Manual 0-5492 5-19 MIG (GMAW) WELDING
Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed
Wire feeding problems can be reduced by checking the following points.
FAULT CAUSE
1 Feed roller driven by motor in the
wirefeed compartment slipping.
A Wire spool brake is too tight. (Refer 5.08).
B Incorrect feed roll fitted for wire used. Check and
change to correct feed roll if necessary. (Refer options
and accessories table 2.11 for feed roll options)
2 Wire spool unwinded and tangled. Wire spool brake is too loose. (Refer 5.08)
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 Wire rubbed against the mis-aligned
guides and reduced wire feedability.
Mis-alignment of inlet/outlet guides
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 5-3: Wire Feeding Problems
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