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1: No wire feed
Possible Reason
Suggested Remedy
Wrong mode selected
Check that the TIG/MMA/MIG selector switch set to MIG position
Wrong torch selector switch
Check that the STANDARD/SPOOLGUN selector switch is set to STANDARD position
for MIG welding and SPOOLGUN when using the Spoolgun
2: Inconsistent / interrupted wire feed
Possible Reason
Suggested Remedy
Adjusting wrong dial
Be sure to adjust the WIRE FEED and VOLTAGE dials for MIG welding.
The AMPERAGE dial is for STICK and TIG welding mode
Wrong polarity selected
Select the correct polarity for the wire being used - see machine setup guide
Incorrect wire speed setting
Adjust the wire feed speed
Voltage setting incorrect
Adjust the voltage setting
Mig torch lead too long
Small diameter wires and soft wires like aluminium don’t feed well through long torch
leads - replace the torch with a lesser length torch
Mig torch lead kinked or too sharp
angle being held
Remove the kink, reduce the angle or bend
Contact tip worn, wrong size, wrong
type
Replace the tip with correct size and type
Liner worn or clogged (the most
common causes of bad feeding)
Try to clear the liner by blowing out with compressed air as a temporary cure,
it is recommended to replace the liner
Wrong size liner
Install the correct size liner
Blocked or worn inlet guide tube
Clear or replace the inlet guide tube
Wire misaligned in drive roller groove Locate the wire into the groove of the drive roller
Incorrect drive roller size
Fit the correct size drive roller eg; 0.8mm wire requires 0.8mm drive roller
Wrong type of drive roller selected
Fit the correct type roller (e.g. knurled rollers needed for flux cored wires)
Worn drive rollers
Replace the drive rollers
Drive roller pressure too high
Can flatten the wire electrode causing it to lodge in the contact tip - reduce the drive
roller pressure
Too much tension on wire spool hub
Reduce the spool hub brake tension
Wire crossed over on the spool or
tangled
Remove the spool untangle the wire or replace the wire
Contaminated mig wire
Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc
The following chart addresses some of the common WIRE FEED problems during MIG welding. In all cases of equipment
malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.
MIG WIRE FEED TROUBLE SHOOTING
At initial set up and at regular intervals we recommend to check for gas leakage. Recommended proce-
dure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the flow rate on the regulator to approximately 8-10 l/min.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure
gauge on the regulator, if the needle drops away towards zero there is a gas leak.
Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the
regulator and line for an extended time period. In this situation it is recommended to open the
cylinder valve, set the flow rate to 8-10 l/min, close the cylinder valve and check after a
minimum of 15 minutes.
5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying
with soapy water, bubbles will appear at the leakage point.
6. Tighten clamps or fittings to eliminate gas leakage.
Important:
We strongly recommend that you check for gas leakage prior to operation of your
machine. We recommend that you close the cylinder valve when the machine is not in use.
Esseti NZ Ltd, authorised representatives or agents of Esseti NZ Ltd will not be liable for the loss
of any gas.
ATTENTION! - CHECK FOR GAS LEAKS
MIG WIRE FEED TROUBLE SHOOTING