Wire sticks spool stops, causes flat spot, sticks again...

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I have a Lincoln 135 wirefeed.  I don't use it much but maybe that's because I'm having an issue with the wire not wanting to feed.  That causes it to stop spooling out and then that causes the rollers to rub a flat spot which makes it stick again when it gets to the tip causing it to happen all over.  I don't know how much wire I have wasted clipping off the end trying to get the flat spots out.  I have an 8lb spool and originally it had no center so it wasn't rolling well on the spool wing nut.  So, I made a center for it and figured that would help but it still sticks.  If I tighten the rollers/pinchers anymore it will just not feed at all.  If I loosen them it wont push the wire through.  I'm using .032 I think and I can't seem to figure it out.  When I ran the 4lb spool at first I was doing ok with it but that was a few years ago.  I don't weld that often so the 8lb will last me a couple years since I only use it for small garage projects and what not.  This whole problem causes my wire to burn out when I go to weld and that makes it stick also.  Maybe I should replace the tip?  I don't think the inside of the cable needs replacing since I've only been through one 4lb spool and maybe 2lbs of the 8lb spool.  I'd like to get more practice and do more stuff but it makes it almost impossible to weld anything with it like this.  Any help would be appreciated.Last edited by hotamuh; 09-01-2007 at 02:12 PM.
Reply:I can empathize. A lot of little things contribute to wire feed problems but they all add up to dissappointing experiences.   I've never had to operate without the correct reel adapter for the 4" vs 8" inch reels but I can see a lot of room for problems there. My guess is getting the right adapter would be a good first step. Another issue could be simple corrosion inside the liner. Imagine a small bit of metallic dust in the liner and high humidity setting idle months at a time.  A shovel that gets used doesn't get rusty, eh.  Then another thing that doesn't get much mention is proficiency. Many wire feed issues sort of just go away as a person gains expertize  with their particular brand and model. Four pounds of wire over a few years isn't much run time ... Get it going and don't let it stop till you feel good about your performance level.
Reply:Another issue I've seen a lot is how the spool is loaded onto/into the machine. The wire has to feed into the back guide with as little angle as possible, whether that be coming off the top or bottom of the spool. It can and will wear a groove into the back guide, might be hanging in a groove. Once you have that problem fixed, adjust the rollers correctly or your next problem will be a clogged liner.Anything worth doing is worth doing RIGHT
Reply:I'm new to MIG welding and have not had your problem yet but I think I remember reading that if the tip size is worn or too big then it can arc from the tip to the wire and cause the wire to jam. Make sure whatever the wire size is that the tip is the right size for it. Also make sure you have the right type and size rollers for the wire.You said you think it is .032 wire are you sure it isn't .030 or .035 wire, if it is .030 wire and you have .035 tip in the gun that might be causing the wire to arc and weld itself to the tip before breaking loose.I am sure you will get some more experienced welders to comment and help fix your problem.
Reply:Maybe your drive rolls are set too tight. You want your drive rolls set so that when you pinch the wire coming out of the tip, you can almost make it slip in the drive rolls, but not quite.  Also, maybe the tension on the spindle that goes in the spool is too tight.  You could have a liner blockage...use some shop air to blow it out (or just replace it).  Also, replace your tip because sometimes they get burrs on the inside.
Reply:The spool can tighten the "adjustment" screw as it unwinds wire.  I put a pencil inside the  threads so the tension screw can only go in so far.  I have also used a 3/8 bolt, flat washer and double nutted it.Always try changing the contact tip.Good luckDavid Real world weldin.  When I grow up I want to be a tig weldor.
Reply:On the Lincoln 135 there should be an allen head set screw down in the hole that the wing nut screws into. reach down in and adjust it so the wing nut bottoms out on it, you can tighten the wing nut that holds the spool good and tight and have the right tension on the spool. Some times it takes a couple of tries to get it where you want it
Reply:One other possible problem: Is the wire wrapped under itself?? If you have the wire crossed under another wrap, and it won't freely feed off the wheel, you are gonna fight it all the way to the end of the spool. If the wire is crossed under, back the wire out of the gun, and clear the crossed wire, then re-feed it. There are only 3 or 4 things that can go wrong with the mig setup, and all have been described as far as I can tell. Good luck, keep us tuned. Paul.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:One thing, be sure your rollers are stamped with the correct size wire on the side, for the wire diameter you use.City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:ive got one just like this and my bet would be in the spindle adapter for the bigger roll of wire. if its not right it can be a real hassel. and check the wire for looping like rojo said.
Reply:oh, just about forgot...you can get those spindle adapters for about eight bucks at lowes.
Reply:I just came across this post from way back.  I never saw all these responses but I appreciate them.  I finally found the reason for the sticking.  The tip was bad and wasn't allowing the wire to slip through.  It must have been worn and was causing the sticking and making the problem worse as the flat spot came through.  Changing the tip fixed it and it has been so much better.  I just remembered this problem yesterday as I was welding some chains to my bush hog in the 92 degree heat.  I have gotten much better from a couple years ago and love my wirefeed welder.JoeSavannah, GA
Reply:Here's a tip since you revived this thread.When replacing a tip or checking an old one, I always run out 2-3 inches of wire.  Slip the tip onto it until the wire just peeks out the end.  Then point it up in the air.  The tip should slide down the wire on its own.  If it doesn't, give it a spin with your fingers to clear any dust and try it again.  If it fails a second time and it is a used tip, throw it away.  If it's a new tip that fails the test, run a torch tip cleaner through it and you should be good to go.  I've been doing good lately with tips. I think I ran damn near 30lbs through each of the last two tips before having to replace them.  They should prolly be replaced more often than that whether or not they are causing problems.