Issue
Inconsistent / interrupted
wire feed
Possible Reason
• Adjusting wrong dial
• Wrong polarity selected
• Incorrect wire speed setting
• Voltage setting incorrect
• MIG torch lead too long
• MIG torch lead kinked or too
sharp angle being held
• Contact tip worn, wrong size,
wrong type
• Liner worn or clogged (the
most common causes of bad
feeding)
• Blocked or worn inlet guide
tube
• Wire misaligned in drive roller
groove
• Incorrect drive roller size
• Wrong type of drive roller
selected
• Worn drive rollers
• Drive roller pressure too high
• Too much tension on wire
spool hub
• Wire crossed over on the
spool or tangled
• Contaminated MIG wire
Suggested Remedy
• Be sure to adjust the wire feed and voltage
dials for MIG welding. The amperage dial is for
MMA and TIG welding mode.
• Select the correct polarity for the wire being
used - see machine set up.
• Adjust the wire feed speed
• Adjust the voltage setting
Small diameter wires and soft wires like
aluminium don’t feed well through long torch
leads - replace the torch with a lesser length
torch.
•Remove the kink, reduce the angle or bend
• Replace the tip with correct size and type
• Try to clear the liner by blowing out with
compressed air as a temporary cure
• Clear or replace the inlet guide tube
• Locate the wire into the groove of the drive
roller
•Fit the correct size drive roller e.g.0.8mm wire
requires 0.8mm drive roller.
• Fit the correct type roller (e.g. knurled rollers
needed for flux cored wires).
• Replace the drive rollers
Can flatten the wire electrode causing it to
lodge in the contact tip - reduce the drive roller
pressure.
• Reduce the spool hub brake tension
• Remove the spool untangle the wire or
replace the wire.
• Use clean dry rust free wire. Do not lubricate
the wire with oil, grease etc.
MIG WIRE FEED TROUBLE SHOOTING
The following chart addresses some of the common WIRE FEED problems during MIG welding.
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