Clarke MIG 240, 6014200 User guide

WARNING: Read these instructions before using the machine

The welder is supplied set up for no gas welding

GAS/NO GAS MIG WELDER

MODEL NO: MIG 240

PART NO: 6014200

OPERATION & MAINTENANCE

INSTRUCTIONS

DL0422 - ISS 3

INTRODUCTION

Thank you for purchasing this CLARKE MIG Welder.

Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also look forward to the welder giving you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt as proof of
purchase.

This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.

Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.

This guarantee does not effect your statutory rights.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.

In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.

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GENERAL SAFETY INSTRUCTIONS

WARNING: WHEN USING ELECTRICAL TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF
FIRE, ELECTRIC SHOCK AND PERSONAL INJURY

WARNING: READ ALL THESE INSTRUCTIONS BEFORE ATTEMPTING TO
OPERATE THIS PRODUCT AND KEEP THESE INSTRUCTIONS IN A SAFE PLACE.

ELECTRIC SHOCK

• Remove the plug from the socket and wait 5 minutes to allow the capacitors
to discharge before carrying out any servicing or maintenance on this
welder.

• DO NOT touch live electrical parts.

• NEVER use electrode holders or cables which are damaged.

• Keep working environment, equipment, cables and clothing free from
grease, oil, moisture and dirt.

• Ensure welding machine has been correctly earthed.

• The operator must be insulated from the floor and work bench using a dry
insulation mat.

• ALWAYS ensure a second person is present in case of accident.

• NEVER change electrodes with bare hands or damp gloves.

• ALWAYS keep welding cables away from power cables.

• Regularly inspect the condition of the cables for signs of damage.

• Remove the plug from the mains socket when not in use, DO NOT leave the
machine unattended.

• Make sure that the earth clamp is secured to bare metal adjacent to the
weld seam and when not in use is insulated for safety.

• Keep all equipment well maintained.

• The operator shall prevent gas cylinders in the vicinity of the work piece from
becoming part of the welding circuit.

FUMES & GASES

• The welding process generates hazardous fumes as a by-product. Inhalation
of these fumes is hazardous to health.

• Keep your head away from the weld to avoid breathing the fumes.

• If welding in confined spaces ensure adequate ventilation and use a fume
extractor.

• By-products of welding can react to create a toxic/explosive environment.

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FIRE OR EXPLOSION

Welding can cause fires and explosions. Precautions should be taken to
prevent these hazards.

• Before starting work ensure the area is clear of flammable materials.

• Move any combustible materials to a safe distance, especially substances
likely to generate a dangerous vapour.

• The welding arc can cause serious burns. Avoid contact with skin.

• Sparks and molten metal are ejected during welding. Take precautions to
prevent fire.

• Sparks and molten metal can pass through gaps. Be aware that fire can
start out of sight.

• DO NOT weld pressurised containers. or containers containing flammable
vapours e.g. fuel tanks.

• ALWAYS have appropriate fire fighting equipment to hand suitable for use in
electrical environments.

• Avoid carrying any fuels with you e.g. cigarette lighters or matches.

PERSONAL PROTECTION

• The body should be protected by suitable clothing.

• The use of neck protection may be necessary against reflected radiation.

• Arc machines generate a magnetic field which is detrimental to
pacemakers. Consult your doctor before going near active welding
equipment/operations.

• The UV and IR radiation generated by welding is highly damaging to the
eye, causing burns. This can also affect the skin.

• ALWAYS use suitable welding shields equipped with appropriate protection
filters.

• Where there are pedestrians and traffic ensure a protective screen is used to
avoid accidental arc glare.

• DO NOT weld in the vicinity of children or animals and ensure no one is
looking before striking an arc.

• ALWAYS wear hearing protection if required.

• Allow the weld time to cool. Hot metal should never be handled without
gloves.

• Take care when adjusting or maintaining the torch, that it has had time to
cool sufficiently and the welder is disconnected from the mains supply.

• First aid facilities and a qualified first aid person should be available unless
medical facilities are close by for immediate treatment of flash burns of the
eyes and skin burns.

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• A hard hat should be worn when others are working overhead.

• Flammable hair sprays/gels should not be used by persons intending to weld
or cut.

PROTECTIVE CLOTHING

• Wear gauntlet gloves designed for use in welding.

• Wear an apron, and protective shoes.

• Wear cuffless trousers to avoid entry of sparks and slag.

• Avoid oily greasy clothing.

• Protective head and shoulder coverings should be worn when overhead
welding.

• Wear helmet with safety goggles or glasses with side shields underneath,
appropriate filter lenses or plates (protected by clear glass). This is a MUST for
welding (and chipping) to protect the eyes from radiant energy and spatter.
Replace cover glass when broken, pitted or spattered.

NOTE: ALL protective wear inc. masks & head shields MUST comply with PPE
Directive 89/686/EEC

GAS CYLINDERS:

• Gas cylinders should be located or secured so that they cannot be knocked
over.

• Shield gas containers can explode if damaged. Take care when handling.

• Ensure gas cylinders are shut-off when not in use and between operations.

• Take care that a build-up of gas is not permitted to form in confined areas.

• Cylinders must be in an upright position at all times during use and storage.

• The gas cylinder must never come in to contact with the electrode.

• Follow the manufacturer's instructions for handling, storing and using the gas
bottle correctly and safely.

• Use the correct equipment to connect the gas bottle to the welding torch.

ADDITIONAL SAFETY PRECAUTIONS FOR MIG WELDING

• ALWAYS ensure that there is ample free air circulating around the outer
casing of the machine, and that the louvres are unobstructed.

• ALWAYS inspect the hose before use to ensure it is in good condition.

• ALWAYS keep the free length of torch hose outside the work area.

• ALWAYS remove all flammable materials from the welding area.

• ALWAYS keep a fire extinguisher handy;-Dry Powder, C02 or BCF, NOT Water.

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• NEVER remove any of the panels unless the machine is disconnected from
the power supply, AND never use the machine with any of the panels
removed.

• NEVER attempt any electrical or mechanical repair unless you are a
qualified technician. If you have a problem with the machine contact your
local CLARKE dealer.

• NEVER use or store in a wet/damp environment.

• NEVER continue to weld, if, at any time, you feel even the smallest electric
shock. Stop welding IMMEDIATELY, and DO NOT attempt to use the machine
until the fault is diagnosed and corrected.

• NEVER point the MIG torch at any person or animal.

• NEVER touch the MIG torch nozzle until the welder is switched OFF and the
nozzle has been allowed to cool off.

• NEVER allow the earth cable or hose to become wrapped around the
operator or any person in the vicinity.

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ELECTRICAL CONNECTIONS

A STANDARD 13AMP PLUG MUST NOT BE USED WITH THIS UNIT.

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.

The unit must be connected to a 230V socket cabable of supplying 32 Amps,
We recommend that you consult a qualified electrician and connect the
mains lead, through a suitably fused isolator switch

Before switching the product on, make sure that the voltage of your electricity
supply is the same as that indicated on the rating plate. This product is
designed to operate on 230VAC 50Hz. Connecting it to any other power
source may cause damage.

WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE
COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH

If the colours of the wires in the power cable of this product do not correspond
with the markings on the terminals of your plug, proceed as follows.

• The wire which is coloured Blue must be connected to the terminal
which is marked N or coloured Black.

• The wire which is coloured Brown must be connected to the terminal
which is marked L or coloured Red.

• The wire which is coloured Yellow and Green must be connected to
the terminal which is marked E or or coloured Green.

We strongly recommend that this machine is connected to the mains supply via
a Residual Current Device (RCD)

If in any doubt, consult a qualified electrician. DO NOT attempt any repairs
yourself.

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OVERVIEW

1

2

3

4

NO DESCRIPTION NO DESCRIPTION

1Handle 5Torch Hose

2 Gas Connection Point 6 Earth Clamp

3 Control Panel 7 Shield/Mask

4Torch

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THE CONTROL PANEL

1. Wire speed control knob. As a general rule, a higher current requires a

higher wire speed.

2. Current setting dial. Provides 6 increasing power levels.

Dial Setting Welding Current in Amps

0 0A (Gas Output Test Only)

1 50A

2 75A

3 100A

4 130A

5 180A

6 240A

3. Power ON/OFF switch. When the power is ON the green switch will be
illuminated. When the welder is no longer required, the Power On/Off switch
should be switched to the OFF position and the welder should be
disconnected from the power supply.

4. Thermal overload light. If the duty cycle is exceeded as a result of welding
for too long with a high current, the overload light will illuminate and the
welder will turn off. When the welder has cooled down (approx. 5 to 10
minutes), the power will be restored and welding can recommence.

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OPENING THE SIDE PANEL

WARNING: DO NOT OPERATE THIS MACHINE WITH THE SIDE PANEL
OPENED OR REMOVED.

IMPORTANT: Make sure that the
welder is not connected to the mains
supply.

1. Push the latches down and let the
side panel drop down.

2. Remove loose items that have
been transported inside.

UNPACKING

Any damage or deficiency should be reported to your CLARKE dealer
immediately. Some of the components are stored within the machine side
compartment.

The components include the following:

1 x MIG TORCH Euro connection Torch (Quick release)

1 x 0.8mm tip for no gas welding in the torch

1 x 0.9mm tip (loose) 1 x hammer brush

1 x 0.6mm tip (loose) 1 x torch neck

1 x 0.8mm tip (loose) 1 x torch shroud

1 x 1.0mm tip (loose) 1 x gas bottle bracket

1 x welding shield 1 x chain

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ASSEMBLY

FITTING THE GAS BOTTLE BRACKET

1. Place the bottle bracket into
position and secure in place using
the screws provided.

CONNECT THE TORCH

Connect the plug on the end of the
torch hose to the socket shown on
the welder.

CONNECT THE EARTH LEAD

Insert the earth lead plug as shown.

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ASSEMBLING THE WELDING SHIELD

1. The welding shield shown on
page 12 is supplied flat for
shipping. Fold the sides of the
shield around and clip to the top
panel.

2. Insert both the glass lens panels
into the recess inside the shield.

• The clear glass must be fitted

first to face the outside.

3. Insert the two plastic screws and
use the plastic wingnuts to clamp
the glass panels to the shield.

• The clear glass panel should be
replaced when it becomes badly
pitted.

4. When replacing the glass panels, only use parts supplied by Clarke
International. The dark panel is a certified, optical glass and should not be
exchanged for any other type.

5. Secure the handle in
position using the plastic
nuts provided.

• The handle will be on the
inside of the shield.

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PREPARATION FOR USE

MOUNTING THE WELDING WIRE SPOOL

WARNING: MAKE SURE THAT THE WELDER IS NOT CONNECTED TO THE
MAINS SUPPLY.

NOTE: Spools of welding wire are available from your Clarke dealer.

1. Open the side panel by pushing
the latch down and allowing the
side panel to open.

2. Remove the locking screw and
retaining spring.

3. Place the spool of welding wire
(not supplied) over the spindle.

• Do not release the tension on

the wire as it will unravel,
causing feeding problems later.

• The wire will feed off the spool clockwise from the top of the reel.

• The spool must be fitted with the correct orientation otherwise it will

not feed correctly.

4. Replace the retaining spring and locking screw.

SETTING THE DRIVE ROLLER SIZE

1. Loosen the tensioning knob and
pivot it towards you.

2. Lift up the arm.

3. Remove the drive roller
thumbscrew.

4. Pull the roller retainer off the drive
spindle to reveal the roller.

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5. Pull the roller off the drive spindle.

• The groove size is stamped on

the corresponding side of the
roller. Select the groove size
according to the size of the
wire you are using and put the
roller back on the spindle with
your chosen side facing you.

6. Replace the drive roller
thumbscrew.

THREADING THE WIRE

IMPORTANT: Do not release the tension on the wire as it will unravel causing
feeding problems later.

1. Pull out the end of the wire from the spool, taking care not to release the
tension.

• We recommend you cut off and discard the first 10 cm of wire from

the spool to avoid burrs and then straighten the next 15 cm of wire
to help with feeding.

2. Loosen the tensioning knob and pivot it towards you.

3. Lift up the arm.

4. Feed the wire through the guide,
over the drive roller and into the
torch liner.

• Push about 10-15 cm into the

torch liner.

5. Lower the arm and refit the
tensioning knob.

• Tighten the tensioning knob

sufficiently to hold in position,
but do not fully tighten.

NOTE: Correct tension will allow the wire to feed into the torch liner

smoothly, but will allow the drive roller to slip in the event of a
blockage.

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6. Close the side panel of the
welder.

7. Pull off the torch shroud with a
twisting movement, then unscrew
the contact tip.

8. Connect the welder to the power
supply and switch ON.

9. Set the ‘WIRE FEED’ rotary control
on the front panel to position 7 or
8 and squeeze the trigger on the
torch body.

• The wire will feed through the

hose until it appears at the
torch tip.

• Ensuring the hose is free from

kinks during this process will
assist the wire in its passage
through the hose liner.

10. Release the trigger and switch off the welder and disconnect the machine
from the mains supply.

11. Refit the appropriate size contact tip to suit your wire. then replace the
shroud.

• Spare tips or various sizes are supplied loose and should be used

when appropriate.

12. Trim the welding wire so that it protrudes no more than 5 mm from the end
of the contact tip.

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MIG WELDING PRINCIPLES

MIG (Metal Inert Gas) welding allows you to fuse together two similar metals
without altering the properties of the metal.

A consumable wire electrode is continuously fed through the welding torch
that is fitted with a concentric gas nozzle. the wire is connected to a high
voltage supply which creates an electric arc between the electrode (the
wire) and the workpiece. The arc is used to create the required heat to turn
the metal into a molten state. The wire is used as both the electrode and as a
filler.

The gas is used to prevent oxidation and to shield the arc and the weld from
atmospheric contamination. The choice of gas is dependent upon the
material being welded

Metal Being Welded Suitable Gas Part number

Mild Steel Carbon Dioxide (CO2) 6000643

Stainless Steel Argon 6000661

Aluminium

Thin Sheet Metal/Mild
Steel

When using the welder in a gasless configuration the shielding gas is created
from the flux within the welding wire.

When using the welder outside, you may need to erect a wind break to make
sure the shielding gas is not blown away, thereby leaving a poor quality weld.

Carbon Dioxide (CO2)/Argon Mix 6000660

GAS/NO-GAS SELECTION

The welder can be configured to
weld, with or without a gas supply
according to the type of welding
wire being used.

• Mild Steel Solid Core (With

Gas),

•Flux Cored (No Gas)

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WELDING WITHOUT GAS

1. If you use 0.9mm flux cored wire,
connect the terminal as shown.

• The earth cable must be

connected to the positive
(upper) terminal.

• The cable from torch must be

connected to the Negative
(lower) terminal.

WELDING WITH GAS

1. If you use solid cored wire 0.6/

0.8mm mild steel, connect the
terminal as shown.

• The earth cable must be

connected to the negative
(lower) terminal.

• The cable from torch must be

connected to the positive
(upper) terminal.

CONNECT THE GAS SUPPLY

2. Place the gas bottle
(maximum10kg) on the platform
and secure it using the chains
provided.

3. Connect the gas supply hose
(included) to the connection at
the rear of the welder. (hose clips
have been provided).

4. Connect the other end of the gas
supply hose to a suitable gas
bottle.

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OPERATING THE WELDER

PREPARE THE WORKPIECE

The welded area must be clean. Coatings, plating or corrosion must be
removed. If not, you will not be able to achieve a good quality weld.

Attach the earth clamp to the workpiece as near to the point of weld as
possible.

OPERATION

CAUTION: THE DUTY CYCLE MUST BE FOLLOWED TO PREVENT THE
THERMAL OVERLOAD PROTECTION FROM OPERATING.

1. With the welding current set and the wire trimmed, set the wire feed
control to 6.

2. Plug the machine into the mains supply and switch on.

3. ALWAYS cover your face with a welding mask or welding shield.

• This is essential.

4. Lower the torch to the workpiece with one hand and approach the work
with the torch tip at an angle of about 35

• As the wire touches the workpiece an arc will be struck.

5. In order to produce a good quality weld, the controls can be fine tuned as
required. This will come with practice.

NOTE: MIG welding is an acquired skill. It is strongly advised that if you are

not fully familiar with this type of welding, you practice on a piece
of material with the same characteristics as your workpiece, until
you are satisfied with the result, and you have fine tuned your
welder to produce a satisfactory weld.

NOTE: One of the problems experienced with novice welders, is the

welding wire sticking to the contact tip. This is as a result of the
wire feed speed being too slow. It is always better therefore to
start with too high a speed and back off slightly, to avoid the
possibility of the wire welding itself to the tip. This is the reason
position 6 is recommended for start up.

o

and pull the trigger fully.

NOTE: The wire feed control is for fine tuning the wire speed. The speed

of wire delivery will increase automatically as the current is
increased. Therefore, once the ideal speed is achieved by fine

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tuning, it should not be necessary to adjust this control when the
welding current is changed.

NOTE: Listen to the sound made. An irregular crackling sound denotes

too high a wire speed. Decrease the speed until a regular, strong
buzzing sound is heard.

THERMAL OVERLOAD

The ‘Thermal Overload’ shuts off the
welder when it becomes too hot due
to the duty cycle being exceeded.
This is to prevent any damage to the
machine.

When this occurs, the warning lamp
shown will glow (amber). Allow the
welder to cool, until the amber light
extinguishes before resuming work.

DUTY CYCLE

The duty cycle determines the machine ‘down time’. i.e 10% means 1 minutes
operation followed by 9 minutes of rest. The duty cycle must be followed to

prevent the thermal cutout protection from activating

These welders are covered by
regulations EN 60974-1 and EN 50199,
where the duty cycle is expressed as
a percentage of time the machine
may be used in a given period for a
specified welding current.

Using illustration of the data plate
shown;-

e.g. when welding at 98 amps the
machine may be used for 6 minutes
(60%) in any 10 minute period.

Duty Cycle (%) 10 60 100
Rated Welding Current (A) 240 98 75
Conventional Load

Voltage (V)

26 19.5 17.7

Do not exceed the stated duty cycle for this machine. Failure to heed
this warning may invalidate your warranty.

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MAINTENANCE

WARNING: ELECTRICITY CAN KILL - NEVER TOUCH LIVE ELECTRICAL
COMPONENTS.

WARNING: DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS
AND MAINTENANCE OPERATIONS. BEWARE HOT SURFACES.

WARNING: ALWAYS LET THE WELDER COOL DOWN BEFORE ACCESSING
INTERNAL COMPONENTS.

Frequency of maintenance operations depends on the operating conditions,
how intensively the welder is used and how clean or dirty the welding site is
(aggressive environments etc).

Always inspect the earth cable and torch hose before use, to ensure they are
in perfect condition and that the earth clamp is clean and secured correctly
to the cable.

Check the hose for security and damage.

As a general rule the power supply should be inspected at least annually.
Consult your CLARKE dealer for advice if necessary.

Wire feed unit:

The feed roller wire guide plays an important part in obtaining consistent
results. Clean the rollers weekly, especially the feed roller groove, removing all
dust deposits.

Torch:

Protect the torch hose assembly from mechanical wear. Clean the liner from
the machine forwards by using compressed air. If the liner is blocked it must be
replaced.

Contact tip:

The contact tip is a consumable item and must be replaced when the bore
becomes enlarged or oval. The contact tip MUST be kept free from spatter to
ensure an unimpeded flow of gas.

To keep the contact tip free from spatter, we recommend the use of anti­spatter spray (6000715) available from your CLARKE dealer.

Torch shroud:

The torch shroud must also be kept clean and free from spatter. Build-up of
spatter inside the gas cup can cause a short circuit at the contact tip which
will result in expensive machine repairs.

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RATING PLATE

1 Name and address of

manufacturer

2 Model number, part number 14 Energy Input symbol

3 Batch number 15 Rated supply voltage

4 Single phase transformer-rectifier16 Rated maximum supply current

5 British Standards applied 17 Maximum effective supply current

6 Welding process 18 N/A

7 This symbol indicates that the unit

is suitable for carrying out
welding operations in an
environment which has an
increased risk of electric shock.

8 Welding Current symbol - direct

current.

9Rated no-load voltage 21N/A

10 Min+max welding current and

corresponding load voltages

13 Load Voltage symbol

19 N/A

20 N/A

22 Degree of protection

11 Duty Cycle symbol 23 Class of protection.

12 Rated Welding Current symbol 24 N/A

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CONSUMABLE

The following are some of the consumables available from your CLARKE
dealer. Please quote the part numbers shown below:

PART DESCRIPTION PART

NUMBER

Welding Wire
Spools

Welding Gas CO2 (250g) 6000642 For welding mild

Flux cored mild steel (4.5kg)

0.9mm

Mild steel - 0.6mm (5 kg) 6000476 Use for gas welding

Mild steel - 0.8mm (5 kg) 6000475 Use for gas welding

Mild steel - 0.8mm (15 kg) 3050522 Use for gas welding

Stainless Steel 0.8mm (mini
spool)

CO2 (600g) 6000643 For welding mild

Argon 6000661 For welding stainless

CO2/Argon Mix 6000660 For welding stainless/

6000666 Use for no gas weld-

8132090 Use for gas welding

COMMENT

ing

steel

steel

steel / aluminium

thin sheet mild steel

ARC ACTIVATED HEADSHIELDS

These highly popular headshields available from your Clarke dealer activate
the instant the arc is struck and allow you to have both hands free when
welding.

Model Arc Activated Grinding function Solar Powered Part No.

GWH4 ✔✔ ✔6000706

GWH7 ✔✔ ✔6000709

GWH5 ✔✔ ✔6000707

GWH6 ✔✔ ✔6000708

PG4 ✔✔✔6000716

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SPECIFICATIONS

Model MIG 240

Part No 6014200

Weight 49.05 kg

Dimensions (l x w x h) mm 828 X 420 X 590

Power Supply 230 V @ 50Hz

IP Rating IP21S

Output Min/Max Amps 50 /240 Amps

Open Circuit Voltage 19 - 38V DC

Rated Max Input Current (A) 50A

Welding Capacity (Mild Steel) 1-8 mm

The details and specifications contained herein, are correct at the time of
going to print. However, CLARKE International reserve the right to change
specifications at any time without prior notice.

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TROUBLESHOOTING

Your CLARKE MIG Welder has been designed to give long and trouble free
service. If, however, having followed the instructions in this booklet carefully,
you still encounter problems, the following points should help identify and

resolve them.

PROBLEM CAUSE SOLUTION

No response
from welder.

Welder does
not feed wire.

Feed motor
running but no
wire being fed
from welder tip.

Check fuses and mains
lead.

Feed motor has
malfunctioned.

Insufficient Feed Roller
pressure.

Burr on end of wire. Re-cut wire square with no

Liner blocked or damaged. Clean with compressed air or

Inferior wire. Use only good “clean” wire.

Roller worn out. Replace roller.

Replace fuses as necessary, If
problem persists return
welder to your local dealer.

Check fuse size.

Return welder to your local
dealer.

Increase roller pressure.

burr.

replace liner.

Wire welds itself
to tip.

Wire feeds into
‘birds nest’
tangle.

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Wire feed speed too low. Unscrew tip, cut wire and fit

new tip.
Increase wire speed before
operating again.

Wrong size tip. Fit correct size tip.

Wire welded to tip. As above plus reduce feed

roller pressure.

Wire liner damaged
preventing smooth
operation.

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Renew wire liner.

PROBLEM CAUSE SOLUTION

Loose coils of
wire tangle
around wire
drum inside
machine.

Erratic wire
feed.

Locking knob too slack. Tighten Locking Knob slightly.

Do not over-tighten.

Tensioning Knob too tight. Loosen Tensioning Knob

slightly.

Tension roller worn. Check and replace if

necessary.

Insufficient pressure on
tension roller.

Increase pressure on tension
roller
Caution: Do not over-tighten.

Wire dirty, rusty, damp or
bent.

Re-cut wire and ensure it is
clean.

Liner partially blocked. Clean with compressed air.

Poor quality
welds.

Welder cuts out
whilst in use.

Insufficient gas at weld
area.

Check that gas is not being
blown away by draughts and
if so move to a more
sheltered work area. If not
increase gas supply.

Rusty, painted, damp, oil or
greasy workpiece.

Ensure workpiece is clean
and dry.

Rusty/dirty wire. Ensure wire is clean and dry.

Poor earth contact. Check earth clamp/

workpiece connection.

Duty cycle exceeded (auto
cut-out operates).

Allow welder to cool 15-30
mins before continuing.
Note: If duty cycle is
continually exceeded,
damage to the welder may
result and welder output is
probably too small for
application.

If you have any problems which cannot be resolved by reference to the above, or if you
require spare parts for your welder please contact your local Clarke dealer.

25

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

DECLARATION OF CONFORMITY - UKCA

26

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

DECLARATION OF CONFORMITY - CE

27

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]