wire burning where it feeds into liner

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I was looking threw the site before I asked this but there is a ton of threads on here. This just started happening today. The wire gets hot and burns threw right where it feeds into the liner. I have never seen this before nor have the guys I work with. Does anyone know what the cause of this might be? Machine is a snap-on mig 140. .030 lincoln wire. This is happening right when I start the arc. I replaced the tip and checked the ground. All looks good. The tip and liner are the right size. Using 75/25. Thinking maybe the liner or trigger is shot? Anyone have any thoughts on what it might be? Attached Images
Reply:Not really sure what I'm looking at but could the liner or inlet guide be touching the drive roll or close enough to cause an arc? Most power cables attach on the drive roll assembly so something is either arcing or the the liner is getting current from the power cable in the torch cable. Does the trigger work OK? It could be a trigger wire is shorting out when you pull it. Some better pictures might help to get a better idea of what's going on.
Reply:Thats a close up of where the wire burned, broke and bird nested a little. The trigger works fine and the wire seams to feed threw smooth. It only does it when I start the arc and just started doing this today. It doesn't seam to be to close to the drive roll. The welder is at work and I'm home so I won't be able to get any better pictures until tomorrow. This is my own personal welder so I will be fixing it myself. Attached Images
Reply:Your gun connection is bad, awhile back I had an ESAB 250 doing the same stuff. The worthless "Euroconnect" block on the machine side had a loose connection that made the wire carry the current and did exactly the same thing.
Reply:Thanks for the tip. I will definitely be checking it in the morning
Reply:Originally Posted by 12V71Your gun connection is bad, awhile back I had an ESAB 250 doing the same stuff. The worthless "Euroconnect" block on the machine side had a loose connection that made the wire carry the current and did exactly the same thing.
Reply:I will look at that too. Thanks for the tips
Reply:Originally Posted by GambleDoubt it. Never seen that happen before.The most common issue that causes this is a direct short generally from a piece of wire on the back of the spool touching the cabinet.
Reply:I kinda think 12v71 is right on.    A while back, i had it happen on my lincoln mini mig.     What happened is I didn't have the set screw tightened down on the guns rear end, and i must of pulled on it just right to make it lose contact.
Reply:If the braided copper lead somewhere in the length of the gun was torn/broken, from kinking and abuse maybe
Reply:You may have a kink in the liner or obstruction in the gun somewhere.It also looks like the wire is not centered in the roller groove (maybe optical?)Make sure that the liner is not touching the rollers.Buy American, or don't whine when you end up on the bread line.
Reply:If it is getting hot from the liner to the drive wheel ,the drive wheel is grounded.If it is getting hot from the liner to the spool, the spool is grounded.The wire will get hot from the liner to where ever it is going to ground.
Reply:Thanks for the tips everyone. I'm heading to work in a little bit so I will let you all know if I get it figured out.Facebook=captain93ronInstagram=captain93ronSnapchat=captain93ronYouTube=captainron93
Reply:Originally Posted by WeldingMachineYou may have a kink in the liner or obstruction in the gun somewhere.It also looks like the wire is not centered in the roller groove (maybe optical?)Make sure that the liner is not touching the rollers.
Reply:So I checked. No wired hitting the housing off the spool anywhere. I did fin the set screw for the gun loose. I also noticed that the end of the cable would almost touch the rollers when I would clamp it down. I took the cable out, cleaned everything and put it back in. I have it set back away from the roller a little now and set screw is tight. I did a couple of quick plugs welds (didn't even clean the metal lol) on some junk pieces. So far its working good. Time to dial it in and get some work done. Hopefully no more problems... Thanks for the help everyone  Attached ImagesFacebook=captain93ronInstagram=captain93ronSnapchat=captain93ronYouTube=captainron93
Reply:Originally Posted by 12V71I have.. Twice. Apparently those connectors don't like spool after spool of 1/16" dual shield. Go figure.