i bought an older Miller 200 Mig recently and when i hit the trigger i gets no feed. if pulled on the wire it fed, but it wont feed without ***istance. the rollers are spinning and they match the wire size. i clipped the wire at the rollers and pulled the entire length out of the gun, fed new wire into the gun and it feeds fine until it gets about 4 or five inches from the tip. right about where the gun starts to make the curve. i tried running a length of wire the other way and i could feel a rough spot in the tube where it would get tough to feed. am i in for a new gun? any advice?
jsut might need a new liner,, my lincoln had the same problem,, 25bux for a new liner, good as new...
X3 on the liner..they get full of **** than no feed or jerky feed. it looks like a bolsens cable outer liner..you can remove it from the gun and feed. and it slides out of the cable housing..usually allen set screws hold it in at both ends.
Yep! New liner... I think someone was making something to help keep things slick inside the liner as well, but I've never had to use it.
Before you by a liner, take it apart and make sure there isn't a burr where it was previously cut off, after I cut mine, I take a little file and de-burr it.
As well as a new liner you might also consider up sizing your tip one size to help keep the tip cleaner longer. At home I run .035 tips on my .024 wire and have for years. The tips last much longer with less problems from hanging the wire up from slag. At work, I use an .045 tip with .035 wire. Just my humble opinion based on years of welding/use. I get tired of unscrewing the tip and cleaning it with a tip cleaner. Using a slightly larger tip allows the wire to flow more easily for much longer.
Also a good point! Doesn't cost anything to pull it all apart and give it a good once over and a cleaning to make sure it's not just pooped up inside.
This might be a little hard to explain, but ...... as the wire comes off the roll, you might have a br*** tip (same as tip on end of gun) that the wire feeds thru before entering the rollers & feeding into your liner........that tip, like the tip at the end of the gun gets clogged with rust from the wire and will slow down wire feed... they make a little scrubby thing like an abrasive pad that simple clips onto the wire as it leaves the roll to clean the wire before the rollers..... or new liner...... or.....even though you have the right rollers, the wire may not actually be lined up in the roller groove, thus not digging into the wire or gripping the wire to drive the feed of the wire..... or ...... you using some wire smaller than .030 thus, that's like pushing a wet noodle down the entire length of the liner...... Cool.......Carl Hagan
I was going to say that Marlo Triet imports Migs for sale and might know about the guns. But I see that is not the question.
the problem is inside the gun. i've already taken apart the rollers and guides and inspected everything. with the gun disconnected, everything works fine. when you feed fresh wire into the gun it feeds just fine for the first 8 feet or so, then it gets jerky and then just jams about 4 inches from the tip.
Theres really nothing else in the gun except the br*** fitting, the tip, nozzle. ??? That liner runs all the way to the br*** fitting the tip screws into. Too much tension on the roll of wire itself, with the big plastic nut too tight?? Carl
like i said, it runs just dandy for the first 9.5 feet of the work lead then it simply jams 4 inches from the tip. i ran a piece of clean wire back thru the tip and you can feel the bad spot. i think putting a liner in it might not be a bad idea. its an old machine and has been sitting unused for many years.
After you replace the liner, make sure the transition right at the back end of the gun is supported when you hang the gun on the machine. If the whip acquires a kink right there at the base of the gun you will have the same wire draging situation. I've seen many guys just hang the gun on the machine with the handle portion dangling (unsupported) by the whip itself. Dan Stevens dba, Steelsmith
the outer bits had a little rust on it and you could feel a little drag, but this gun simply jams at a certain spot. i cut of a number of feet and its pretty clean down below. we'll see how it acts with a new liner.
Using a larger tip than the wire is not good advise. The machine will run better with a new liner and the correct size tip. Also the lube and cleaner pad will help keep the liner clean thus making it last longer. Although it sounds like yours has a kink in it. Just my opinion. 41 Plym
i had the same problem once and had to get a new roll of wire it had lite rust on the whole roll and keept getting stuck put a new roll on it and worked perfect
X2. Rust on the spool of wire will cause problems with a new liner as well. Doesn't take much moisture/humidity at all to ruin a spool o' wire-and a new liner. If it's light, zip tying some scotch brite before the rollers will help minimize what gets into the liner.
I have a Miller 135 and had a similar problem. The driven roller that pulls the wire off of the spool is reversible, one side has a smoothe groove and the other side has a knurled groove. It seemed to me that the wire was slipping at this point.I read the owners manual and it said to use the smoothe side for bare wire and the knurled side for flux wire. A buddy told me that he had always run the bare wire using the knurled groove. I switched the driven roller so the knurled wire grabbed the bare wire and never had a feed problem again. You might want to give that a shot.
Some or most liners have o-rings to seal the shielding gas at the entry point, look for a small set screw that retains the liner before removal
You've answered your own question, Liners don't last forever. We change them about every 3 months in the welding shop (where a mig will run day in day out). In the body shop they seem to last a year or so depending on how much use the machine gets. Your 'old' machine has probably seen many miles of wire. If you are rough with the stinger you can put a kink in it which kinks the liner. The most common place is where the stinger meets the gun, the exact place that you describe. Change the liner and always try to weld with out lopping the stinger (causes excess wear on rollers and liner). Its always best to 'snake' the stinger across the floor to where you are working without any loops or sharp bends. .
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