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Millermatic 250 wire feeder surging

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  • Millermatic 250 wire feeder surging

    I need some help guys. My personal welder is giving me FITS!!! The wire feed motor is surging like it has a tight spot in a bearing. Or it is getting a power surge from something.

    My question is, does anybody know what voltage or resitence I should get between feeder motor and circuit board or the rheostat on the speed control? Could it be the high-low switch going bad?

    Im on the fence of buying a new one or sending it in and dropping know telling what in getting it fixed. Any help would be appreciated.

  • #2
    Did you blow out the liner or replace it? Do you have any kinks in the line somewhere? Those can cause feed issues. Also if your tension is set wrong.
    MillerMatic 251
    Maxstar 150 STH
    Cutmaster 42
    Victor Journeyman OA

    A rockcrawler, er money pit, in progress...


    • #3
      It's not the liner or gun related. If the feeder motor is ran without feeding wire, you can visually see the drive roller surge. You can also hear a change in the motor sound. I've removed the brushes and they look new. No burns or gouges on them.

      Im leaning more towards the speed controller or the high/low switch. I had the main control board replaced 5 years ago.