so i have a little lincoln "weldpack 100 HD" running some 030 welding wire (flux core) and i keep getting a bird's nest right after the feeding mechanism. i've used about half the reel so i know it probably isn't the wire, but it's happening more and more frequent now so i wanted to figure things out before i break anything. any ideas on what could be causing this?
you liner is probably going bad and the drive mechanism is having a hard time pushing the wire through it
hmm, that would make scence. i did change the tip, to no avail. so am i going to need to buy a whole new lead then
No you dont have to buy a new lead just a liner. Check feed roll tension I had about the same problem not long ago wire was fine until mid spool then got soft flatened wire caused birds nest. Just my 2cents.
If the tension nut on your wire feed is not tight enough, it will let the spool run on after you release the trigger. Sometimes that will cause a birds nest.
the feed rollers are to tight for one thing, even if you held the wire at the tip so it could not come out the rollers should slip before they make a birds nest, but because you have a blockage some place down the line and the rollers are to tight your getting the bird nest, its normal to have to remove your liner and blow it out, sometimes even run some thinner in the liner and then blow it out, then before you install the tip try running the wire, then install the tip and try, but first loosen your feed rollers.
Go to a welding supply store and pick up a 6 pack of Lubematic cleaner pads. They go right on the wire and sit right in front of the in wire guide for the drive. Also pick up a 3oz. can of Lubematic fluid. Pour a good amount on the pad. This helps lubricate the wire and makes for better feeding through the liner. Also, if you have a knurled drive wheel, which is used for flux core wire, take a small stiff bristle brush and periodically clean the wheel. Contaminants get on the wire, especially if it sits too long in the welder. These contaminants can flake off and clog the wheel. If you have a gas difusser in the head, take this out and clean it also. My company uses these regularly in all of their suitcase and portable MIG welders, and we weld in power plants all over the country. Also try twisting the head of the mig gun with one hand and holding the feed cable with the other, while the trigger is pressed. See if the wire sputters through. The liners do twist occasionally and bind up. A new liner wouldn't hurt, especially if it's a couple of years old.
when i bought mine i forgot to tighten down the wing nut for the lead .. and it kept birdnesting in that area because it was allowing the lead to move might be one thing to check, it may have came loose
If your using harbor freight wire,toss it, it varies in size pretty bad so it could be the problem. Before feeding your wire into the liner stick it threw an ear plug so the earplug will wipe the wire as it feeds to clean the muck off the wire.
I had to go to a larger tip size when I changed to the flux wire. It appears there is some inconsistancy in that wire OD so I use a .40 tip with the .35 wire and it works for me. Scott...
i have the same welder its the liner i fix my liner you can disconnect the lead unplug the two little wires inside take the tip off at the base of the lead you will see a little screw in the part that connects to the machine after screw is out pull liner out its a very tight coil of wire that the welding wire slides in like a speedo cable find the kink and rework it i wasted a whole roll before figuring it out too
you can clean the liner buy coiling it in a cake pan with thinner. let it soak for a couple hours then blow it out. might take a few trys. one more bad thing about cored wire...it's dirt as hell. a wiper like has been suggested will help. the ear plug is a new one on me but i will try it. when you set the tension on the drive wheels, start with it loose engought so it won't push the wire through. then tighten it slowly till it dose. if you over tighten the drive wheels, it crushes the hollow core wire and it's then too big to go through the liner. the liner is probably an .035 size. find someone that uses .035 solid wire and get about 10 or 12 feet of it. use that as a cleaning tool. push it slowly through the liner after you clean it with thinner. be sure to go in from the feed end of the linner. Ron
A couple thoughts. I also have a Lincoln 100 (an SP 100, very similar to yours, an older model) and I only run .024 through it, .030 doesn't feed through my machine for shit. Also, the little screw tab that holds the spool in place? Sometimes it'll catch and bind up, and sometimes it's too loose and the wire will unspool itself inside the machine, causing a big mess. A friend of mine has a Weld-Pac 100 and his does the same. He turns his tab to where it feels right (enough for the spool to turn without binding) and he clamps a little needle nose vice grips on it, the weight of the hanging vice grips keeps that tab from getting too tight or too loose. Now I do the same with mine and it works great. Don't know if your problems are similar but figured I'd mention this, I've had this welder for about 12 years now and I really like it but occasionally I have to tinker with it. When it's set up right it's a great machine.
Had the same problem on the same brand welder. Broke down and read the corrections. Followed the prompts and fixed it at no expense. My $0.02.
awesome, thanks all you guys for all the help. i was curious how tight the reel should be (as well as the feeder). i'm going to replace the liner anyway because it seems to be falling apart (i just pulled a small piece out). so can i get a replacement liner at sears or something
sears wont have a liner but any welding supply shop should just take your old liner with you so you get the correct end
I replaced the plastic screw with a longer bolt and a C706 spring from the hardware store and a washer. Best change you can do as mine was forever tightening up in the middle of a weld. Consistent now.
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