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Hi Al, Lets start from the tip and work backwards: Wrong size contactor tip(CT)?
SS also has a habbit of filling the cup up with fine metal to short out against the CT. Needs to be kept clean. A product called Nozzle Clean also helps. Next check the contact insualtor. This is the part that the cup slides onto. Look for cracks or missing pieces. Next check where the liner end mates with the CT. This needs to be cut square without ruff edges. The end gap between the CT and liner should be snug. Next check the liner for kinks. Slowly draw the liner between two fingers. Any bumps felt on the liner, then the liner needs replaced. A teflon liner works well with SS wire. Next check the roll feed tip for excessive ware and burr free. Also make sure it fits tight against the liner end. Check the distance from the tip to the drive rolls. This should be about 1/32" from the drive roll. Next check the drive rolls are in alignment with the liner feed tip and the rolls are the correct size for the wire size. Check for the correct tension on the drive rolls. Back the tension completly off, then add tension until the wire will not slip on the rolls while holding firm pressure with two fingers on the wire at the CT. Next use a felt wire cleaner before the drive rolls. I use a foam ear plug that works well. I poke a hole in the foam with the wire letting the large end of the foam rest against the roll face. Next check for the correct wire spool tension. Back off on the spool tension, then add tension until the wire lays evenly on the spool without becoming a wire rats nest. To test, press the trigger while observing the wire spool when it stops. When you let off the gun trigger the spool should stop moving at the same time. Run several feet of wire thru the gun (without welding) while observing the spool for smoothness. The wire spool should run smoothly without jerking. Flip the roll tension lever up and rewind the wire on the spool being careful not to cross the wire. Next observe the wire spool while welding. Once again the spool should be smooth as when not welding. You didn't say where the wire was hanging up so this should help no matter where the problem is. Also, My main puter crashed and alot of my files are not on this puter, so until I get my other puter up and running again, I won't be answering alot of welding questions. T_Bone
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