Hobart 210 spring loaded feed roller popping off with .023 wire

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Hi, new member here. I have a Hobart 210 and when I run .023 wire and set the spring loaded feed roller to the correct detent for the .023 wire I am having problems with the roller popping off the shaft. I have to use the groove for .030 and feel I need to make the pressure to tight on the tension adjustment and have frequent bird nesting with the wire.The unit works fine with .030 and .035 wire. I am only having trouble with the .023 wire. I like to do a bit of sheet metal work and would like to use the Hobart but I end up using my old 110 welder that has no problem with the .023 wire. Any suggestions? Thanks
Reply:" to the correct detent for the .023 wire "I'm not sure what you mean by proper detent for .023 wire as the Tension knob does not have markings for the different size wires.You just tighten as need so the wire does not slip.Look over section 5-12 Threading Wire:https://www.hobartwelders.com/files/...27978D_HOB.pdfEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:I think you might mean the drive roll.

I don’t see how it would pop out if the pin is in the proper detent. (At least not on mine)
Reply:ahh.Seems like he might be trying to line up the pin with the .024 marking on the Drive Roll.Which wont work as that spot is not deep enough to hold the pin.To The OP,The .024 marking is not there to line up the pin, it's just a marking on the drive roll so you can see witch side of the roll to use.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Tuna,one side is for .024, .030/.035  Solid wireThe other side is for Fluxcore wire.https://www.hobartwelders.com/consum...ve-roll-261157Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Dang it, you made me search the manual to check that

https://www.hobartwelders.com/files/...60274F_HOB.pdf

That detent should be deep enough to hold on the 024 mark.His may be different and may need to be flipped but mine allows the roll to move to keep each groove lined up with liner.
Reply:I have the 3 groove roller. The .024 detent should be for the .024 wire, correct? When I squeeze the trigger the the spindle spins, the roller will pop off the drive spindle(excuse my lack of proper terminology for the part names). It seems like the detent for the .024 wire is barely 1/16" deep.Also, the 3 groove roller, which I have,  cannot be flipped over. My 110 machine has a 2 groove roller that can be flipped but not my Hobart.I'm going to call the Hobart help line as was suggested on another forum. I'll let you guys know what they suggest.Last edited by tunahelper; 12-07-2020 at 06:17 PM.
Reply:Ahh..I forgot they used different Drive Rolls depending on which machine you received.Hopefully Hobart can get ya sorted.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:I would check the tension on the roll of wire. What's probably happening is the force required to pull the wire off the roll is causing the drive roller to jump one notch. That would cause it to fall into the "removal" detent. That would be exacerbated by over-tensioning the spring on the drive.Jim