100sg Spool Gun Problem

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I searched the forum and I could not find a similar problem so I started a new thread.When I first got my gun, I used it for about 2 hours with no problems.  Just playing around trying to get feeds and power right.  Was really happy with the results.  I put it away and have not used it for a couple months.Pulled it out tonight to do some aluminum welding and I am having a problem with the wire dropping out of the wire roller/tension roller.  It drops down below both rollers.  It does it after welding about 1/2" to 3/4" of weld.  Get everything cleaned out and all lined up again and go to welding, and only get 1/2" to 3/4" again before it drops out of the roll.I tried .030" and .035" wire, same with both wires.  I tried both wire sizes with a .035" (alum) tip.  I checked the tension with a scale and I only have 1.0 to 1.5 pounds of tension.Even if you pull the wire out of the end by hand, it drops out of the roller.  It almost looks like it comes from the "spool end" too low for the roller.  Should there only be a plastic hole in the gun for the wire to ride through, or should there be a "bushing" of some sort there??Help!!Jamie WebbWelder & InspectorBusiness and HobbyLincoln Pro-Mig 180 with Spool Gun and Lincoln AC225
Reply:Are you using a grooved roller?  Is the wire starting out inside the groove?  Are your springs oriented correctly?  The spring that stick up should be in front of the lower spring?  Is you cam lock in place holding the roller in place?  Make sure the screw is tight.   Perhaps the roller is moving up not the wire moving down.Your metal liner should come from the nozzle to quite close to your roller.  However, I don't know how much that should cause it to fall below the roller, since it is recommended you align the for minimal to no touching the liner at that point inorder to reduce metal shavings.Oh yeah, tighten screws that mount drive assembly in the gun.  Good luckLast edited by tapwelder; 06-04-2009 at 12:18 AM.
Reply:Yes, it is a grooved roller.  It is the smooth .035" roller.  Before I ran the .030" and .035" wire with the .035" roller with no problems.  Yes, the wire is starting out in the groove.  The spring is installed just like the book says.  The camlock is holding the roller in place.  I will have to check the screws though, I did not think to check those.Jamie WebbWelder & InspectorBusiness and HobbyLincoln Pro-Mig 180 with Spool Gun and Lincoln AC225
Reply:I have some hard plastic tubing in the shop that is .190" od and .125" id.  I cut a peice 3/4" long and pushed up into the hole leading from the spool to the drive roll.  Ran about 3' of weld with it tonight with no problems.  I think it was just coming off the spool too low and rolling off the drive roller.Do you guys have any type of "insert" in that hole from the factory??  Maybe something got knocked out of mine??Jamie WebbWelder & InspectorBusiness and HobbyLincoln Pro-Mig 180 with Spool Gun and Lincoln AC225
Reply:Are you using 5356 or 4043?  The harder wire might be an issue.  It also requires the coil spring under the spool.  I use 4043 without issue.I have no insert other that the liner in my gun.
Reply:4043.  I am using .030" and .035".Jamie WebbWelder & InspectorBusiness and HobbyLincoln Pro-Mig 180 with Spool Gun and Lincoln AC225
Reply:Just registered so I could comment..  I have the same spool gun and had the same problem from day one.  I discovered that the gun was missing  a small white plastic guide that guides the wire into the roller. The gude is not in the parts list and Lincoln recommended I return the unit since I couldn't order the part.  Might be your problem..