Hi guys, I have a problem with the wire inlet guide (part#203-025) on the Handler135. It seems that the wire is getting hot and is grooving itself into the plastic wire inlet guide. It will "walk" from the center guide tunnel towards the edge of the guide at which point it finally jammed itself. The wire will get jammed bad enough that it will not roll out from the gun when the trigger is pressed. The wire tensioner is set at 3 according to the spec.
The machine was purchased late last year brand new from Northern Tools. I have been using .023 Firepower ER70S-6 on it since it was brand new with the Argon+CO2 mix. Last week, I switched to CO2 only for shield gas. I like the way the weld is with the pure CO2. The bead visually looks flatter and appears to have a better penetration into base metal. I dont know if the probem with the wire inlet guide is related to me switching to pure CO2 gas or not, but it only started happening after the switch.
At first, I thought that the tensioner is probably too tight, so the tensioner is backed out of 3 a little bit and I loosen up the wing nuts on the spool retainer shaft. I took out the plastic guide and reinstall it so that the bad groove is at the 9 o'clock position. I was hoping that was it and was hoping that the wire will be able to glide on the still smooth portion of the guide. No luck for me. I continued welding for maybe another 10 minutes before the wire got jammed again. I opened up the side cover and discovered that we now have a new groove again at the 12 o'clock position. Not knowing that to do and because it was getting late (local welding shop already closed) and I have just a little bit more of pipings to weld, I reposition the wire inlet guide again and continued with welding.
Tonight after dinner, I went into the garage to curiously check on that wire inlet guide and guess what...yet another new groove. We now have 3 grooves on the plastic wire inlet guide that was perfect yesterday.

What is happening here? It never did this before today and today is the first day I weld with the CO2 gas. Is my hunch correct? Did switching the CO2 gas have anything to do with this at all?
Andre
The machine was purchased late last year brand new from Northern Tools. I have been using .023 Firepower ER70S-6 on it since it was brand new with the Argon+CO2 mix. Last week, I switched to CO2 only for shield gas. I like the way the weld is with the pure CO2. The bead visually looks flatter and appears to have a better penetration into base metal. I dont know if the probem with the wire inlet guide is related to me switching to pure CO2 gas or not, but it only started happening after the switch.
At first, I thought that the tensioner is probably too tight, so the tensioner is backed out of 3 a little bit and I loosen up the wing nuts on the spool retainer shaft. I took out the plastic guide and reinstall it so that the bad groove is at the 9 o'clock position. I was hoping that was it and was hoping that the wire will be able to glide on the still smooth portion of the guide. No luck for me. I continued welding for maybe another 10 minutes before the wire got jammed again. I opened up the side cover and discovered that we now have a new groove again at the 12 o'clock position. Not knowing that to do and because it was getting late (local welding shop already closed) and I have just a little bit more of pipings to weld, I reposition the wire inlet guide again and continued with welding.
Tonight after dinner, I went into the garage to curiously check on that wire inlet guide and guess what...yet another new groove. We now have 3 grooves on the plastic wire inlet guide that was perfect yesterday.



Andre
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