Millermatic 250 wire feed issues

Hey guys, just trying to troubleshoot my 30 year old MIG welder. Recently, it started getting difficult to weld with and I noticed that the wire wasnt feeding consistently. I am a ****py welder, so I need all of the equipment to do it's part.

I replaced the drive spool wheels and liner and it still seems to be slipping. I have ordered a new drive spool tension spring to see if mine is possible losing it's tension.

It's a 1995ish Millermatic 250.

Any ideas?

 

Correct wire size for the driver rollers.

 

Checked that first. In my old age, I wondered

 

When u pull the trigger do they spin and try to drive the wire?

 

I'll have to take a look. I believe it starts then stops....just going from memory.

 

Please check your gun liner
They don't last forever and beleave it or not ca get some "copper gunk" built up in side. I went to a Tweco Gun in 1980 and have never had a "gun liner issue"

 

I put a new gun in it about a year ago. It’s a generic Amazon job.

 

Does your welder have 3 switches upper left corner when you open door ? My 250 does and you maybe set to spot weld

 

Dunno. I don’t think so. I’ve owned it for 30 years and don’t remember seeing that. I’ll look though.

I’m sure it’s lack of maintenance. I’ll spend some time chafing all the consumables etc adjust the tension, once I get new drive wheels and spring. We will see if that makes any change.

 

Once you get it to behave properly take a piece of cloth fold it around the wire before it goes into the gun and put a clothes pin on it. This will clean the copper dust or whatever grime off and will keep it from slowing down and becoming erratic. Also if you’re not careful you will actually weld the wire inside the liner and then you have to replace it. Depending on the welder you might have to replace the entire thing like my little Lincoln 110.

I’ve done this for years and never had any problems with the liners.

 

I use scotch bright and one of spring type paper clips for this chore .

 

Check how tight the wire roll is,if the big plastic nut is too tight it makes it hard to spin.also the tension on the wire roller maybe wind it down a turn or two.The problem is likely there if it is not "birdnesting",thats when the wire all backs up in the machine. I also take the rollers out and spray them with cleaner and wipe them off,that helps some too.

 

So basically what it does is you are welding along, s as md the wire just stops coming out. No bird nesting. It makes it very hard to get a consistent weld. Lord knows, I need all the help I can get.

 

They are tough as a nail