Sputtering MIG solved.

[Redneck in training]

I have a Lincoln 255 MIG. It started to sputter once a while. I removed the rollers but found them more or less clean and in good order. Checked all the connections etc. and found no issues. Then I looked at the cable and it occurred to me that was the culprit. It had all kind of convoluted bends and turns while laying on the floor. Placed it in nice single arc and it started welding as expected again. Rookie error.

 

[dragoneggs]

Troubleshooting is much easier in hindsight!

 

[Redneck in training]

Troubleshooting is much easier in hindsight!

Yes. That is definition of experience. It is something you get right after you needed it.

 

[WranglerX]

Keeping gun lead as straight as practical is a must.... Any sever bends or kinks or being crushed (run over by wheels in shop) will cause you grief..... To much abuse might cause you to have to replace it .....

Dale

 

[Industrial Toys]

I personally prefer silver MIG wire that is a bit more expensive than the copper colored stuff. If you don't weld all the time, I think the copper stuff on the outer reel will tarnish and effect weld quality. I COULD be totally wrong, it's just the impression I get. My shop can sweat and have everything in there dripping wet.

 

[yomax4]

The trouble can go all the way back to the inlet guide. What size wire you are running through what ever size liner makes a big difference too. I use at least 1 size larger liners than the wire I'm running. I have a 200 amp synergic mig tig stick 2 wheel drive that sees nothing but .023 wire in a 12' gun. I run an 030 liner with no issues. On my go to welder I run a 15' gun with a 1/16 liner with 035 wire and can tie a pretzel not in the gun and still weld just fine but it has 4 wheel drive. If I have a feed issue I check tension, Inlet /Outlet guides and or change the liner. It certainly helps to keep that gun spread out around your weld area as well. I always Bum wire off of the local Reps so sometimes I get copper coated, Sometimes copper free. I like both equally but high quality wire is needed for Twin Pulse and or Robot work. Cheap stuff is ok for hand held repairs and non essential welding. Just watch for Rust and don't use any bad looking wire. It's all fun..

 

[crazyal]

How old is our Lincoln? I recently had to replace my liner and gas diffuser on my 255C. Although it didn't look damaged over the years the liner did take a hit or two. Before I did I was always trying to keep the cable as straight as possible. With the new liner it's not an issue.

 

[drizler]

My Handler drove me nuts for years. Then I pulled the liner. It had a gentle bend where I must have crunched it . It didn’t take much to make the wire sputter more or less all the time. You might need a new one and they’re cheap.

 

[Mark @ Everlast]

New units can be damaged as well. I often get calls from people who have tightly wound up their gun much the same as you would a small extension cord. And a lot of people who don't want to admit it but their problems do stem from rolling over their cable or dropping a metal object on the cable.

 

[aczlan]

New units can be damaged as well. I often get calls from people who have tightly wound up their gun much the same as you would a small extension cord. And a lot of people who don't want to admit it but their problems do stem from rolling over their cable or dropping a metal object on the cable.

Mark, did you get my PM?

Aaron Z