Everlast POWER i-MIG 253DP Operator's Manual page 28

Section 2
Side Description and Explanation:
1. Wire Spool Carrier Assembly. Make note of the
correct assembly order if disassembled. The or-
der in which they are assembled is important to
be able to provide enough resistance to prevent
de-spooling of the wire. When inserting the
spool , make sure the small tab or dowel on the
inside of the spool holder is correctly located in
one of the recesses made into the spool. After
installing the spool of wire, tighten the hex head
tensioning nut located under the spool retaining
nut so that the wire will not continue to roll
more than a 1/8th to 1/4th of a turn after the
wire has stopped feeding. Do not tighten the
tensioning nut to the point that the drive roller
slips or the feeder motor strains while feeding
the wire. The spool carrier assembly can accom-
modates rolls of wire 12" in diameter. The carri-
er can also support the use 8" rolls of wire with
an optional adapter. If you do not have an adapt-
er, contact Everlast to purchase one. NOTE: 4"
rolls of wire are not supported.
2. Polarity Connection. Note the "+" and "-" sym-
bols located on the inside of the unit next to the
round brass terminals. One terminal will have a
cable attached to it. The MIG unit is shipped
with the torch polarity connected to the positive
terminal. Positive polarity is designed to weld
with solid wires. To weld with most Flux-core or
dual shielded wires, the polarity must be
changed to negative. To change the polarity to
negative, simply remove the screw on the posi-
tive and move the cable over to the negative
terminal. Reinstall the screw on the negative
terminal. Standard polarity for MIG is
"+" (DCEP) with the work clamp in the negative.
3. Wire Feed Assembly. Note the numbers on the
side of the tensioner. These numbers are a refer-
ence point to help properly tension the wire so
that the drive roller will not slip. Do not over-
tension the wire because it can create a condi-
tion known as birds nesting, where the wire will
tangle up around the feeder and will not slip if
the wire burns back into tip, sticks fast in the
weld puddle or other resistance is met. This will
continue wrap the wire around the drive mecha-
nism (bird's nesting) or will jam wire inside the
gun liner until the trigger is released. Considera-
ble effort is usually needed to clear out a bird's
nest condition. Too little tension will result in
wire slippage and cause rapid wear on the drive
Setup Guide and component Identification
components. Do a feed test before beginning a
weld. Always make sure that correct wire size has
been selected for both drive rolls. Make sure that
the correct type has been selected to feed your
wire. The size and type is stamped on the side of
the drive roll. To identify type, note that a V mark-
ing denotes a V-Groove and is used for steel and
stainless wires. A U marking is U-Groove and is
used for Aluminum and Bronze. Occasional clean-
ing of the feeder mechanism is necessary to pre-
vent wear and damage to the feeder and to the
MIG gun liner. Regularly monitor any metal flaking
and dirt build up that may occur in the wire feed
area. Clean it away gently with compressed air.
Also to improve MIG gun liner service life, blow out
the gun liner with compressed air after running a
complete full size roll through. Do not use harsh
cleaners or solvents to maintain the cleanliness of
the feeder mechanism. Felt wire lubricators may
be bought and used to keep the wire feeding
smooth and clean while using steel or stainless
wire. Do NOT over lubricate! Your unit has been
supplied with additional drive roll sizes. Do not
forget to change the contact tip size when chang-
ing to a another wire diameter. If a special Alumi-
num tip is not available for use, when welding
with aluminum wires, use the next size up to pre-
vent feeding problems. Typically an aluminum tip
is drilled oversize to prevent sticking as the alumi-
num heats up and expands. Depending upon the
diameter and type of wire used, the MIG gun liner
may need to be changed to work properly. The
unit is supplied with an extra Polymer liner that
should be used with Aluminum and Bronze wires.
This allows the gun to be used while welding with
these wires. If this isn't changed, then "bird's
nesting" will occur. However, the 24 series gun
with the stock length should be able to feed most
Steel and Stainless Steel wire diameters without
requiring a liner change. If trouble is experienced
with feeding, purchase a liner specifically sized for
your type and diameter wire.
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