23
Setup Guide and component Identification
Section 2
C
INSTALLING THE WIRE SPOOL
-
To thread the wire from the spool properly through the wire feeder into the gun:
1.
Install the MIG gun as instructed in
“
To install the MIG gun (torch)
”
above. Loosen the top idler roller tensioner, rotating the black tensioner knob counter
-
clockwise.
2.
Flip the tensioner down, toward you, releasing the carrier arm that holds the top drive rolls.
3.
Raise the carrier arm up. Inspect the drive rolls to make sure that each roller
’
s groove size matches the wire diameter. Also make sure correct type of drive rollers are used. i.e.
Flux
-
Core drive rolls use special serrated rolls. (Top driven rollers do not have grooves and are not to be removed).
4.
Reversal of the lower drive roll to select the right size drive groove may be necessary.
To reverse the lower drive roll:
Remove the retaining screw with the black plastic
securing the lower drive roll. Remove the outer ring of the drive roll and flip the drive roll over. The drive roll is actually made of two pieces. Hold the inner assembly of the drive
roll on with one finger (to prevent it from slipping off the shaft), while slipping the outer
“
rim
”
of the drive roll off with the other hand.
NOTE: Both inner and outer parts of the
assembly have locating keys.
To reinstall: Line up the outer rim of the drive roll keyway with the locating key. Reassemble and tighten. Before finishing assembly, make
sure the locating key is fully in place and have not slipped out of the key way during assembly. Lightly coat the inner mating surfaces with light weight lubricant oil if necessary to
prevent future seizure. Do not lubricate the surfaces of the drive rolls or wire slipping and erratic feeding may result.
5.
Follow instructions above:
“
To Load Spool of Wire.
”
Make sure the spool of wire is loaded correctly so that the wire unrolls from the bottom of the spool (counter
-
clockwise).
Thread the wire into the coiled guide and over the matching groove in lower drive roll. Thread the wire fully through until it threads into the gun section
4”
-
6”.
Lower the upper
drive roll into contact with the lower drive roll while keeping the wire securely fixed in the groove. If needed, use a screwdriver with a fine blade or small pick to keep the welding
wire from moving out of the grooves until step 6 is completed. Recheck once again that the correct drive groove has been selected.
6.
Raise drive roll tensioner back into place. Tighten it slightly so the wire will feed. Make a note of the visible markings on tensioner handle for future reference.
7.
Remove the contact tip from the torch. (Not Shown).
Hold the torch cable and gun as straight as possible, in direct line with the unit so feeding of the wire through the gun
liner is smooth and easy. Press the gun trigger to feed wire until the wire exits the end of the torch. Reinstall the contact tip over the wire over the wire and tighten it.
8.
To prevent bird nesting or slipping of the wire, adjust the tensioner clockwise until the drive rolls will not slip when the wire comes into contact with a hard surface. The wire will
curl up on end while feeding under power. If you over
-
tension the wire, you will increase the chances of bird nesting of the wire (balling up of the wire or curling of the wire
around the drive rolls), so it is best to tighten just until wire stops slipping and is able to curl up. Extra tension can deform wire and prematurely wear the drive rolls. Slowing of
the feeder may result as well.
Remember not to test on any metal attached to the work clamp to prevent the wire from arcing while performing this test.
1
4
5
A
B
C
To load the spool of wire:
1.
Loosen and remove the small threaded tensioning nut on the spool
carrier by turning it counter
-
clockwise.
2.
Remove the tensioning spring and outer hub spacer.
3.
Slide spool onto the shaft. Make sure wire is unwinding from the bottom
of the spool. Lift the spool enough to ensure that the hub seats on the
inner shoulder of the carrier. (For
4”
rolls, spool will fit against inner
shoulder). Some rolls, depending upon brand, may fit slightly different.
4.
Reinstall the outer hub spacer, with the short side of the spacer
’
s
shoulder facing in. (For
4”
rolls, the long side will face in and sandwich
the roll between the inner and outer hubs).
5.
Reinstall the tensioning spring and threaded tensioning nut
6.
Lightly spin the spool. If it free
-
wheels more than 1/4 turn, tighten the
tensioning hex nut slightly, 1/4 turn and retest the free wheel. If it does
not free
-
wheel at all, loosen the nut until it free wheels 1/4 turn.
7.
Locate the end of the wire and clip the bent end of the wire so that it will
feed through the wire feed mechanism smoothly. Carefully hold the
spool of wire with one hand so the wire will not de
-
spool.
Be sure to
clip the end of the wire with a pair of sharp wire cutters so the wire is
cut completely straight
. Proceed to instructions listed below:
“
To
thread wire from the spool properly through the feeder.
”
8
Bottom Drive Roll Sizing
(See side for stamped size)
.6mm=.023
”
-
.025”
.8mm=.030
”
.9mm=.035
”
1.0mm=.040
”
1.2mm=.045
”
To change the polarity of the MIG gun:
Unscrew the screw from the (+) terminal. Move copper
cable lug to the hole in the
(
—
)
terminal lines up with the hole in the buss bar. Reinstall the
screw into the ( —
)
terminal. Tighten until cable is secure and will not rotate if moved by hand.
To install the MIG gun (torch).
A.
Align pins on the torch connector with the feeder receptacle.
B.
Fully engage the connector into the receptacle on the welder.
C.
Twist the plastic hand nut on the connector clockwise until it is
snug.
Tighten only by hand or damage may result.
4
5
3
2
6
