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Airco Dip/stick 160


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  #1  
Old 02-02-2008, 06:30:38 PM
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Default Airco Dip/stick 160

We have an Airco welder model Dip/Stick 160 that is about 25 years old. When welding (mig) the arc sputters, runs good, then sputters again, no pattern to the sputtering.
We took the covers off and looked for bad/loose connections but all appear ok (disconnected several and cleaned). No smoke or arcing visible while welding, just a humming/buzzing from the weld current contactor that changes with the sputtering.
We disassembled the contactor and cleaned the contacts, but no change.
Wondering if anyone has experience with this problem?
It is 220AC single phase powered.

Ident Tag:
Code 0037
Serial # DG606072
Stock # 1346-6010

Any ideas greatly appreciated. PT
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Old 02-02-2008, 08:27:02 PM
Ed Radtke Ed Radtke is offline
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Default Re: Airco Dip/stick 160

I assume you changed the contact tip on the gun.If not,that is likely the problem.
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Old 02-03-2008, 09:22:30 PM
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Bill Geyer Bill Geyer is offline
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Default Re: Airco Dip/stick 160

Had a wire welder at work that acted like that. A school bus had backed over the hose/lead. The flow meter showed gas was flowing, but it wasn't coming out the nozzle properly
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Old 02-26-2008, 07:38:35 PM
FlyingWrench FlyingWrench is offline
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Default Re: Airco Dip/stick 160

Flux core or bottled shield? Not welding in excessive breeze, are you?
Just basic thoughts here
Inconsistent wire speed or incomplete shielding causes many ill characteristics.
S.M
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Old 02-27-2008, 02:38:14 AM
Paul Schultz Paul Schultz is offline
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Default Re: Airco Dip/stick 160

Another thought on that sputtering/ stuttering. .how long has it been since the liner was cleaned or changed? Or the feed rolls cleaned and adjusted? Do you have a wiper on the wire before it goes though the feed rolls? A lot of wire has a coating in it that will eventually plug up the liner, not to mention spalling off in the feed rolls, hence the felt wiper on the wire. This isn't as noticeable in the .045 and up sizes but in .035 and smaller, I've found it to be the culprit. Dust floating in the air in a fab shop can add to the problem with spools that aren't enclosed or machines that have the lid open.
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Old 02-27-2008, 09:07:54 PM
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Default Re: Airco Dip/stick 160

Thanks for the tips.
We haven't been able to get a new contact tip yet, the welding supply we deal with can't match it and they can't identify the gun.
The welder uses CO2 gas and it flows ok.
We keep a felt wipper on the wire, but the liner hasn't been changed recently.
The feed motor and rolls turn smoothly and the wire appears to move at a uniform speed (speed does change when the speed control is adjusted.
At the present time my brother has borrowed the other welder (DIP PACK 200) from our other brother, he hasn't been using it anyway. It has been working fine and the wider wheels are almost finished.
I guess if we want the DIP STICK to work right we may have to go for a new gun assembly as this one is 20+ years old, unless we can find a dealer that can get parts for this one.
THANKS AGAIN EVERYONE. PT
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Old 03-01-2008, 08:59:16 AM
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Default Re: Airco Dip/stick 160

Here's the wider wheels project for his Super MTA.
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Old 04-04-2008, 10:23:15 PM
OneWelder OneWelder is offline
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Default Re: Airco Dip/stick 160

If the other suggestions did not fix it- check drive wheel groove for wear- that machine may have a doubled groove drive wheel which can be reversed
Co2 is alright to use- but C-25 (25% Co2 75% Argon) Would give you a smoother arc, more uniform weld, less spatter,better looking weld usually. Co2 is best for down beads,also cheaper but C25 will handle higher welding voltages.
The wire feed amperage settings can be varied from the premarked thickness settings- a little higher on the voltage amperage setting to compensate old age ,low input voltage.
Make sure you keep ground clamp contact clean also!
The gun was probably a Bernard
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Old 04-05-2008, 08:29:04 PM
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Default Re: Airco Dip/stick 160

Since this got bumped back up, I'll give an update. My brother went to a different supply and got a new liner (had to shorten it, generic I guess) and that helped some. A friend noticed that the contact tip looked like his so he got us the part number and the 2nd supply place ordered a package, perfect fit. It's now back to almost original, good enough for most of our stuff.
THANKS ALL, PT
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Old 01-03-2010, 09:04:16 PM
Ted Godzisz Ted Godzisz is offline
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Default Re: Airco Dip/stick 160

would you please tell me the part number of the tip of your 160 welder as I have one and need tips and tip shields thanks. TED
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Old 01-25-2010, 09:36:17 PM
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Default Re: Airco Dip/stick 160

Sorry to be so late responding, but didn't catch the post until last saturday.
Still have to remember to look up the tip number and where we got them. Our gun is a Bernard I think but not sure. Does yours look like ours in the attached picture?
PT
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Old 02-06-2010, 09:02:01 PM
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Default Re: Airco Dip/stick 160

Found the info on the tips we got:
Brand: ESAB
Size: .035
Part No.: 996995 Replaces 23612708
Source: Airgas ( www.airgas.com )
Hope this helps.
PT
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