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Topic Review (Newest First)
06-11-2017 04:49 PM
hduff Running some wire backwards through the cable "fixed" the problem. It appears that the rollers are plastic and there is no spring on the switch; it relies completely on the springiness of the long brass tab. It's working fine now. Thanks, guys!
04-27-2017 01:04 PM
rip-tide Problem was intermittent, the theory you have presented would be a continual event.

I cannot see a switch that gets the amount of cycles, as a MIG torch switch would have, not having a spring return.....then again there are those HF welders out here.

I have it nailed and am quite satisfied it has been corrected.

Thanks,
Greg
04-27-2017 10:14 AM
hduff
Quote:
Originally Posted by rip-tide View Post
Talking about wire feed, bad mojo stuck my machine. The welder started to feed wire on its own. Picking up the torch every so often it would shot out 6 -8 inches of wire ....... silly a s s thing

Greg
From what I saw inside my torch, the switch relies on bending a small metal blade so that it makes contact with a standard crimped wire terminal. It's not unreasonable to assume that the blade will fatigue over time to not make contact at all or make contact all the time.
04-27-2017 09:45 AM
rip-tide
Quote:
Originally Posted by S10xGN View Post
It's a Miller 175, had seen about 10 yrs of occasional use.



The trigger wiring in the whip may be loose or the switch is about to wear out, or... The new whip I bought from UASWeld has a very touchy trigger!

Russ
Russ,

Have the same machine, you are correct that was exactly what happened, wiring was the bad actor. Took a couple of times to catch it, thought it was me at first. Fat fingering the switch.

Wires were crossed over themselves. Movement of the whip and handle was enough to make the spade clips touch intermittently. Only took ten years to show up.

The switch actually has a tang that hangs below to keep them apart......

You can never go wrong with a Miller that's for sure..

Cheers

Greg
04-27-2017 08:12 AM
S10xGN
Quote:
Originally Posted by rip-tide View Post
Had an increase in the argon usage did you? How old is that welder you replaced the liner on, I'm curious?

Greg
It's a Miller 175, had seen about 10 yrs of occasional use.

Quote:
Originally Posted by rip-tide View Post
Talking about wire feed, bad mojo stuck my machine. The welder started to feed wire on its own. Picking up the torch every so often it would shot out 6 -8 inches of wire ....... silly a s s thing

Greg
The trigger wiring in the whip may be loose or the switch is about to wear out, or... The new whip I bought from UASWeld has a very touchy trigger!

Russ
04-26-2017 09:25 PM
rip-tide Talking about wire feed, bad mojo stuck my machine. The welder started to feed wire on its own. Picking up the torch every so often it would shot out 6 -8 inches of wire ....... silly a s s thing

Greg
04-26-2017 09:23 PM
41'srfun
Quote:
Originally Posted by hduff View Post
I 'm having a problem with my C-H MIG. I needed to use a new spool of .030 un-shielded wire, so I grabbed a new spool and began to feed it through. I've done it plenty of times before, but this time was different.

The wire will feed almost completely, but stops short of exiting the torch. The old spool was feeding fine just prior to this. I dismantled the torch itself and don't see what would stop the wire there. I've tried feeding it without the contact tip and nozzle, but no luck.


Any suggestions? Besides buying a better MIG welder, that is. 8)
I do quite a bit of contract welding for a local machine shop, but I do it in my home shop and it provides income for my projects and toys. I usually go thru at least 30 to 60 lbs. of wire a month.
I had a problem like yours a few months back with a roll of ESAB wire. I fought it for about 20 minutes trying to get it to feed thru a fairly new liner but the welding tip was worn pretty bad, so it would feed a few feet and then hang up. I finally got really frustrated with it and got my calipers and checked the diameter of the wire and it was .045 that was marked as .035 and I was using .035 feed rolls and a worn out .035 welding tip.
I took it back to the local welding supply where I buy all my wire and they said they had gotten an entire shipment of wire like that that was mis labeled and they had a lot of real mad customers over it.
I have been doing buissness with them for over 20 years and they always treat me fairly. I ended up with a replacement roll of wire for the mis labeled roll and another roll for my trouble. They are a really nice bunch of guys to deal with!
04-26-2017 12:35 PM
hduff
Success!

I inserted a wire the wrong way and I was able to successfully feed the wire all the way through.

Thanks, guys!
04-26-2017 10:17 AM
rip-tide
Quote:
Originally Posted by S10xGN View Post
Do like Brian said if you're not already doing it. Another possibility is the liner has come loose inside the whip. I had to replace mine not long ago, it fed OK but most of the gas was leaking out. Sure made for some [email protected] welds...

Russ
Had an increase in the argon usage did you? How old is that welder you replaced the liner on, I'm curious?

Greg
04-26-2017 09:34 AM
astroracer Like Russ, I would suspect the liner has gone bad. It's easy enough to replace and isn't expensive.
Mark
04-26-2017 07:36 AM
S10xGN Do like Brian said if you're not already doing it. Another possibility is the liner has come loose inside the whip. I had to replace mine not long ago, it fed OK but most of the gas was leaking out. Sure made for some [email protected] welds...

Russ
04-26-2017 05:54 AM
rip-tide What are the wire feed rollers made of?

Greg
04-25-2017 07:56 PM
MARTINSR Also check the tip, I always remove the tip like this. Then after the wire is through run the tip over it and screw it in.



Just a tiny bend on the wire and it will get caught going through.

Brian
04-25-2017 03:55 PM
rip-tide Check the feed roller pressure; make sure the wire and the grove of the feed rollers match wire .030 groves in roller .030.

Feed rollers are typically marked, stamped with the size on the side. The torch tip also need to be the correct size, look at the tip if burned, could need a tip, hole needs to be clean no blockage.


Wire spool drag set to tight ?


That's about all I can come up with.


Greg
04-25-2017 03:15 PM
gc408 probably not serious. wire is iether to straight or to bent or has a burr. back it off alittle and try feeding through by hand. cut off some wire and feed it into the torch end to make shure there is no blockage. if it dont feed smooth from the torch end the 'liner' is worn out or kinked (which happens)
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