Lincoln Electric KP653-035S Drive Roll Kit Instruction Manual

1. Introduction

This manual provides essential information for the proper installation, operation, and maintenance of the Lincoln Electric KP653-035S Drive Roll Kit. This kit is designed for feeding .035 inch (0.9 mm) solid welding wire in compatible MIG welding machines. Adhering to these instructions will help ensure optimal performance and longevity of the components.

2. Product Overview and Components

The KP653-035S Drive Roll Kit includes the necessary components for precise feeding of .035 inch (0.9 mm) solid welding wire. The kit typically consists of a drive roll and a guide tube.

This image displays the components of the Lincoln Electric KP653-035S Drive Roll Kit. It includes a metal drive roll with '0.9-0.35' and '0.035' markings, a brass guide tube with a white plastic tip, another brass guide tube with a pointed end and a black O-ring, and a C-shaped brass retaining clip.

• Drive Roll: A grooved wheel that grips the welding wire and pushes it through the welding gun. The grooves are specifically sized for .035 inch (0.9 mm) solid wire.
• Guide Tube: Directs the welding wire from the spool to the drive roll, ensuring smooth and consistent feeding.

3. Setup and Installation

Proper installation of the drive roll kit is crucial for reliable wire feeding. Always refer to your specific MIG welder's instruction manual for detailed steps on accessing and replacing drive roll components. Ensure the welding machine is disconnected from the power source before performing any installation or maintenance.

1. Power Disconnection: Turn off and unplug the welding machine from the power outlet.
2. Access Drive Roll Area: Open the wire feeder compartment door on your MIG welder.
3. Remove Existing Components: If replacing an old kit, carefully remove the existing drive roll and guide tube. Note their orientation for correct installation of the new components.
4. Install Guide Tube: Insert the new guide tube into its designated slot, ensuring it is seated correctly to align with the wire path.
5. Install Drive Roll: Place the .035 inch (0.9 mm) drive roll onto the drive shaft. Ensure the correct groove for solid wire is aligned with the wire path. The markings on the drive roll typically indicate the wire size.
6. Secure Components: Secure the drive roll and guide tube according to your welder's design, often involving a retaining clip or lever.
7. Close Compartment: Close the wire feeder compartment door.

4. Operation

Once installed, the drive roll kit facilitates the feeding of .035 inch (0.9 mm) solid welding wire. Ensure the wire tension is correctly set on your welding machine. Too little tension can cause wire slippage, while too much tension can deform the wire or damage the drive motor. Adjust tension until the wire feeds smoothly without slipping or deforming.

5. Maintenance

Regular maintenance of the drive roll kit ensures consistent wire feeding and extends the life of the components.

• Inspection: Periodically inspect the drive roll grooves for wear, debris, or damage. Worn grooves can lead to inconsistent wire feeding.
• Cleaning: Clean the drive roll and guide tube regularly to remove any accumulated dust, metal particles, or wire coating residue. Use a clean, dry cloth or compressed air.
• Replacement: Replace the drive roll and guide tube if they show signs of significant wear, damage, or if wire feeding issues persist despite proper cleaning and tension adjustment.

6. Troubleshooting

If you experience issues with wire feeding, consider the following common troubleshooting steps:

• Inconsistent Wire Feed: Check drive roll tension. Ensure the drive roll grooves are clean and not worn. Verify the guide tube is clear of obstructions.
• Wire Slipping: Increase drive roll tension slightly. Inspect drive roll for wear or contamination.
• Wire Deforming/Flattening: Reduce drive roll tension. Ensure the correct drive roll groove is being used for the wire size.
• Wire Tangling: Check for proper spool tension. Ensure the guide tube is correctly aligned and free of bends or damage.

If problems persist, consult your welding machine's manual or contact Lincoln Electric customer support.

7. Specifications

8. Warranty and Support

For information regarding product warranty, technical support, or service, please refer to the official Lincoln Electric website or contact their customer service department directly. Warranty terms and conditions may vary.

Visit the Lincoln Electric Store for more products and information.