Ironman 210 not feeding wire correctly

[Nit4gudtime]

Hello I'm new to this site but not to welding but I am having issues with my welder. It doesn't push the wire thru the lead unless the lead is completely straight. First I switched wire thinking that was the problem. That didnt work so I put a new liner in the lead, that didn't work so I put a whole new lead. Still same issue. I put new drive rollers and still the same thing. I've tightened down the tension control all the way with no help. The drive motor is spinning when the button is pushed but it won't push the wire unless the lead is almost perfectly straight. Also if you don't have a the ground hooked up to the work u can squeeze the button and it won't even push the wire, the drive motor just spins but won't push the wire. Ive never had a issue like this. I'm lost. Any help would be much appreciated. Thanks

[Hobartuser]

Have you tried checking the tip? I've had the tip clog from running a lot of wire through it and was preventing the feeding. I just took the tip off and the wire spooled out fine, so I replaced the tip and it solved the problem.

[Nit4gudtime]

Sorry forgot to put that down. Yes I've put several new tips on also. If I take the tip off you can take you finger and put it in front of the wire and pull the trigger and it won't even push like the tension on the drive roller is at it's softest setting but it's not. Idk

[SidecarFlip]

Your tension spring (that applies roller pressure is weak or broken. Thats why cranking the adjustment knob all the way down does nothing to increase tension. replace it and possible the rollers.

[Dan]

How tight is your spool hub tension?

Take a look at an exploded view of the spool hub assembly to make certain all components are there and assembled properly.

Look to see if the spool hub or the wire spool are catching on something.

[St. Paddie]

My 210 also has the feeding issue and I have run through all the trouble shooting options with no problems anywhere. However mine feeds fine on full feed but doesn't seem to be as fast as it should. I have also noticed that if I try to hold the feed roll I can stop it completely just by holding onto it. On the 20 setting sometimes it will feed for a few seconds and then stop. I can also grab hold of the feed roller and help it along and it will start feeding. I noticed in the included parts that there are two gears with a 7/8 inch diameter. I wondered if this was anything to do with the feed motor? I bought this unit in the spring and haven't had the chance to use it until now! I'll bet there isn't one half hour of welding on it. I am disappointed.

[Nit4gudtime]

Ok, it might be the spring tension even though the spring isn't broken as I can tell but maybe it's weak. I'll try ordering a new one.
Also the spool is free and spins freely as it's suppose to.