Need Help Diagnosing Why My Lincoln SG Spool Gun Feeding and Arc Issues

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I have a Lincoln PowerMig 215 with an air cooled SG Spool Gun (and PM 215 conversion kit) that I cannot seem to get to feed correctly ever since I bought it brand new unused third hand.I am trying to weld aluminum with it and have the knurled drive rollers but it keeps sticking to the heavy duty relief cut contact tips. I am using the arc and wire feed guidelines that are noted in the manual for my material uses.Any suggestions to as why the wire is sticking to the contact tips?ChadMy JeepLincoln Power Mig 215 / Magnum 300 Mig Gun / SG Spool Gun / Dual TankLincoln X-TRACTOR 1GCMiller Digital Elite
Reply:Check and tighten all connections.  Make sure wire is feeding smoothly, no shavings in sided the gun. Also , tip to work distance should be rather long, 3/4" +.I had issues at one time and notice found a loose connection at the machine (a lug was loose). I checked lots of stuff prior to noticing that at a time when is wasn't even doing aluminum.
Reply:You should have smooth drive rolls for aluminum,  knurled ar for flux core.   My SG uses a smooth V drive roll.   B urning back into the tip is either too much voltage or too low a wire speed.   Turn wire speed all the way up and then back It down as u run a test bead till u get the feed right.  If u have been using a knurled drive roll I bet mmoney the liner is buggered up.  Pull it out an blow it out with compressed air to start.    I got the same spoolgun so let me know if I can help.On mine I just had to remove one washer/spacer from the spindle and grease th shaft of the tension nut so it moved properly and didn't hang up.  Also to get the correct tension on the spool.   If u r too tight on spool tension ic can cause your problem too.Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:You know Souttpaw... you actually sound like you know what you're talking about. Not bad for graduate of Yoda's College of Applied-All-Pervasive Force! Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:I have heard tons of problems with people pushing aluminum through a liner. Almost all of them I know of have gone to a spoolgun. I would be interested to know if anyone has a successful non-spool-gun solution (and what the solution is of course) Edit: you have a spoolgun. I need thicker glasses. I would still be interested in any non-spool-gun working solutions because bigger wire rolls are usually cheaper and spool guns could be a pain in tight areas.Last edited by yorzaxt; 11-27-2012 at 11:24 AM.
Reply:Originally Posted by yorzaxt I would be interested to know if anyone has a successful non-spool-gun solution (and what the solution is of course) .
Reply:Start with the wire speed too fast and slow down until you hit the lowest speed where you have spray transfer and some wire stickout. There should be a bit of wire extending past the contact tip before the spray starts, the spray should not emanate straight from the contact tip.Ian TannerKawasaki KX450 and many other fine tools
Reply:Originally Posted by yorzaxtI have heard tons of problems with people pushing aluminum through a liner. Almost all of them I know of have gone to a spoolgun. I would be interested to know if anyone has a successful non-spool-gun solution (and what the solution is of course) Edit: you have a spoolgun. I need thicker glasses. I would still be interested in any non-spool-gun working solutions because bigger wire rolls are usually cheaper and spool guns could be a pain in tight areas.
Reply:Sounds like Southpaw hit this one right. I have helped other that have bought units and forgot to switch out the feed rollers as well as adjust roller tension. Cleaning out your liner will be neccessary wihen changing the rollers and tension.Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:I will have to check to see if the drive rollers are correct.Thank you all for the suggestions!ChadMy JeepLincoln Power Mig 215 / Magnum 300 Mig Gun / SG Spool Gun / Dual TankLincoln X-TRACTOR 1GCMiller Digital Elite
Reply:also make sure you are using the appropriate contact tip for the size of wire you are using. Often it is suggested that you go up one size of tip while using aluminum,Nothing Ever Got Done By Quitting, Never Give Up.