XMT 304 / S-60 series wire feeder?

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This is the set up.  XMT 304 power source,  S-60 series Miller wire feeder,  20' Abicor Binzel Alpha 3 Mig gun, currently running Esab .045 hard wire. When welding on larger projects.  The longer you weld the rougher the start up gets.  Sometimes when you are welding you can feel the wire stutter.  When welding spots or short tacks first start is rough then goes smooth for the next however many you want to do until you stop for more than a few seconds.  When you start again same sequence. It has been suggested that I try a shorter gun assembly.  Where I am located it hard to get Abicor Binzel parts.  Don't mind buying a new gun if that is going to fix the problem.  Just don't want to spend the $$ and find out it is in the wire feeder itself. I have looked at the drive rolls and they don't look worn.  Looking for advise on the wire feeder and also a source for Abicor Binzel?Thanks
Reply:Have you cleaned or changed you liner?Is the drive roll tension set correctly?No pro here, but I can't see any issue pushing .045 20' if the setup is correct.  Sounds like wire is binding or rolls are slipping.What liner is in the gun?  Is it .045-1/16"?Are you burning back to the contact tip? How does it look?Last edited by Drf255; 09-30-2014 at 06:10 AM.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Another place to look is in the gas setup. That sounds a lot like the problems I had with mine when I had a long hose on my flow meter. It would be start out crappy and then straighten up after a short bit of weld. It was caused by to much flow at the beginning of the weld.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:All good stuff.  I hadn't thought about tension on the spool itself.  How many lbs. of gas at regulator? 4 drive rolls on this feeder.  Alignment is OK.  I will take out brass guides and look them over.  Went to change out gun liner but the one in stock was too short waiting for new one to arrive.  Miller hookup.
Reply:Try the run-in adjustment. Binzel guns parts are pretty easy to find, Generally feed excellent if in good shape. One of the easier guns to convert over from Euro/Tweco/Miller. Pin,and and possibly just a liner change.. Is the Gun neck jump liner the correct size?(If it has a removable neck) Call or e-mail Binzel for parts or info.. I find lots of parts like liners on E-bay. guns too.. Check your ground lead too.. http://www.binzel-abicor.com/US/eng/ I would never throw away a Binzel gun if it's in good shape.. Feeds way too nice when correctly setup..Last edited by Brand X; 09-30-2014 at 10:39 AM.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Thought I would follow up on the wire feed problems.  I put on a new 15' Bernard Gun.  This seems to have greatly improved the situation.  I talked with one of the repair people for a local supplier.  His thought was that I was loosing my gas from the longer gun.  Thus the first few seconds of start up being so rough.  I'm thinking that there could have been some other issues with the liner also causing the problems with smooth welds when the temp. was up.  His suggestion on the gas problem was to hit the purge button on the feeder for a few seconds before a cold start up.  I may have had a leak in the other gun as well.  We were running at about 20 CFH and now with the new gun I backed the regulator down to 12 CFH just to see if it would weld and seems to be doing fine.  Maybe I had to much gas at times before.  ??????Not sure what fixed my problem,  I'm happy it is fixed.  Thanks again for your help.
Reply:Had similar issues on the same setup. Turned out to be a loose connection in the recepticle I was using. Also had the same issue with poor work clamp connections. Check all your wiring connections. They should be clean, bright and tight.