WELDSKILL 100, 135, 150 MIG
5-3
Service
Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed
Wire feeding problems can be reduced by checking the following points.
FAULT CAUSE
1 Wire spool brake is too tight Feed roller driven by motor in the cabinet will slip.
2 Wire spool brake is too loose Wire spool can unwind and tangle.
3 Worn or incorrect feed roller
size
A Use a feed roller matched to the size you are welding.
B Replace feed roller if worn.
4 Mis-alignment of inlet/outlet
guides
Wire will rub against the mis-aligned guides and
reduces wire feedability.
5 Liner blocked with swarf A Increased amounts of swarf are produced by the
wire passing through the feed roller when excessive
pressure is applied to the pressure roller adjuster.
B Swarf can also be produced by the wire passing
through an incorrect feed roller groove shape or size.
C Swarf is fed into the conduit liner where it
accumulates thus reducing wire feedability.
6 Incorrect or worn contact tip A The contact tip transfers the weld current to the
electrode wire. If the hole in the contact tip is too
large then arcing may occur inside the contact tip
resulting in the wire jamming in the contact tip
B When using soft wire such as aluminium it may
become jammed in the contact tip due to expansion
of the wire when heated. A contact tip designed for
soft wires should be used.
7 Poor work lead contact to
work piece
If the work lead has a poor electrical contact to the
work piece then the connection point will heat up and
result in a reduction of power at the arc.
8 Bent liner This will cause friction between the wire and the liner
thus reducing wire feedability
Table 5-2
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