Wire Feed Problems PLEASE HELP ME!!!!!

[MrJoePodge]

So I borrowed this welder of my dads friend to weld my go kart together. Its a cheapo gas less mig, and i was pretty happy with it for welding the frame together. Then the wire slowly started to come out a little less smoothly and now it doesn't come out at all when you press the trigger! You can here the motor spinning and i took apart the wire feed assembly and it had a few stripped gears. So i replaced the wire feed mechanism completely and it started feeding smoothly until the wire reached close to the end of the gun/nozzle. I pulled the gun apart and i cant get in there to see whats stopping the wire?????????? I need help urgently as i need to fix this otherwise ill have to get a completely new welder for this guy and Ive already spent $75 useless dollars trying to fix the bloody thing! I'm almost finished the cart too which is the most frustrating part!!!!!!!!!!!!!!!!!
Any help would be greatly appreciated!!!!

 

[Rustydog2010]

I'd say you need to get into that gun. I have found when installing new rolls of wire that it gets stuck in/behind what I would call the contact tip.

Jeremy.

 

[MrJoePodge]

I'd say you need to get into that gun. I have found when installing new rolls of wire that it gets stuck in/behind what I would call the contact tip.

Jeremy.

Sometimes it does come out, but once it does, it stops

 

[Benjo]

have you got the right size tip?

 

[MrJoePodge]

well it was working when i first got it so i assume so

 

[T-man]

Joe, be sure to clean the roller that the wire comes in contact with "IN " the machine. It sounds like you have multipal things happening.
remove the brass tip from the front of the gun , clean that. then tap the gun on a table ... pointed down. some times when welding sparks fly up into the nosel then in through the gas outlets and fuse to the wall and wire ... the wire can brake loose and keep going through but the bur will remain , creating problems in the future.
These cheepo welders normaly will have issues that can be avoided with just keeping the wire clean before it even enters the welders process.

 

[MrJoePodge]

Thanks very much for that. Ill give that a go and see what happens tommorow

 

[mckutzy]

What is the make/model of the welder?
Did you kink the cable liner, and is the tip completely clean? Does the wire feed throught the tip with out the tip screwed on tight? Lay the gun cable out flat and try to feed wire. Wire tension on the rollers, is it enough? the right rollers on the replacement feed mech.?

Some thoughts.

 

[petty]

The feed wheels, wire, and tip all need to match the wire size in order to work properly. If the tip is too small or if you got some wire stuck in it while welding, it can cause this issue. replace the tip, they are like 5 for $5 or soemthing like that.

 

[Bluethunder3320]

mine always gets stuck (90 amp flux)

i have to take the tip out every time i replace the wire, and force the tip onto the wire....

its almost like the tips need to be bored out more.


maybe ill get some lincoln tips. (same threads?)

 

[devino246]

mine always gets stuck (90 amp flux)

i have to take the tip out every time i replace the wire, and force the tip onto the wire....

its almost like the tips need to be bored out more.


maybe ill get some lincoln tips. (same threads?)

You do realize there are different sizes, dont you?

 

[mckutzy]

I totally forgot the tip size/wire size/wheel matching. a burn back could plug the tip or block it significantly.

 

[TorqueRanger]

Also make sure your liner is still in good shape.. I believe that Lincoln tips should on any machine..

 

[Doc Sprocket]

i have to take the tip out every time i replace the wire, and force the tip onto the wire....

its almost like the tips need to be bored out more.


maybe ill get some lincoln tips. (same threads?)

I HAVE a Lincoln, and you DO take the tip off when re-spooling. The ID of the cable liner is larger than the hole in the contact tip, so it creates a bit of a shoulder. Also, the wire comes off the spool with a curve to it, so as it feeds, it rides the edge of the liner 'till it hits the shoulder of the tip. So- remove the tip when feeding in a new spool. It's a good time to put on a new tip, too- Don't forget, they ARE a consumable and need to be replaced regularly, or it won't do it's job.
Trust me- I used to go thru a 10lb spool of .035 flux every few days!

 

[MrJoePodge]

Thank for your help everyone I got the bloody thing working, but i have to return it today

i have to take the tip out every time i replace the wire, and force the tip onto the wire....

its almost like the tips need to be bored out more.

I actually had to drill out the nozzle bit and that fixed the problem because it had crap all built up inside!! I also finished the steering on the go kart today and I only need to get the axle and then im done!!! But i have to give the welder back despite the fact i only need to make like 4 more welds

 

[redsox985]

The actual cover nozzle was jammed? The one with like a 1/2" hole in it? I've always just hit it off something solid or dug around in there with some pliers to break the crap off.

 

[mckutzy]

I clean my nozzle and tip( if needed) every session of welding, to make sure there is no arcing from nozzle to ground( I have a clarke90 mig no gas 120v w/live ground).

 

[birddog1148]

Thank for your help everyone I got the bloody thing working, but i have to return it today


I actually had to drill out the nozzle bit and that fixed the problem because it had crap all built up inside!! I also finished the steering on the go kart today and I only need to get the axle and then im done!!! But i have to give the welder back despite the fact i only need to make like 4 more welds

Why are you on the computer telling us stories when you could be out doing those 4 welds?