Clarke 135TE Turbo - issues

[Escy]

I bought a used Clarke 135TE a year ago and it's never worked quite right but i've managed to soldier on with it, working around it's problems. Now i'm getting fed up, i'm either going to repair it or buy something better.

Because it's my 1st mig welder i'm having problems trouble shooting it, some of the issues may be me rather than the welder.

It doesn't seem to feed the wire through at a consistent speed. When I watch the spool feed the wire, it seems there is resistance it has to overcome.

What's really ******* me off is when i'm trying to weld, the wire gets stuck. When it starts welding fine, the wire never gets stuck during welding but what seems to always happen is when the wire touches the metal, it doesn't start welding, I just get a pop and the wire burns back to the tip. It then sticks in the tip. Sometimes it'll pop out itself, sometimes I have to tap the torch, sometimes I need to remove the tip. I've tried all the power settings, changed the tips and speeds. There is something wrong. I just watched the video of the mig welder wire speed demonstration, I can't do this on my welder, anything other than the perfect speed and the wire sticks in the torch. It's ******* me off.

 

[Cobbler]

Check the torch liner, the older Clarkes were fitted with a liner similar to windscreen washer tubing, the wire digs in & sticks causing allsorts of feed problems. If you remove the tip, undo the wire feed & tension on the reel, then pull the wire at the torch there should be little or no resistance. If there is any drag, change the liner for a steel one. You can get one from Machine Mart or Weldequip, click on the button on the top of the page. On second thoughts, if it's plastic, change it anyway, it makes the world of difference for not much money. Several on here have fitted curtain wire with good results as its the same size & cheap. Sorted you have a useful machine there, don't give up on it.

 

[DunnyD]

I cant really help as this is all brand new to me but I have the same machine (bought new a few days ago) and mine seems to spool the wire pretty well. Dont know whether mine has a plastic or metal inner, and of course its going to be clean given its new. Just thought I would mention it......

 

[Escy]

I did what you said and there was resistance, i'll try a new liner. I noticed when feeding the wire through and looking at the reel, it seems quite laboured although does seem to be a consistent speed. Once it comes out of the torch it moves at half the speed and the reel is stop start.

Another thing I often get is if the wire hits metal (say I have a bad earth and it doesn't weld), the wire kinks at the roller and goes all over the place. Is this common? The 1st time it happened I didn't know and it ended up feeding inside the welder and short circuited the circuit board (I bought a replacement)

 

[Cobbler]

When you fit the liner, finish it as close to the roller as possible, almost touching if you can. This leaves no room then for it to birds nest. The liners are longer than required so there is plenty of spare. On the bit between the roller & the reel, put a spare bit as a guide. Generally if it tangles up & birds nests the feed roller tension is too high as well. You should be able to just stop it with your fingers at the torch end & make it slip on the rollers. If the liner was shot you may have had to have the feed pressure up high to overcome the resistance of the liner.

Another thing, is the wire rust free, this can cause big feed problems, if so unwind it until clean. You don't say what wire your using, but some of the small reels sold are rubbish, bought in from where is cheapest & rebadged. I've not used it, but people have said the M.Mart wire is of variable quality, some OK, some not.

I hope this gives a few pointers to help you.

 

[T0rnado69]

also to add are you feeding gasless wire or gas wire.
are the rollers set correctly for the correct wire.

i had my mig start to bird nest all the time.
it turned out to be the wire liner....
i then thought about it and i had never changed the liner in 15 years

oppsss.

new liner installed and what a difference.

and as stated you only need the rollers tension on lightly.
so if the wire does stick to the tip etc
the feed rollers will slip on the wire instead of bird nesting it.

 

[Escy]

I'm using gas wire. The rollers are the right size 0.8mm. I'll pick up a metal liner from Machine Mart tomorrow and see how I get on.

 

[Cobbler]

Good move, takes about 1/2 hour & a bit of fiddling to get it up the sleeve.let us know how you get on.

 

[Escy]

I fitted the liner today and it's spot on now. Thanks for the advice

 

[T0rnado69]

great stuff happy welding.

 

[Cobbler]

Thanks for letting us know, I thought it would be something simple, they are pretty robust machines & parts are readily available.