After performing several SMAW repairs throughout the day, a heavy equipment technician notices that their welding cables are becoming excessively hot and the machine's output seems inconsistent. The welding leads are 15 metres long. What is the most probable cause of this issue?

Question: After performing several SMAW repairs throughout the day, a heavy equipment technician notices that their welding cables are becoming excessively hot and the machine's output seems inconsistent. The welding leads are 15 metres long. What is the most probable cause of this issue?

Answer options: ✅ The welding cables are undersized for the current and length, leading to voltage drop and excessive resistance.

• The ambient shop temperature is too high, causing the cables to overheat.
• The electrode holder is faulty and drawing too much current.
• The welding machine's cooling fan is not operating correctly.

Correct answer: The welding cables are undersized for the current and length, leading to voltage drop and excessive resistance.

Explanation: Excessively hot welding cables and inconsistent output, especially with longer leads, strongly indicate that the cables are undersized for the amperage and length being used. Undersized cables have higher resistance, leading to significant voltage drop, reduced current at the arc, and I2R losses manifesting as heat in the cable. While other issues could cause problems, cable sizing is critical for long runs.