Snap On welder problems.

[John99]

Wondering if anyone on here can help me with a problem I've got with my Snap On Pro 160 welder.

Basically what's happening is the wire is sticking to the tip. I don't think it's a wire feed issue, I've fitted a euro torch conversion, changed the liner and so on, the wire runs free when not welding and pulls through ok, but when I weld either just as I start or after it's been welding a bit it will stick in the tip, normally with 5mm or so sticking out. If I then flex it, it will ping free and the wire shoots out a bit. If I then feed the wire out, the wire feels rough as if it has spatter stuck to the wire but it's well back inside the tip. If it's been welding ok and I stop and wind out more wire it feels smooth as you would expect. The wire is good and clean and I have tried lots of wire. It also appears worse on the higher amperage settings.

I cannot understand how this can be happening, so any help or insights would be greatly appreciated.

 

[pedrobedro]

Are you using the correct size tip for the wire you have ?

 

[John99]

Yes using 0.6 wire and 0.6 tip. Actually tried a 0.8 tip with the same wire but was the same.

 

[John99]

Here are some pictures I took. Not very clear but you can just see the marks on the wire.

 

[Sub-arc]

I think it is a feeding issue.
Either dodgy random wound wire or the liner. You say you've changed the liner but something could have happened to it in the mean time ie. something fell on the torch hose and while no obvious damage on the outside, the liner could be kinked inside. Have a look.

 

[John99]

I really don't think it's the liner, I will take it out again and check, but it did it with the old torch, then I changed it to a euro torch and then I changed the liner again and nothing seems to improve it. The last liner was fitted about a week ago. I don't know about the winding of the wire, it all looks ok, if I pull it through by hand it feels smooth and pulls easily. Thanks for your reply's though, this is a really annoying problem.

 

[Sub-arc]

Are those marks on the wire, all the way along the wire and at the exact same spacing ?

 

[John99]

I don't think so, I can't say I've checked how far back they go but it's probably just beyond the length of the tip I would guess and no it's pretty random, if you run the wire between your fingers it just feels rough.

 

[Sub-arc]

Snip off the wire between the feed roll and entry point of the torch, then pull it through the torch from the nozzle end and see where the marks are in relation to the length of the torch. What I'm getting at here is- possible problem with the feed roll itself marking the wire before it enters the torch.

 

[John99]

Ok that's a good idea, I'll do that tomorrow. Thanks.

 

[Sub-arc]

Also have a look here. Post #5
http://www.mig-welding.co.uk/forum/showthread.php?t=33450

 

[shenion]

What size liner are you using and length of torch?

 

[John99]

Yes I did have a read of that, I've got the wire support as close to the rollers as I can. With the euro torch conversion it's a brass tube, or a least it is on this one. I will check it again and take a photo. Thinking about it now the new liner I fitted was too long and I had to cut it off, is that normal?

 

[shenion]

Mot liners are near 16' with extra so you can cut to length. If you have a shorter torch, there is a lot to cut off.

Again, what size liner and length of torch?

 

[John99]

The torch is 4 meters, the liner was supposed to be 4 meters but there was about 8-10 inch's left to cut off.

 

[shenion]

I meant what size wire is the liner for?

I have liners for 0.6, 0.8-0.9, 1.0-1.2, and 2mm wire.

The 0.6 wire will barely work on the 0.8-0.9 liner. Will jam and stutter on the 1.0 liner.

 

[John99]

Sorry misunderstood you, the liner was listed as being for 0.6 - 09 wire.

 

[shenion]

That will work but you may get a bit of stutter in the wire with a 4m torch.

Try a new tip. You said you move the wire sideways and it comes loos. There should be very little play in the tip. Sounds like it is arcing as it is loose.

You can also try increasing the tension on the roller.

 

[John99]

Do you think I should get a smaller diameter liner to stop any stutter?

Tried countless new tips, it does it even with a brand spanking new tip. Yes if I move it, it ping's loose, I have to sort of flex my wrist, or if I touch the end of the wire against something it will come loose.

If I give it any more tension it just bunch's up in the welder.

 

[shenion]

You said "higher power settings" what size metal are you trying to weld? I would not try 0.6mm on anything over 2mm, the feed is just too frantic and hard to control.

I assume they are 0.6mm tips. Could be poorly made. I have had some no-name ones that did not make good contact.

The only other thing I could think of is tarnished wire (or Chinese junk wire.)