Help with wire feed problem

[Laura]

Hi,

I have a Miller 175 mig and am having problems with the wire feed. I am using .030 wire and a .030 contact tip. When the tip has been removed the wire feeds easily for as long as I have the trigger pressed. However when I put the tip back on I can weld only about a 1/4" - 1/2" bead before it stops feeding. Then I have to pull the wire out with pliers while holding the trigger to get it moving again. I am using Miller consumables and have tried 3 different tips but the same thing keeps happening. I have also tried removing the tip and using a metal tip cleaner and then putting it back. Nothing works. Any ideas how I can fix this problem?

Thanks,
Laura

[SundownIII]

Laura,

Try swapping out the .030 contact tip with a .035 tip.

Sometimes you'll get a spool of wire that your tips just don't like.

Might try checking your drive roll tension. If it's too tight, it may be slightly deforming the wire (even though I assume it's solid).

Try those two things and get back if it doesn't solve the problem.

[TopRet]

Great advice from Sundown. You may have gotten a mis-marked roll of wire.

[dabar39]

Laura, Follow sundown III's advice and if that doesn't help check your gun liner for a kink or bent spot, that can effect the wire feed. How old are your drive rollers they may be worn or out of alignment. Oh, and by the way welcome to the board. Dave

[jwsrep]

Laura,
Are you having to use the pliers to pull out the wire when the tip is installed or out? If out, chances are your liner is either kinked or pluged. Often times, especially when a welder is rarely used, dust builds up on the top of the wire. It is then pulled thru the monocoil liner and clogs where the gun tube bends. Sometimes you can remove the liner, straighten it out and blow it out with an air nozzle. Or you can replace the liner for around $18. This is a very common problem. Once you have remedied the problem you can help it from happening again by installing a wire pad cleaner on your mig wire just before it enters the drive rolls. These can be purchased at any weld supply shop. Weld Aid makes a product called Lubematic wire pads and are sold in a pkg of 6 for around $7 or $8.

[Laura]

Still Trying

Thanks so much for the help everyone I really appreciate it!

I have tried the larger tip and it is a bit better but still stopping (and on the last attempt even stopped with the tip off). However I did notice as I moved the wire through the gun with the tip off that there are very slight curves in the wire. I then loosly held the wire as it came off the spool before going to the rollers and realized that the curves exist before it even gets into the rollers or liner. In the morning I am going to pull the spool and install a new one. If that doesn't help I will pull the liner out. Can you tell me if there are certain brands of wire known to be bad so I can avoid buying them? The one I have on now is Forney.

Laura

[SundownIII]

Laura,

Should have asked earlier, is the wire solid or flux cored? Makes a big difference.

I have used the .030 Forney wire on my HH187 and have never had a problem, however I've only used the 10# spools.

When you look at your spool of wire, while it's installed in the machine, does the wire come off the spool straight or is there wire laid over the wire as it leaves the spool. If there is wire over the wire coming out, you have a spool that has been miswound and should be replaced by your supplier.

Did the problem just start when you installed a new spool?

[cat]

.o35 tip

Definitely try the .035 tip with the .030 wire-made a big difference for me. Ever since I bought my miller135 welder tho, I've had more problems with wire and the tips - I was sorry my Cricket gave out. Don't know if it's worth trying to get the Cricket running again. Any opinions? Cat

[Bert]

WOW! GREAT ADVICE HERE!!!
I want to say welcome to the board, and of all these tips, it's GOT TO WORK
How 'bout posting telling us the stuff you weld and posting some pics of your stuff?

[Laura]

Hi SundownIII,

This has been happening the entire spool and it has been crossed over itself twice. It is also one of the small spools. Do you recommend using the 10" spools instead of the little ones?

Laura

[Laura]

Ooops in answer to your question it is solid wire, not flux core.

Laura

[crawler]

I'd think the 10# spool would work better since the spool is bigger. I've never used the small 1# spools, so I can' comment.

[SundownIII]

Laura,

In answer to your question, yes, I have had better luck with the 10# spools.

Sounds to me like you got a bad spool of wire. Wire should not overlap on the spool. Will definitely cause it to bind/hang up.

I'd try a different spool of wire before I went any further.

The problem you're experiencing is much more common with cored wire than it is with solid. Generally comes from too much pressure on the drive roll thereby slightly deforming the wire.

Let us know if a new roll of wire solves the problem. If not then we do need to start looking at the liner.

Sorry. Bad manners. Welcome to the board. Think you'll find some great people here who are ready to help.

[mwccwi]

All of these suggestions, but I didn't here anyone ask if the correct drive rollers are being used. if the grooves in the rollers are to big it won't push real good.

[Laura]

Yes I double checked and I am using the correct roller slot for the .030 wire.

Thanks
Laura