincoln weld pack 100 hd, and i want to weld aluminum but i dont know how to start. i buy a 4043 fil d aluminium mig and i dont know if my welder it ill be fine to weld,


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The F 1 circuit breaker, manual reset is tripping not allowing it to weld. Could it be something as simple as the reset itself


Rated Output at 20% Duty Cycle 150 A at 16 VAC
150 A at 16 VDC Welding Amperage Ranges AC/DC 10 - 165A Max. Open-Circuit Voltage 80 V Amps Input at Rated Output AC-230V: 21A
DC-230V: 23A You need to configure the machine to specifications of the material you going to weld.That is :
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1. The best feeding of wire for aluminum is done with a spool gun. If you can't use a spool gun, use the shortest gun possible and keep the gun as straight as possible. Use Argon only for shielding gas. Only use a push gun technique when welding aluminum. 2. If you are having feeding problems, one thing you can try is a contact tip that is one size bigger than your wire. 3. The most common wire type is ER4043 for all-purpose work. ER5356 is a stiffer wire (easier to feed), and is used when more rigid, higher-strength weld properties are needed. 4. Clean the aluminum before welding, to remove the oxide layer. Use a stainless steel wire brush used only for cleaning aluminum. 5. Fill the crater at the end of the weld to avoid a crack. One way to do this is to dwell in the weld pool for a second at the end of the weld.
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1 Answer

I have a weldmark 140. When you turn the voltage knob it controls the wire speed. The wire speed knob does nothing


Flip up the cover on the side to expose the welding wire rool.
push the feed button on your welding gun, and watch the feed rollers.
If they are turning, then you need to increase the force on your rollers untill the wire starts feeding.

If the rollers do not turn, then you most likely have a bad switch, or connection in your welding gun or your speed control

Good Luck

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Too much tension would smash your wire and it would not run correctly. Are you sure you are using the correct size rollers for the wire you are using. Rollers come in various sizes and applications. A knurled roller is used for flux cored wire. Make sure you sizes match up. They are stamped on side of rollers. Good luck!

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Wire feed


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1 Answer

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Usually a flux core only welds steel. It is a higher penetration weld than a MIG. Usually it acts similar to 6011 rods in SMA (Shielded Metal Arc) welding -- a.k.a. stick welding -- if you're familiar with that. I don't believe there is such a thing as flux wire for aluminum. There may be stainless wire for it, but I've never seen it. It probably could also be used for building up cast iron and cast steel, but nothing structural. I have a Chicago Electric one and I love it -- simple and it penetrates hard. My 90 amp will weld to 3/8" without breaking a sweat and if I baby it will go to 1/2" or better. It is difficult to go much lower than 12 or 14 gauge though due to the high penetration.

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