Mm252 feed issue

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Hello guys I am having wire feed issues on a Miller 252. The wire doesn’t like to feed out the gun. It’s as if the drive rolls aren’t tight. The rolls have been replaced as has the gun. Currently running a 15’ 400 amp Bernard gun with .035 solid wire. If the gun is straight it’s not terrible but a couple of loops and it’s almost unusable. Have to have the tension knob pretty well maxed out to get it to feed. Any thoughts as to what I could be missingMillermatic 252millermatic 175miller 300 Thunderboltlincoln ranger 250smith torcheslots of bfh'sIf it dont fit get a bigger hammer
Reply:Is this a new problem or new machine?  Could the drive rollers be not set for .035.  Do you have any knurled drive rollers for flux core in size .035.  I always try to leave my whip as straight as possible for best feeding results.  New gun does not mean the liner is not kinked.  Have you pulled the liner to make sure it is the right liner with no kinks in the liner?  How is the tip, correct size tip.  Is the wire spool loose enough to feed properly without dragging.  How about the input / output wire guides for the drive motor?  Any kinks, wear, blockages, misalignments?first place I’d start is pull the tip and see if that changes anything.  No look at the drive feed guides for alignment, etc to make sure wire feeds good into drive motor and rollers, not the problem check drive roller for alignment and set up properly for wire size.  Check you are using .035 wire on the spool. You get the idea.  Process of elimination.  Oh yeah also leave the wire spool door open and watch the drive roller and listen as well to make sure it runs true and not all wobbly as well as maintains a constant speed.  Should be able to hear and see any differences in speeds.  If there are any issues with the drive motor area like for example, the motor speeds up and slows down or the drive motor shaft is bent and changes speed ever so slightly as the wire binds every time the roller wobbles in and out of alignment you should be able to see and hear it.Last thing I can think to check is to make sure the gun is inserted properly into the machine.  Did it get seated all the way flush.  How high up does the machine rest from the floor?  Is it possible someone stepped on the gun cable and bent the brass end that plugs into the machine?Last edited by N2 Welding; 2 Hours Ago at 01:43 AM.Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.