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post #1 of (permalink) Old 08-03-2003, 02:00 PM Thread Starter
 
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OT loading a spool into a welder

I recently purchased a Lincoln weldpack 100HD. I watched the video and read the manual, and I'm having the roughest time loading the spool wire into the loading mechinism.

First off, since I'm new to welding, I'm new to the fact that thoose spools are tighly wound, that was fun. Yes I saw the warning, no I didn't have any comprehension for how tight that thing is wound. I've had to wind it back up a few times now.

Ok, so I get it loaded onto the rod and tighten it. Then I have to pull it to the loading mechinism. Here is where it gets fuzzy. I thought I had it loaded right. So I turn it on and hit the trigger, doens't roll.

Is the spool to tight on with the butterfly clip?

Is it an issue with how it loads to the loading mechinism?

Sorry for the vague question, but I'm at a loss. I'm also trying this by myself, any hints? or should I wait to get someone else involved, maybe it's a 2-4 hand operation.


Thanks

Andy

Oh yea, I tried to rewatch the tape, it's destroyed, cheezy $5 add in, and the manual isn't much help.
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post #2 of (permalink) Old 08-03-2003, 04:01 PM Thread Starter
 
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Re: OT loading a spool into a welder

Got it, just needed it pressed in harder. Now to go test.
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post #3 of (permalink) Old 08-03-2003, 04:43 PM
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Re: OT loading a spool into a welder

I have found with my hobart that the window between too loose and to tight is fairly narrow. Just takes a feel. Mine caused me some problems until I got some lubricant made for the gun and that solved all troubles. [img]images/graemlins/40BEER.gif[/img]
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post #4 of (permalink) Old 08-03-2003, 05:30 PM
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Re: OT loading a spool into a welder

I'm not sure how yours is set up but on our wire feeders the electric line from the gun (trigger) always is comming unplugged from the feeder, wiggle it a little or plug it back in and retry it. Don't know if that helps....
post #5 of (permalink) Old 08-03-2003, 09:46 PM Thread Starter
 
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Re: OT loading a spool into a welder

I got it now, it was a combination of getting it through the input mechinism and getting it to make contact with the roller gear. And making sure the butterfly screw that was holding the spool on wasn't too tight, I think that was aiding in the problem.

I ran into a problem when I first started using it. Since I've never welded before, I had some issues getting the circuit to complete. Contact wasn't doing much to get things started. Took a little bit to figure out how to get the ground right. Need to dig around work tomorrow to dig up some scrap metal to practice on.
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post #6 of (permalink) Old 08-04-2003, 08:29 AM
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Re: OT loading a spool into a welder

Properly setting the drag on the spool and the squeeze on the drive wheels is very important.

Run the wire all the way through the liner and out the tip. Then back off the drag on the spool until it rolls about a quarter turn after you release the trigger. Too loose and you will get a loop of free wire. Too tight and it will take too much drive force.

Next set the drive force. Back off the tension on the drive wheels until you can put the tip against a block of wood and keep the wire from feeding. Then add a little more. Not enough and the wire will stutter when it feeds, or not feed at all. Too much and if the wire gets jammed you can generate a bird's nest in the welder.

These settings are critical when using aluminum wire, especially 4043.

You should have a toothed drive wheel for flux-core wire, and a smooth drive wheel for everything else. Especially don't use the toothed wheel on aluminum.
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post #7 of (permalink) Old 08-04-2003, 09:13 AM
 
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Re: OT loading a spool into a welder

One little hint that someone showed me... make sure to round off the end of your wire before you start feeding it through the tube to the gun. Wire cutters will leave a very sharp cut and the edges of the cut end can shred your liner tube before you realize it. Mine has had to be replaced twice over the years.... inexpensive but a PITA when you in the middle of a project and can't continue. Just my $0.02. Good luck with it.
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