Miller welders

First thing to do is put on a new tip as thats 99% of the problem.

Next check the wire drive roll adjustment and make sure theres enough tension on the feed roll and the roll groove is not dirty.

Next the liner could be dirty or have a small kink in it. If dirty it can be cleaned with a small rag soaked in alcohol blown thru with compressed air. To check for a kink, take the liner out and run your fingers accross the liner and you will feel the kink and if kinked time to buy a new liner. A new liner runs about $30 to $50 depending on the model of gun.

Next check the liner feed tip to make sure it's cleaned and aligned properly to the feed rolls.

I use a foam ear plug to clean the wire coming off the spool just before it enters the feeder rolls. Just poke a hole with the wire as that will create just the correct amount of drag to preclean the wire and the ear plug rides up against the case.

T_Bone

Could worn drive rollers be a possibility too?

JohnP