CLARKE 130TE Wire Feed problems

[funstuie]

I recently got a Clarke 130TE from someone on ebay. I have replaced the wire liner, swan neck etc (from weldequip) but the feed is still all over the shop.

I think the problem is the rollers. When I lift the top one the other one moves fine when I push the button but when I put the other one down the movement is intermitent and it doesn't seem to make much difference how much tension I put on the roller. It either spins and the wire doesn't move or I put too much tension on an neither roller move.

I cleaned up both rollers with a bith of cloth and some 800 grit sand paper and it made a little bit of difference but not enough to make the welder useable.

Can the roller be replaced? I put some wd40 on the top roller (the one with the tension thing) but I don't think that was a good idea as that one spins freely but doesn't move when the two rollers are on the wire.

I realise I have just posted a load of gibberish, sorry.

 

[weldequip]

First thing to check is it set up in the correct groove for the size of wire you are using? There are two grooves on the bottom feed roller (0.6 & 0.8mm) and you reverse it round (using an allan key) depending on the size of wire you are using; also make sure it is aligned correctly on the drive shaft.
Next check the tension on the top roller adjustment, it should be enough to just pick up the wire & feed it smoothly...too much tension can cause wire slip & bunching up at the rollers.
Another test is to hold the bottom feed roller between finger & thumb whilst pressing the torch trigger. If you can physically stop the roller (without gripping it with mole-grips!) you have a more serious problem...stripped gears in the gearbox, = new gearbox/motor assembly
weldequip

 

[shenion]

If neither rollers move, then sounds like it may have stripped gears.

Also check if the set screw on the main roller is loose.

 

[rtbcomp]

It either spins and the wire doesn't move or I put too much tension on an neither roller move.

Are you saying the top roller (ie both rollers spin) spins without the wire moving? In that case it sounds like you're using the 0.8 groove with 0.6 wire like Weldequip says, or the grooves are worn. Also the top roller may be canting over so it contacts the bottom roller.

The two rollers should be parallel, the bottom roller drives the wire and the wire drives the top roller.

Also check for play (worn bearings) on the rollers.

 

[funstuie]

I changed the roller over to the smaller groove (and gave it a good clean while I had it off the shaft) and it has made a bit of a difference.

If I try stop it with my fingers I can if I grip it really tight (wearing a glove as it would just slip out of my fingers).

It looks to me like the top roller is not doing it's job, it takes very little tension to get the bottom roller to seize.

As I said swapping over the groove to the smaller one seems to have made a difference, I can now weld but I can hear the roller slipping every now and then.

 

[shenion]

You should not be able to stop the bottom roller. Does sound like stripped gears.

Check the pinch roller if it is parallel to the lower roller. Some older ones had problems with the upper roller flexing (the pivot) and the roller sits at an angle. Same if the upper roller is loose in its mount.

 

[funstuie]

The upper roller is parallel, if I take it out it does spin very fast and easily.

If the gears are stripped what is the solution?

 

[weldequip]

If it were stripped gears you'd be able to stop the bottom roller virtually straight away as soon as you gripped it, no need for any heavy pressure.
Try backing off the tension on the top roller and, with your torch lead straight, press the torch trigger & start to wind down the tension again until it starts to pick up the wire & feeds smoothly. Sounds like it is wound down too far to me & you have too much tension.
Post pictures if you can.
weldequip

 

[weldequip]

Another point, before putting the top tensioning arm down on the bottom roller ensure the wire is actually sat in the groove; quite often you have to physically hold the wire in the groove whilst putting the top tensioning arm down, so it doesn't 'spring' out of the groove
weldequip

 

[malcolm]

Is the motor stalling as the wheels stop? That might make the problem a tangled wire reel or overtightened reel tensioner. Juist a thought as I didn't notice the motor mentioned.

 

[funstuie]

If it were stripped gears you'd be able to stop the bottom roller virtually straight away as soon as you gripped it, no need for any heavy pressure.

I have to apply a pretty strong grip to stop the roller. Without wearing a glove I was not able to stop it at all, it would tear my finger off.

Try backing off the tension on the top roller and, with your torch lead straight, press the torch trigger & start to wind down the tension again until it starts to pick up the wire & feeds smoothly. Sounds like it is wound down too far to me & you have too much tension.
Post pictures if you can.
weldequip

I did that last night and it seemed to make a difference but it requires very little tension to stop the rollers. To me it seems as though the top roller is not doing it's job.

Another point, before putting the top tensioning arm down on the bottom roller ensure the wire is actually sat in the groove; quite often you have to physically hold the wire in the groove whilst putting the top tensioning arm down, so it doesn't 'spring' out of the groove
weldequip

I will try that tonight. I am using .8mm wire but I have changed the roller over to the smaller groove (which I though was for .6mm wire?) and it made a difference. But I will make sure the wire is actually in the groove as up to now I have just assumed the wire would automatically sit in the groove.

Is the motor stalling as the wheels stop? That might make the problem a tangled wire reel or overtightened reel tensioner. Juist a thought as I didn't notice the motor mentioned.

The reel tensioner is useless, it's a wing nut which if I tighten at all the wire reel will not move so I have to leave it loose.

I will get some pics up this evening.

 

[shenion]

The reel tensioner is useless, it's a wing nut which if I tighten at all the wire reel will not move so I have to leave it loose.

I will get some pics up this evening.

Sounds like the spring is missing. Ther should be a spring between the wing nut and the hub so you can dial in tension.

 

[funstuie]

Sounds like the spring is missing. Ther should be a spring between the wing nut and the hub so you can dial in tension.

There isn't one. Where could I get a spring to replace it?

Thanks for all the help folks

Stu

 

[shenion]

weldequip would probably have them.

If not, i remember it as being about 1/2" in diameter and maybe 3/4" long. Could probably find one at a hardware store. Not a real strong spring as it only needs to apply an ounce or so of pressure.

 

[jugs]

Sounds like the spring is missing. Ther should be a spring between the wing nut and the hub so you can dial in tension.

There isn't one. Where could I get a spring to replace it?

Thanks for all the help folks

Stu

Had this problem on my clark 130, as reel turned it tightened up the w'nut gave allsorts of problems.
Replace w'nut with a Nyloc nut & a std spring washer samwitched betwen 2 plane washers, job sorted no wire feed problems in 6-7 yrs

 

[funstuie]

Here are some photos so you can see what I am on about:

 

[rtbcomp]

When you spin the top roller does it emit a rattling sound? If so the bearing is worn. It shouldn't be free enough to spin and should be silent. It will jam under pressure.

I got a replacement roller for my SIP from here http://www.simplybearings.co.uk/shop/index.php

You can order by size.

 

[weldequip]

There should be a spring under the wing nut on the spool holder. This puts tension on the wire spool & stops it un-ravelling itself & over running when you stop welding. Without that spring you will have probably had to tighten the wing nut right up which will cause the wire spool to be too tight & the rollers to slip as the motor trys to pull the wire through...could well be the cause of your problem. Also, the torch lead is dodgy where it goes into the front panel of the machine, which will cause feed problems. The black plastic outer sheath of the torch lead should be clamped in the plastic wire feed assembly, ie.no gap exposing the inner cables as in your picture.
weldequip

 

[shenion]

That pressure roller looks smaller than I remember mine. It also does not seem to line up with the main roller in the first pic. The vertical line on the tensioner should be through the center of the main roller. It looks too far forward.

Maybe the older ones weer that way, but I seem to recall others having feed issues due to a worn tension roller.

 

[wyn]

I've had the paper label on the wire reel cause wire feed problems......too much friction between it and the plastic cover