Clarke 160EN Turbo Wire Feed Problems

[JonnyAlpha]

Trying to get my Clarke 160EN Turbo setup for the first time and I can't seem to get the wire speed correct, what's hampering my progress appears to be a wire feed problem.

When the torch is activated the wire feeds for about 1 to 1.5 seconds then stops for 1/2 second or so then repeats the process.

When this happens the motor and feed roller rotates normally but the wire slips.

After stripping the whole thing down (not yet removed the liners) it appeared to be OK and was still feeding fine with the swan neck fitted however once the contact tip is on it just seems too much and the intermittent feed re-appears.

The swan neck liner protrudes beyond the aperture where the contact tip screws in, is this normal or should it be flush with the end of the swan neck?

I have a spare liner hose and swan neck liner and having stripped it down once will try and replace them and see if this solves the problem.

I bought the welder second hand on this site and its only been used to weld 300mm of steel, the wire was rusty but I removed all the affected wire and the wire in the liner appeared OK, so no rusty wire has been fed through the liners.

I understand from this site that when setup correctly the wire friction screw should just be done up enough to prevent the wire from running on and birds nesting and the feed roller should slip when light pressure is applied to the wire at the tip end.

Does this sound like a liner problem.

 

[JonnyAlpha]

Just did a search and found this LINK I,ll grease (probably Vaseline) the wire reel roller and have a look and see if the label on the back of the wire reel is not catching as the intermittent cycle has a rotational feel to it like a cam shaft.

Could this also be the top roller off centre or something stuck in the roller groove?

 

[malcolm]

Sounds like a contact tip problem to me. Try removing the contact tip again, running a couple of inches through, then gripping the wire between your fingers right where it comes out. I a really light grip stops the wire then liner or feed rollers. If it slides through with a moderate grip then it was the contact tip.

 

[JonnyAlpha]

Think Ive found the culprit, the feed roller appears to be off centre, either that or the motor shaft is bent. With the motor running the top roller only rotates for about 2/3 rotation unless i press hard down on the top of the roller support.

Is this common for clarkes?

This machine is fitted with a Knurled feed roller which probably isn't helping smooth wire feed, according to my earlier post on maintenance HERE I need a smooth roller but I'm sure this is the original, where can I get a U or V smooth roller for a Clarke 160EN Turbo.

Anyway I fitted it all back together and can get a constant wire feed but have to have the top roller a little tighter than it probably should be but the motor isn't noticeably struggling and if I stop the wire I can get intermittent slippage.

 

[shenion]

I had issues with the top roller not following right. Turned out there pivot had a mold line that caused it to be stiff. Sanded it a bit and it was fine.

I had some runout in the wheel, I could see the pinch roller move up/down a bit. Seems the nature of the beast for the Clarkes.

Earlier ones the pivot was weak and needed a support as the roller would tilt off to one side.

I have not seem smooth rollers for the Clarkes, I ended up making one.

 

[JonnyAlpha]

Ill check the top roller but I reckon the culprit is the feed roller or the motor shaft.

 

[JonnyAlpha]

I emailed Clarke and a new wire feed is £14.99 but does not come with a motor.

 

[DIY]

Setting

Trying to get my Clarke 160EN Turbo setup for the first time and I can't seem to get the wire speed correct, what's hampering my progress appears to be a wire feed problem.

When the torch is activated the wire feeds for about 1 to 1.5 seconds then stops for 1/2 second or so then repeats the process.

When this happens the motor and feed roller rotates normally but the wire slips.

After stripping the whole thing down (not yet removed the liners) it appeared to be OK and was still feeding fine with the swan neck fitted however once the contact tip is on it just seems too much and the intermittent feed re-appears.

The swan neck liner protrudes beyond the aperture where the contact tip screws in, is this normal or should it be flush with the end of the swan neck?

I have a spare liner hose and swan neck liner and having stripped it down once will try and replace them and see if this solves the problem.

I bought the welder second hand on this site and its only been used to weld 300mm of steel, the wire was rusty but I removed all the affected wire and the wire in the liner appeared OK, so no rusty wire has been fed through the liners.

I understand from this site that when setup correctly the wire friction screw should just be done up enough to prevent the wire from running on and birds nesting and the feed roller should slip when light pressure is applied to the wire at the Titan the wire feed drive roles

 

[JonnyAlpha]

Just resurrecting this post, I have been using the Mig OK but I need to do some low power slow wire speed welding and this problem is gonna make it virtually impossible. I pinned the wire feed problem down to an off centre motor shaft. As I said in my post previously a new feeder does not come with a motor. So does anyone know where I can get a new replacement motor for a Clarke 160EN?

 

[shenion]

My 130 was off center too but was not a problem after I fixed the follower. Like I said, the arm was tight on the pivot so the idler did not follow correctly. Then the spring takes up the wobble in the roller.

You do have a spring on the tension thumbwheel?

 

[JonnyAlpha]

My 130 was off center too but was not a problem after I fixed the follower. Like I said, the arm was tight on the pivot so the idler did not follow correctly. Then the spring takes up the wobble in the roller.

You do have a spring on the tension thumbwheel?

Thanks Shenion - By follower do you mean the roller that presses against the roller on the motor spindle? I'll have a look tomorrow, I am sure there is a spring on the tensioner but it was second hand?

 

[shenion]

Yes, the follower or idler is the bearing the presses down on the grooved wheel.

Loosen the tension adjuster way out. The lever should easily move up and down; to the point if you lift it it will fall back down by its own weight. Mine was tight due to burrs on the lever pivot hole.

 

[JonnyAlpha]

Shenion - The follower / tensioner arm is very stiff so I took it off and sanded down the pivot and the hole in the arm, with a little silicone grease it now drops (slowly) by itself. I put it all back together and adjusted the tension so that with pressure applied the wire slips but the motor continues without struggling and I now seem to have a pretty constant wire feed even at speed setting 3.

Your'e a star :-)

Thanks

 

[shenion]

Good to hear. Yeah, it stumped me for a while.

After the fix, my 130EN was a real nice welder to use. It even worked with the 15' torch I added to it.