Clarke MIG 110E, MIG 110EN, MIG 130EN, MIG 135TE, MIG 151TE User guide

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MIG WELDERS

MIG110E - MIG135TE - MIG151TE

MIG110EN - MIG130EN - MIG160EN

OPERATING & MAINTENANCE

INSTRUCTIONS

0719

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CONTENTS PAGE

Guarantee .............................................................................................. 3

Enviromental Recycling Policy ............................................................. 3

Parts & Service Contacts ....................................................................... 3

Electromagnetic Interference (EMC) .................................................. 4

Safety Precautions ................................................................................. 6

Additional Safety Precautions for MIG Welding ............................... 11

Principles of Operation........................................................................ 13

Electrical Connections ........................................................................ 14

Unpacking and Parts Identification ................................................... 15

Assembly ....................... Loose Components.................................... 15

Welding Shield ........................................... 16

Installing the Welding Wire ....................... 16

Connecting the Gas Supply ..................... 18

Preparation for Use ....... Electrical Connections .............................. 19

Welding Gas Settings ................................. 20

Setting the Controls .................................... 20

Welding Wire Preparation ......................... 21

Attaching the Earth Clamp ....................... 21

MIG Welding Operation ...................................................................... 22

Welding Tips.......................................................................................... 22

Maintenance ........................................................................................ 23

Control Settings Reference Tables ............................................. 24 - 25

Welder Specifications.......................................................................... 26

Wiring Diagrams ........................................................................... 27 - 29

Parts Lists and Diagrams ............................................................. 30 - 41

Troubleshooting.................................................................................... 42

Accessories .......................................................................................... 43

Parts & Service Contacts ..................................................................... 43

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Thank you for purchasing this CLARKE MIG Welder.

The ‘EN’ versions are designed to operate with or without gas....so-called GAS/

NO-GAS welders. The ‘E’ and ‘TE’ versions are designed to operate using a gas cylinder with plain metal welding wire ONLY. This is explained in greater detail within the manual.

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.

ENVIROMENTAL 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.

PARTS AND SERVICE CONTACTS

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400

PARTS & SERVICE FAX: 020 8558 3622

or e-mail as follows:

PARTS: [email protected]

SERVICE: [email protected]

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ELECTROMAGNETIC INTERFERENCE (EMC)

Whilst this unit complies with EMC regulations, the user is responsible for installing and using the welding equipment according to the manufacturers instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation. In some cases this remedial action may be as simple as earthing the welding circuit, see ‘Note’. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note - The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

1.ASSESSMENT OF AREA

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. Avoid using your inverter in the vicinity of:

a) other supply cables, control cables, signalling and telephone cables;

above, below and adjacent to the welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g. guarding of industrial equipment;

e) pacemakers and hearing aids etc.;

f) equipment used for calibration or measurement;

g) other equipment in the environment. The user shall ensure that other

equipment being used in the environment is compatible. This may require additional protection measures;

It may be possible to avoid the above by changing the time of day that welding or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

2. METHODS OF REDUCING EMISSIONS

2.1 Mains supply

Welding equipment should be connected to the mains supply according to the manufacturers recommendations. If interference occurs, it may be necessary to

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take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

2.2 Maintenance of the welding equipment

The welding equipment should be routinely maintained according to the manufacturers recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturers recommendations.

2.3 Welding cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

2.4 Equipotential bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrodes at the same time. The operator should be insulated from all such bonded metallic components.

2.5 Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g. ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances.

Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment.

Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

2.6 Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.

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SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING

1. WARNING:

As with all machinery, there are certain hazards involved with their operation

and use. Exercising respect and caution will considerably lessen the risk of

personal injury. However, if normal safety precautions are overlooked, or

ignored, personal injury to the operator may result.

FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY

2. GENERAL PRECAUTIONS

A) Burn prevention

Wear protective clothing - gauntlet gloves designed for use in welding, apron, and protective shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag. Wear helmet with safety goggles or glasses with side shields underneath, appropriate filter lenses or plates (protected by clear cover glass). This is a MUST for welding or cutting, (and chipping) to protect the eyes from radiant energy and spatter. Replace cover glass when broken, pitted, or spattered. Avoid oily greasy clothing. A spark may ignite them. Hot metal such as electrode stubs and workpieces should never be handled without gloves. 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. Ear plugs should be worn when working overhead or in a confined space. A hard hat should be worn when others work overhead. Flammable hair preparations should not be used by persons intending to weld or cut.

B) Toxic fume prevention

Severe discomfort, illness or death can result from fumes, vapours, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation. NEVER ventilate with oxygen. Lead-, cadmium-, zinc-, mercury- and beryllium-, bearing materials, when welded (or cut) may produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an airsupplied respirator. For beryllium, both must be used. Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator. Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator. Vapours from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapours to form phosgene. DO NOT WELD or cut where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene.

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C) Fire and explosion prevention

Causes of fire and explosion are:

1) combustibles reached by the arc, flame, flying sparks, hot slag or heated material;

2) misuse of compressed gases and cylinders;

3) short circuits.

BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks and slag can fly 10M.

To prevent fires and explosion: keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits. If combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles.

Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot be moved, move combustibles at least 10M, away out of reach of sparks and heat; or protect against ignition with suitable and snug fitting, fire- resistant covers or shields.

Walls, ceilings, and floor near work should be protected by heat resistant covers or shields. Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if:

a) appreciable combustibles (including building construction) are within 10m. b) appreciable combustibles are further than 10m but can be ignited by sparks. c) openings (concealed or visible) in floors or walls within 10m can expose

combustibles to sparks.

d) combustibles adjacent to walls, ceilings, roofs or metal partitions can be

ignited by radiant or conducted heat.

After work is done, check that area is free of sparks, glowing embers, and flames. An empty container that held combustibles, or that can produce flammable or toxic vapours when heated, must never be welded on or cut, unless container

has first been cleaned. This includes.......a thorough steam or caustic cleaning (or

a solvent or water washing, depending on the combustible’s solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment.

Water filling just below working level may substitute for inerting.

A container with unknown contents should be cleaned (see paragraph above), do NOT depend on sense of smell or sight to determine if it is safe to weld or cut.

Hollow castings or containers must be vented before welding or cutting - they can explode.

In explosive atmospheres, never weld or cut where the air may contain flammable dust, gas, or liquid vapours.

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3. ELECTRIC ARC (MIG, TIG) WELDING

Comply with precautions in 1 above, and this section. Arc welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot. The wise operator avoids unnecessary risks and protects himself and others from accidents.

3A) BURN PROTECTION

Comply with precautions in 2. The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light coloured surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas - shielded arcs are more severe and painful.

DON’T GET BURNED! COMPLY WITH PRECAUTIONS!

1) Protective clothing

Wear long sleeved clothing (particularly for gas shielded arc) in addition to gloves, apron and shoes (2A). As necessary, use additional protective clothing such as leather jacket or sleeves, flameproof apron, and fire-resistant leggings. Avoid outer garments of untreated cotton. Bare skin protection: Wear dark substantial clothing, Button collar to protect chest and neck and button pockets to prevent entry of sparks.

2) Eye and head protection

Protect eyes from exposure to arc. NEVER look at an electric arc without protection. Welding helmet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc. Protect filter plate with a clear cover plate. Cracked or broken helmet or shield should NOT be worn; radiation can pass through to cause burns. Cracked, broken, or loose filter plates must be replaced IMMEDIATELY. Replace clear cover plate when broken, pitted, or spattered. WE SUGGEST you wear flash goggles with side shields under the helmet, to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision. Before welding whilst wearing contact lenses, seek advice from your optician.

3) Protection of nearby personnel

For production welding, a separate room or enclosed bay is best. In open areas, surround the operation with low reflective, non- combustible screens or panels. Allow for free air circulation, particularly at floor level. Provide face shields for all persons who will be looking directly at the weld. Others working in the area should wear flash goggles. Before starting to weld, make sure that screen or bay doors are closed.

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3B) TOXIC FUME PREVENTION

Comply with precautions in 2B. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill.

3C) FIRE AND EXPLOSION PREVENTION

Comply with precautions in 2C. Equipment’s rated capacity. Do not overload arc welding equipment. It may overheat cables and cause a fire. Loose cable connections may overheat or flash and cause a fire. Never strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling.

3D) SHOCK PREVENTION

Exposed live conductors or other bare metal in the welding circuit, or in unearthed, electrically-LIVE equipment can fatally shock a person whose body becomes a conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding, without suitable protection.

3E) PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPT DEVICES (PACEMAKERS)

Magnetic fields from high currents can affect pacemaker operation. Persons wearing electronic life support equipment (pacemaker) should consult with their doctor before going near arc welding, gouging, or spot welding operations.

3F) TO PROTECT AGAINST SHOCK:

Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when dampness or sweat can not be avoided. Sweat, sea water, or moisture between body and an electrically LIVE part - or earthed metal - reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body.

1) Earthing the equipment

When arc welding equipment is earthed according to the National Electrical Code, and the workpiece is earthed, a voltage may exist between the electrode and any conducting object.

Examples of conducting objects include, but are not limited to, buildings, electrical tools, work benches, welding power source cases, workpieces, etc. Never touch the electrode and any metal object unless the welding power source is off. When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building earth.

Conductors must be adequate to carry earth currents safely. Equipment made electrically LIVE by stray current may shock, possibly fatally. Do NOT EARTH to electrical conduit, or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel.

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2) Electrode holders

Fully insulated electrode holders should be used. Do NOT use holders with protruding screws or with any form of damage.

3) Connectors

Fully insulated lock-type connectors should be used to join welding cable.

4) Cables

Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable. Keep cable dry, free of oil and grease, and protected from hot metal and sparks.

5) Terminals and other exposed parts

Terminals and other exposed parts of electrical units should have insulating covers secured before operation.

6) Electrode

a) Equipment with output on/off control (contactor)

Welding power sources for use with the gas metal arc welding, gas tungsten arc welding and similar processes normally are equipped with devices that permit on/off control of the welding power output. When so equipped the electrode wire becomes electrically LIVE when the power source switch is ON and welding gun switch is closed. Never touch the electrode wire or any conducting object in contact with the electrode circuit unless the welding power source is off.

b) Equipment without output on/off control (no contactor)

Welding power sources used with shielded metal arc welding and similar processes may not be equipped with welding power output on/off control devices. With such equipment the electrode is electrically LIVE when the power switch is turned ON. Never touch the electrode unless the welding power source is off.

7) Safety devices

Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out. Before installation, inspection, or service of equipment, shut OFF all power and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Do not open power circuit or change polarity while welding. If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing. Always shut OFF and disconnect all power to equipment. Power disconnect switch must be available near the welding power source.

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PREPARATION OF THE WORKING AREA

The working area must be sufficiently spacious, not humid, and well-ventilated as to avoid any fumes which develop from the welding process and from incidental material adhering to the pieces to be welded (oils, paints, tars...) which may cause annoyance to the operator. Avoid welding by contact with humid parts nearby combustible liquids. Least of all, do not weld upon tanks which may contain flammable residuals.

ADDITIONAL SAFETY PRECAUTIONS for MIG WELDING

✔ ALWAYS ensure that there is full free air circulating around the outer casing of

the machine, and that the louvres are unobstructed.

✔ Welding arc can seriously damage your eyes. Both operator and spectators

must ALWAYS use a proper welding face shield or helmet, with suitable filter lenses. Proper gloves and working clothes should be worn at all times.

✔ ALWAYS check that the pressure regulator and gauges (where fitted), are

working correctly. DO NOT lubricate the regulator.

✔ ALWAYS use the correct regulator. Regulators are designed to be used with

a specific gases.

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

✔ ALWAYS keep the free length of gas hose outside the work area.

✔ ALWAYS remove all flammable materials from the welding area.

✔ ALWAYS Keep fire extinguisher handy....’Dry Powder, C0

or BCF, NOT Water

✗ NEVER remove any of the panels unless the machine is disconnected from

the supply, AND never use the machine with any of the panels removed.

✗ NEVER attempt any electrical or mechanical repair unless your are a qualified

technician. If you have a problem with the machine contact your local CLARKE dealer.

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✗ NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN.

✗ The MIG welding process uses an INERT gas to protect the weld pool. It is

important to ensure the appropriate gas is being used. NEVER use gas from a cylinder, the content of which is unknown.

✗ NEVER a. Use a damaged cylinder.

b. Lift the cylinder by the valve.

c. Expose the cylinder to a heat source or sparks.

✗ 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 connect, disconnect, or attempt to service the MIG torch,

until the machine is switched OFF and disconnected from the mains supply.

✗ NEVER allow the cables to become wrapped around the operator or

any person in the vicinity.

DANGER - ELECTRIC SHOCK CAN BE FATAL.

A person qualified in first aid should always be present in the working area.

If person is unconscious and electric shock is suspected, do not touch the person if

he or she is in contact with the welder or cables. Disconnect the welder from the

power source and then use First Aid. Dry wood, or other insulating material can be

used to move cables, if necessary, away from the person.

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SAFETY EQUIPMENT

A comprehensive range of CLARKE safety equipment for use when welding is available from your local dealer.

MIG WELDING - PRINCIPLES OF OPERATION

MIG (Metal Inert Gas) welding is a process in which a power wire electrode is fed continuously into the weld pool at a controlled, constant rate.

The wire is connected to the positive side of a rectified voltage supply. The workpiece is connected to the negative side of the supply.

When the wire is fed, it comes into contact with the workpiece and an arc is struck. The arc melts the wire and the material, fusing it together.

The wire, which is fed by the wire feed motor is fed into the weld pool, burning itself off at a rate dependent upon the selected wire feed speed.

To protect the weld pool from oxidation and impurities during the welding process, a shielding gas flows over and around the weld pool. This gas flow must be sufficient to protect the weld, but not wasteful.

NOTE:

coverage is wasteful and expensive

Poor gas coverage will result in poor welding. Excessive gas

GAS/NO GAS

The ‘EN’ models are capable of welding with or without gas, so-called ‘Gas/No Gas’. It is MOST IMPORTANT that the operator reads the notes on page 19 before attempting to use this welding technique.

BENEFITS OF MIG WELDING

1. 50% faster welding time.

2. Operator training time kept to a minimum.

3. There is no slag removal, thus eliminating almost all post-welding

cleaning operations.

4. Minimum waste of welding consumables.

5. Overall, a faster more efficient way of getting the job done.

6. Less heat - less distortion.

7. Ability to weld thin material.

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ELECTRICAL CONNECTIONS

WARNING+! THIS APPLIANCE MUST BE EARTHED.

A. MIGs 110E, 110EN, 130EN, 135TE ONLY

These welders are fitted with a standard 13 amp BS 1363 plug, fitted with a 13 amp fuse. Connect to a 230 volt (50Hz) domestic electrical supply and we strongly

recommend that this be done via a Residual Current Device (RCD).

IMPORTANT: If the welder is fitted with a plug which is moulded onto the electric cable (i.e. non- re-wirable) please note:

1. The plug must be thrown away if it is cut from the electric cable. There is a danger of electric shock if it is subsequently inserted into a socket outlet.

2. Never use the plug without the fuse cover fitted.

3. Should you wish to replace a detachable fuse carrier, ensure that the correct replacement is used (as indicated by marking or colour code). Replacement fuse covers can be obtained from your local dealer or most electrical stockists.

Fuse Rating

The fuse in the plug must be replaced with one of the same rating (13 amps) and this replacement must be ASTA approved to BS1362.

B. MIGs 151TE and 160EN ONLY

Connect the mains lead, through a suitably fused isolator switch, to a 230 Volt (50Hz) electrical supply, with a 15Amp fuse rating.

NOT be used with these welders.

A standard 13 Amp plug MUST

C. ALL MODELS

IMPORTANT: The wires in the mains lead are coloured in accordance with the following code:

Green & Yellow .......... Earth

Blue .......... Neutral

Brown .......... Live

As the colours of the flexible cord of this appliance may not correspond with the coloured markings identifying terminals in your plug, proceed as follows:

• Connect GREEN & YELLOW cord to plug terminal marked with a letter “E” or

Earth symbol “ ”, or coloured GREEN or GREEN & YELLOW.

• Connect BROWN cord to plug terminal marked letter “L” or coloured RED.

• Connect BLUE cord to plug terminal marked letter “N” or coloured BLACK.

Extension Cable

If an extension cable is fitted, ensure the minimum cross section of the conductor is 1.5mm2 for up to 15 metres in length, and 2.5mm2 for up to 25 metres.

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UNPACKING & PARTS IDENTIFICATION

Unpack and lay out the components, checking against the following list. Any damage or deficiency should be reported to your CLARKE dealer immediately.

Most of the components are stored within the side compartment. To open the compartment, put your finger in the hole in the side cover, and pull sharply.

1. Welder complete with Torch and Hose, Earth Cable with Clamp and Power cable.

NOTE: Migs 151TE and 160EN are NOT provided with 13 Amp plugs. These machines MUST NOT be connected to a standard 13 Amp domestic supply. See ‘Electrical Connections’ for full details.

2. 2 plastic feet + 2 Wheels w/Axle and 2 Lock washers.(110E, 110EN, - 2 Feet only)

3. 1xHandle Extension and Hand Grip (NOT 110E, 110EN)

4. 1xHandle

5. 1x2-Piece Welding Mask

6. 1xWelding Mask handle, complete with plastic nut and 2xplastic screws.

7. 1xPackage containing 1x Clear Glass and 1x Dark Glass Lens

8. 1xMini Wire Spool, fitted to the Spool Holder

9. 1xplastic bag containing the following:

a1. 110E - 2xSpare Nozzles, 0.6/0.8mm (0.6mm fitted to torch) a2. 110EN, 130EN, 160EN - 0.6/0.8mm (1.00mm fitted to torch) a3. 135TE, 151TE - 0.8/1.0mm (0.6mm fitted to torch) b. 2xScrews for fixing Handle c. 4xSelf Tapping Screws with flat washers for fixing feet d. 1xHex Wrench e. 1xScrew for fixing Handle extension (110E and 110EN)

10. 1xDisposable Gas Cylinder CO

11. 1xGas Regulator (NOT EN Models )

12. 1xLarge Worm Drive Clip (NOT EN Models )

(NOT EN Models)

2 .

ASSEMBLY & INSTALLATION

A. Loose Components

Lie the welder on its side and attach the two feet using the four screws with flat washers provided. For those models with wheels you have the option of fitting the two feet, or the wheels as follows: Remove the plug covering the hole for the axle, insert the axle, then attach the wheels, securing them by pushing the star locking washers provided, on to the axle, using a piece of tube or an old socket, ensuring the centre tines face outwards.

Attach the handle to the top of the machine by slotting it into place and securing with the two screws provided. For those models with a handle extension, simply slide it into the handle and secure with the screw provided.

The gas bottle is secured to the machine using the large worm drive clip which is threaded through the opening provided on the rear panel of the machine, (NOT EN Models).

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B. The Welding Shield

1. Push the two halves of the

shield together as shown.

2. Place the handle into

position and secure using the plastic screw and clip provided

3. Working from the inside of

the shield, insert the clear glass panel into the recess in the shield, followed by the dark glass panel.

4. Secure the glass panels

with the lens surround and plastic screws/clips provided. The clear glass MUST be on the outside of the shield.

5. Finally use the last plastic screw and clip as shown to fix the two halves of the

shield together.

WARNING:

NEVER look at an electric arc without eye protection as this can injure the

eyes permanently. ALWAYS use a protection mask or welding helmet.

C. Installing the Welding Wire

NOTE: These machines are designed to accept either the Clarke ‘Mini’ or 5kg wire spools of mild steel, stainless steel or aluminium according to the type of metal you wish to weld. Mini Mild Steel wire spools are supplied with the machine...others must be purchased separately. See ‘Accessories’ or your Clarke dealer for full details.

1. IMPORTANT: Ensure that the gas and electrical supplies are disconnected.

2. (Ref. Fig. 2). To fit the wire spool (2), firstly pull open the cover, on the left hand

side of the unit, by inserting your finger in the hole provided and pulling sharply.

Fig.2

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Unscrew and remove the plastic knob (5), followed by the spring (4) and collar (3) from the hub (1). (If the spool is already fitted during initial assembly, remove the plastic covering).

3. Slide the spool over the hub, ensuring that it sits snugly, and replace the collar, spring

and plastic knob, tightening it sufficiently to allow the spool to rotate smoothly but with a slight amount of braking friction. Do not over tighten as this will exert undue pressure on the wire drive motor and may cause serious damage.

4. (Ref. Fig. 3)

Loosen the plastic knob (8) by turning it anticlockwise, (this device maintains pressure on the wire).

Pull, on the plastic knob, so that the screw rod hinges out of its slot. This releases the pivoted pressure roller bracket (9). Raise the bracket, in the direction of the arrow, and pull out any wire that has been left in the wire liner (11).

5. If you are changing the size of

wire, you must also select the appropriate groove on the feed roller (6) - see Fig.3A.

To change to the other groove, undo the Hex. Socket Screw, shown in Fig.3A, and remove the roller from its shaft. Turn it through 180 replace it on the shaft, and adjust so that the groove is directly in line with the Wire Liner, as shown. Firmly secure it in that position with the Hex. Socket Screw.

6. Clip the end of the wire cleanly,

ensuring there are no burrs or sharp edges, and, ensuring it is straight (see: Fig.3), feed it through the guide tube (10), over the channel on the roller (6) and into the wire liner (11), by approx. 10 - 15cm.

wire straight

Fig.3

wire bent

Fig.3A

7. Reposition the pressure roller bracket (9) and plastic knob (8) and tighten slightly.

CAUTION:

Tightening the knob (8) too tightly will crush the wire and damage the wire

feed motor, too loose will not allow the wire to be pulled by the roller.

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8. (Ref. Fig 4)

Unscrew and pull off the torch shroud (12) by twisting it anti clockwise, then unscrew the contact tip (13).

Should any wire protrude from

the tip....pull it out completely

and discard.

Close the side panel of the machine, plug into a 230V, 50HZ outlet (or switch on isolator), switch on the machine and press the trigger.

The wire will feed through the hose and when it appears at the torch end, release the trigger, switch off the machine and disconnect the machine from the mains supply. Replace the contact tip and the torch shroud.

IMPORTANT:

Ensure the hose is kept straight during this operation, to assist the wire as it is fed through to the wire liner and contact tip.

D. The Gas Supply

Fig.4

MIG 110E, 135TE and 151TE ONLY

NOTES: These models require the gas bottle and regulator, to be fitted.

A mini gas bottle complete with gas regulator is provided. Should you prefer to use larger gas cylinders, the appropriate gas regulator and fittings need to be acquired. Your Clarke dealer will be happy to advise in this regard.

Always use the appropriate gas for the material being welded. Three types are provided by Clarke International, as follows:

Carbon Dioxide (CO

Argon .................................... For Aluminium................... Part No. 6000661

CO2/Argon Mix ................... For Thin Sheet metal

Additionally a larger CO2 bottle is available ............... Part No. 6000643

Replacement Gas Regulator .......................................... Part No. 8132000

)......... For Mild Steel .................... Part No. 6000642

Mild Steel/ Stainless ......... Part No. 6000660

Page 19

Attach the mini gas bottle to the machine as described in ‘Assembly’ on page 15, then connect up as follows: (Ref. Fig. 5)

1. Remove the protective cap

from the cylinder outlet and screw on the regulator (14), fully, BUT DO NOT OVERTIGHTEN.

2. Simply push the gas hose, at the

rear of the machine, into the gas regulator outlet, as far as possible and release. This is a self sealing coupling.

To remove the hose, hold back the ring (15) then pull the hose out.

All components are now correctly attached, and the welder may now be prepared for operation, as follows:

PREPARATION FOR USE

A.Electrical Connections

Fig.5

1. NO-GAS WELDING (EN Models ONLY)

IMPORTANT: ENSURE THE ELECTRICAL CONNECTIONS WITHIN THE WELDERS SIDE COMPARTMENT ARE CORRECTLY CONNECTED...as follows:

TORCH to the NEGATIVE (-ve) terminal,

EARTH cable to the POSITIVE (+ve) terminal.

The terminals within the side compartment are shown in Fig. 6

Fig.6

Page 20

2. GAS WELDING

Connections should be made as follows:

TORCH to the POSITIVE (+ve) terminal,

EARTH cable to the NEGATIVE (-ve) terminal.

B. Welding Gas

(Models 130E, 135TE and 151TE ONLY)

The Gas Regulator Knob turns on a graduated plate, marked from 0 to 6. With the knob pointer set to zero (0) the gas flow is OFF.

Set the Regulator to 3 or 4 which will provide a gas flow of 2-3 litres per minute. This volume will provide adequate gas for a good weld without porosity under normal conditions.

ALWAYS close the regulator by turning the knob to the 0 (zero) position whenever you finish welding, or when changing gas cylinders.

Fig.7

C. Set the Controls

1. Models 110E, 110EN, 130EN & 135EN

These models are provided with two, 2-position switches and a rotary knob, as shown in Fig. 8.

The rotary knob, with graduations from 0 to 10, is used to control the wire speed.

Two of the 2-position switches are marked 1- 2 and Max - Min respectively, and are used to control the welding current according to the type and thickness of material to be welded, and in accordance with the charts shown in the ‘Reference Tables’ on pages 24 and 25.

The remaining 2-position switch is the ON/ OFF switch

Fig.8

Page 21

2. Models 151TE and 160EN

Fig.9

These models are provided with an ON/ OFF switch, a rotary knob, with graduations marked from 0 to 10, a single two position switch marked Max - Min, and a 3-position rotary switch as shown in Fig.9.

The 10-position rotary switch is used to control wire speed, and the other two switches are used to control the welding current according to the type and thickness of material to be welded, and in accordance with the charts shown in the ‘Reference Tables’ on pages 24 and

25. Set the controls accordingly.

3. ALL Models

The 10-position wire speed control should be set to 6 to begin with for welding steel, and 9 for welding aluminium, then adjusted as required.

Note: This control is for fine tuning the wire speed. The speed of wire delivery will increase automatically as the current is increased and vice versa. Therefore, once the ideal speed is achieved, by fine tuning,it should not be necessary to adjust this control when the welding current is changed.

It is always better to start with too high a speed, and back off slightly, to avoid the possibility of the wire welding itself to the tip.

D. Trim the Welding Wire

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

E. Attach the Earth Lead

Attach the earth lead to the workpiece with the earth clamp, as close to the point of weld as possible, without it being intrusive.

Ensure there is good contact, if necessary, clean the area with a wire brush beforehand.

Your welder is now fully prepared for welding.

Page 22

OPERATION

Plug the machine into the mains supply or switch on at the isolator and ensuring all precautions have been taken and with the machine set up correctly, lower the torch to the workpiece with one hand, whilst holding the welding mask in the other.

Approach the work with the tip at an angle of approx. 45O and pull the torch trigger fully.

As the electrode touches the workpiece, an arc will be struck......before it is struck,

cover the face with the face mask.

Simultaneously gas will be generated, if the wire is flux cored, or gas will be issued if you are gas welding, and the wire will be fed into the molten pool.

Maintain a gap of approx. 5 - 7mm from the workpiece to the tip.

The speed of weld will depend upon the wire speed and welding current. It is advisable to test your settings on a scrap piece of metal with similar characteristics to those of the workpiece. Fine tune the welding speed and/or current flow, as required, until a satisfactory weld is achieved.

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.

Whenever the welding current regulation is changed, a corresponding change in wire speed may be necessary. If the speed is too slow, the wire will weld itself to the tip.

WELDING TIPS

1. Try to maintain the tip of the nozzle at an angle of approx. 45O and at a constant

distance of approx 5-7mm from the workpiece.

2. Try to maintain a constant speed of movement with the torch.

3. Do not weld in windy conditions or in an area where ventilation is a problem,

or where air flow fluctuates.

4. ALWAYS keep the wire and nozzle clean...NEVER use rusted wire.

5. Avoid sharp bends or kinks in the welding hose.

6. Whenever possible, clean out the wire liner with compressed air when

replacing the wire spool.

7. Periodically remove the dust, using LOW PRESSURE compressed air, within the

casing. Adequate heat dissipation is essential during the welders operation.

Page 23

MAINTENANCE

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 atmospheres, etc).

Always inspect the cables, both earth return and torch cable, before use to ensure they are in perfect condition.

Ensure the earth clamp is clean and secured correctly to the cable.

Check the gas hose and Pressure Regulator for security and serviceability, and ensure there is sufficient gas to complete the job in hand.

As a general rule the power supply should be inspected internally at least annually. Consult your CLARKE dealer

WARNING!

ELECTRICITY CAN KILL

NEVER TOUCH LIVE ELECTRICAL COMPONENTS

DISCONNECT THE POWER SUPPLY BEFORE ALL INSPECTIONS AND

MAINTENANCE OPERATIONS

BEWARE HOT SURFACES.....ALWAYS LET THE POWER SUPPLY COOL DOWN

BEFORE ACCESSING INTERNAL COMPONENTS.

WELDING SHIELD

Always maintain the welding mask in good condition. If the clear glass protection lens becomes badly pitted, sufficient to interfere with vision, or cracked, have it replaced immediately.

Replacement clear and dark lenses are available from your Clarke dealer - see Parts Lists for details. NEVER use any dark filter lens other than that provided by CLARKE International, or one with the same certified ‘Optical class’ (degree of protection).

The shield should always be cleaned with a clean soft cloth after use, ensuring the lenses are clean. Remove any dust that may have accumulated and store it in a safe place where it cannot be damaged.

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

NEVER use a shield that is not in perfect condition.

Page 24

CONTROL SETTINGS - REFERENCE TABLES

A. MIGs 110E, 110EN, 130EN & 135TE

STEEL

Workpiece

Thickness

(mm)

0.6 - 0.8 1 MIN 5-6 1 MIN 5-6

0.8 - 1.0 1 MAX 5-6 1 MAX 5-6

1.0 - 2.0 2 MIN 6 2 MIN 6

2.0 - 3.0 2 MAX 7 2 MAX 7

ALUMINIUM

Workpiece

Thickness

(mm)

0.8 1 MIN 8-9

1.0 -2.0 1 MAX 9

2.0 - 3.0 2 MIN 9

0.6 mm Gas Welding Wire 0.8 mm Gas Welding Wire

Welding

Position

AB C AB C

Wire Speed

Adjustment

Welding

Position

0.8 mm Gas Welding Wire

Welding

Position

AB C

Wire Speed

Adjustment

Wire Speed

Adjustment

NO GAS

SOFT STEEL

Workpiece

Thickness

(mm)

0.6 - 0.8 1 MIN 5-6

0.8 - 1.0 1 MAX 5-6

1.0 - 1.2 2 MIN 6

1.2 - 2.0 2 MAX 7

0.9 mm Gas Welding Wire

Welding

Position

AB C

Wire Speed

Adjustment

Page 25

CONTROL SETTINGS - REFERENCE TABLES

B. MIGs 151TE & 160EN

STEEL

Workpiece

Thickness

(mm)

0.6 - 0.8 MIN 1 5-6 MIN 1 5-6

0.8 - 1.0 MAX 1 5-6 MAX 1 5-6

1.0 - 1.2 MIN 2 5-6 MIN 2 6

1.2 - 2.0 MAX 2 6 MAX 2 6

2.0 - 3.0 MIN 3 7 MIN 3 7

>3.0 MAX 3 7-8 MAX 3 7-8

ALUMINIUM

Workpiece

Thickness

(mm)

1.0 - 1.5 MIN 1 9

1.5 - 2.0 MAX 1 9

2.0 - 2.5 MIN 2 9

2.5 - 3.0 MAX 2 9 >3.0 MAX 2/3 10

0.6 mm Gas Welding Wire 0.8 mm Gas Welding Wire

Welding

Position

AB C AB C

Wire Speed

Adjustment

Welding

Position

0.8 mm Gas Welding Wire

Welding

Position

AB C

Wire Speed

Adjustment

Wire Speed

Adjustment

NO GAS

SOFT STEEL

Workpiece

Thickness

(mm)

0.9 MIN 1 5-6

0.9 - 1.0 MAX 1 5-6

1.0 - 1.2 MIN 2 5-6

1.2 - 2.0 MAX 2 6

2.0 - 3.0 MIN 3 7 >3.0 MAX 3 7-8

0.9 mm Gas Welding Wire

Welding

Position

AB C

Wire Speed

Adjustment

Page 26

SPECIFICATIONS

110E 110EN 130EN 135TE

Power Supply(All Models) 230V 50Hz 1Ph 230V 50Hz 1Ph 230V 50Hz 1Ph 230V 50Hz 1Ph

Fuse Rating (All Models) 13Amps 13Amps 13Amps 13Amps

Current Range 30-100A 30-100A 30-130A 30-130A

Max. Metal Thickness 3mm 2-3mm 4-5mm 5mm

Welding Wire Sizes 0.6-0.8mm 0.6-0.9mm 0.6-0.9mm 0.6-0.8mm

Duty Cycle* 8% 100A - 130A 130A

15% - 100A 115A 115A

60% 40A 55A 57A 57A

100% 30A 40A 44A 44A

Dimensions (All Models) 500x280x420mm 500x280x420mm 500x280x420mm 500x280x420mm

Weight 24kg 24kg 24.5kg 28.5kg

Part No. 6015110 6014500 6014530 6015135

151TE 160EN

Power Supply(All Models) 230V 50Hz 1Ph 230V 50Hz 1Ph

Fuse Rating (All Models) 15Amps 15Amps

Current Range 30-150A 30-150A

Max. Metal Thickness 5-6mm 5-6mm

Welding Wire Sizes 0.6-0.8mm 0.6-0.9mm

Duty Cycle* 10% 150A 150A

20% 130A 130A

60% 75A 75A

100% 55A 55A

Dimensions (All Models) 500x280x420mm 500x280x420mm

Weight 24kg 24kg

Part No. 6015151 6014560

* Duty Cycle: Determines the machine ‘down time’.

eg MIG130-EN, operating at 57 Amps - Duty Cycle - 60%. This means that in ANY 10 minute period, the machine may operate for 6 minutes and must have a down time of 4 minutes.

Please note that 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. ALWAYS CONSULT THE MACHINE’S DATA PLATE

Page 27

WIRING DIAGRAMS

MIG 110E

MIG 110EN

Page 28

WIRING DIAGRAMS

MIG 130EN

MIG 135TE

Page 29

WIRING DIAGRAMS

MIG 151TE

MIG 160EN

Page 30

PARTS LIST - MIG 110E

No. Description Part No.

Wire Feeding Motor EM04600141

Complete Thermostat EM04600113

Plastic Handle EM21600021

Torch Grommet on Front Panel EM21690458

Welding Current Switch EM22200038

Potentiometer Knob EM21690310

Yellow Pilot-light Switch EM22200022

Access Panel Hinge EM21690178

Dividing Panel EM33720092

Wire Spool See Accessories

Fixed Spool Holder EM21690714

Spool Holder Retaining Ring EM21690715

Plastic Wire Feeder EM44400024

P.C. Board EM22710043

Cable Clamp EM21605010

Left Access Panel EM33705217

Front Panel EM33710165

Right-side Upper Panel EM33705216

Rear Panel EM33715063

Wire Feed Roll Knurled EM33805001

Front Plastic Frame EM21690175

Side Panel Clip EM21690177

Front Plastic Foot EM21610014

Choke EM44135097

Rectifier EM22400021

Transformer EM44120105

Back Plastic Foot EM21610015

Earthcable EM43210119

Earth Clamp EM22110043

Red Torch compl. EM23000050

Power Cable EM20220068

Back Plastic Frame EM21690176

Spool Holder Handwheel with nut EM21800069

Lower Panel EM33700138

Reducer W/Out Gauge EM22905001

Spare Cartridge C0

Hose Clamp EM22915004

Plastic Mask W/Handle EM21905065

Transparent Glass EM21905020

Dark Glass 82x108 BS Din11 EM21905021

See Accessories

Page 31

PARTS DIAGRAM - MIG 110E

Page 32

PARTS LIST - MIG110EN

No. Description Part No.

Wire Feeding Motor EM04600141

Plastic Handle EM21600021

Complete Fan EM04600055

Torch Grommet On Front Panel EM21690458

Welding Current Switch EM22200038

P.C. Board Knob EM21690310

Yellow Pilot-light Switch EM22200022

Side-panel Pin EM21690178

Dividing Panel EM33720063

Wire Spool See Accessories

Fixed Spool Holder EM21690714

Spool Holder Retaining Ring EM21690715

Plastic Wire Feeder EM44400024

P.C. Board EM22710043

Cable Clamp EM21605032

Left-side Panel EM33705217

Front Panel EM33710165

Right-side Upper Panel EM33705216

Back Panel EM33715063

Wire Feed Roll Knurled EM33805001

Front Plastic Frame EM21690175

2 Pins Male Connector EM22105040

Male Connector EM22105042

Front Plastic Foot EM21610014

Choke EM44135097

Rectifier EM22400001

Transformer + Thermostat EM44120068

Back Plastic Foot EM21610015

Earth Clamp EM22110043

Power Cable EM43210108

Torch Compl. EM23000049

Power Cable EM20220068

Back Plastic Frame EM21690176

Spool Holder Knob 4w/Nut EM21800069

Lower Panel EM33700138

4 Lobe Hand-wheel EM21800051

Gas/No Gas Change Board EM21800050

Side Panel Clip EM21690177

Plastic Mask W/Handle EM21905065

Transparent Glass EM21905020

Dark Glass 82x108 BS Din11 EM21905021

Page 33

PARTS DIAGRAM - MIG 110EN

Page 34

PARTS LIST - MIG 130EN

No. Description Part No.

Handle-extension Grip EM21610032

Handle-extension EM33725054

Wire Feeding Motor EM04600141

Complete Thermostat 100 + Support EM04600113

Plastic Handle EM21600021

Complete Fan EM04600055

Torch Grommet On Front Panel EM21690458

Welding Current Switch EM22200038

Potentiometer Knob EM21690310

Yellow Pilot-light Switch EM22200022

Access Panel Hinge EM21690178

Dividing Panel EM33720063

Wire Spool See Accessories

Fixed Spool Holder EM21690714

Spool Holder Retaining Ring EM21690715

Plastic Wire Feeders EM44400024

P.C. Board EM22710043

Cable Clamp EM21605032

Left Access Panel EM33705217

Front Panel EM33710165

Wheels-axle EM55200014

Right-side Upper Panel EM33705216

Rear Panel EM33715063

Wheel EM21625034

Wire Feed Roll Knurled EM33805001

Front Plastic Frame EM21690175

2 Pins Male Connector EM22105040

Male Connector EM22105042

Front Plastic Foot EM21610014

Inductance EM44135123

Rectifier EM22400049

Transformer EM44120049

Back Plastic Foot EM21610015

Earth Clamp EM22110043

Earth Cable EM43210108

Torch compl. EM23000049

Power Cable w/Plug +13A Fuse EM20220068

Back Plastic Frame EM21690176

Spool Holder Handwheel with Nut EM21800069

Lower Panel EM33700138

4 Lobes Hand-wheel EM21800051

Gas/No Gas Change Board EM21800061

Side Panel Clip EM21690177

Plastic Mask W/Handle EM21905065

Transparent Glass EM21905020

Dark Glass 82x108 BS DIN11 EM21905021

Page 35

PARTS DIAGRAM - MIG 130EN

Page 36

PARTS LIST - MIG 135TE

No. Description Part No.

Handle-extension Grip EM21610032

Handle-extension EM33725054

Wire Feeding Motor EM04600141

Complete Thermostat EM04600113

Plastic Handle EM21600021

Complete Fan EM04600055

Torch Grommet On Front Panel EM21690458

Welding Current Switch EM22200038

Potentiometer Knob EM21690310

Yellow Pilot-light Switch EM22200022

Access Panel Hinge EM21690178

Dividing Panel EM33720092

Wire Spool See Accessories

Fixed Spool Holder EM21690714

Spool Holder Retaining Ring EM21690715

Plastic Wire Feeder EM44400024

P.C. Board EM22710043

Cable Clamp EM21605010

Left Access Panel EM33705217

Front Panel EM33710165

Wheels-axle EM55200014

Right-side Upper Panel EM33705216

Rear Panel EM33715063

Wheel EM21625034

Wire Feed Roll Knurled EM33805001

Front Plastic Frame EM21690175

Side Panel Clip EM21690177

Front Plastic Foot EM21610014

Inductance EM44135123

Rectifier EM22400049

Transformer EM44120049

Back Plastic Foot EM21610015

Earth Cable EM43210119

Earth Clamp EM22110043

Red Torch EM23000050

Input Cable, Plug + 13A Fuse EM20220068

Back Plastic Frame EM21690176

Spool Holder Handwheel With Nut EM21800069

Lower Panel EM33700138

Reducer W/Out Gauge EM22905001

Spare Cartridge C02 See Accessories

Hose Clamp EM22915004

Plastic Mask W/Handle EM21905065

Transparent Glass EM21905020

47 48

Dark Glass 82x108 BS Din11 EM21905021

Page 37

PARTS DIAGRAM - MIG 135TE

Page 38

PARTS LIST - MIG 151TE

No. Description Part No.

Handle-extension Grip EM21610032

Handle-extension EM33725054

Wire Feeding Motor EM04600145

Thermostat EM04600113

Plastic Handle EM21600021

Complete Fan EM04600055

Torch Grommet EM21690458

Welding Current Switch EM22200038

P.C. Board Knob EM21690310

Switch Knob EM21690312

Yellow Pilot-light Switch EM22200022

Side-panel Pin EM21690178

Dividing Panel EM33720092

Wire Spool See Accessories

Fixed Spool Holder EM21690714

Spool Holder Retaining Ring EM21690715

Plastic Wire Feeder EM44400016

P.C. Board EM22710043

Switch EM22205001

Cable Clamp EM21605010

Left-side Panel EM33705217

Front Panel EM33710194

Wheels-axle EM55200014

Right-side Upper Panel EM33705216

Back Panel EM33715063

Wheel EM21625034

Wire Feed Roll Knurled EM33805001

Front Plastic Frame EM21690175

Side Panel Clip EM21690177

Front Plastic Foot EM21610014

Choke EM44135018

Rectifier EM22400038

Transformer EM44120173

Thermostat EM22210016

Back Plastic Foot EM21610015

Earth Cable EM43210119

Earth Clamp EM22110043

Red Torch EM23000050

Input Cable EM20220014

Back Plastic Frame EM21690176

Spool Holder Knob EM21800069

Lower Panel EM33700138

Regul. W/Out Gauge EM22905001

Spare Cartridge See Accessories

Hose Clamp EM22915004

Plastic Mask W/Handle EM21905065

Transparent Glass EM21905020

Dark Glass 82x108 BS Din11 EM21905021

Page 39

PARTS DIAGRAM - MIG 151TE

Page 40

PARTS LIST - MIG 160EN

No. Description Part No.

Handle-extension Grip EM21610032

Handle-extension EM33725054

Wire Feeding Motor EM04600145

Thermostat EM04600113

Plastic Handle EM21600021

Complete Fan EM04600055

Torch Grommet EM21690458

Welding Current Switch EM22200038

P.C. Board Knob EM21690310

Switch Knob EM21690312

Yellow Pilot-light Switch EM22200022

Side-panel pin EM21690178

Dividing Panel EM33720063

Wire Spool See Accessories

Fixed Spool Holder EM21690714

Spool Holder Retaining Ring EM21690715

Plastic Wire Feeder EM44400016

P.C. Board EM22710043

Switch EM22205001

Cable Clamp EM21605032

Left-side Panel EM33705217

Front Panel EM33710194

Wheels-axle EM55200014

Right-side Upper Panel EM33705216

Back Panel EM33715063

Wheel EM21625034

Wire Feed Roll Knurled EM33805001

Front Plastic Frame EM21690175

2 Pins Male Connector EM22105040

Male Connector EM22105042

Front Plastic Foot EM21610014

Choke EM44135018

Rectifier EM22400038

Transformer EM44120173

Thermostat EM22210016

Back Plastic Foot EM21610015

Earth Clamp EM22110043

Earth Cable EM43210108

Torch compl. EM23000049

Input Cable EM20220014

Back Plastic Frame EM21690176

Spool Holder Knob w/Nut EM21800069

Lower Panel EM33700138

4 Lobes Hand-wheel EM21800051

Gas/No Gas Change Board EM21800051

Side Panel Clip EM21690177

Plastic Mask W/Handle EM21905065

Transparent Glass EM21905020

Dark Glass 82x108 BS Din11 EM21905021

Page 41

PARTS DIAGRAM - MIG 160EN

Page 42

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 REMEDY

1. No “life” from welder Check fuses and mains lead a) Replace fuses as necessary If

2. No wire feed Motor malfunction Return welder to your local dealer

3. Feed motor operates a) Insufficient Feed Roller Pressure a) Increase roller pressure but wire will not feed b) Burr on end of wire b) Re-cut wire square with no burr

4. Wire welds itself to tip a) Wire feed speed too low a) Unscrew tip, cut wire and fit new tip

5. Wire feeds into ‘birds a) Wire welded to tip a) As above plus reduce feed roller nest’ tangle pressure so that if blockage occurs

6. Loose coils of wire Drum brake too slack Tighten drum brake tangle around wire Caution: Do not over-tighten drum inside machine

7. Erratic wire feed a) Drum brake too tight a) Loosen drum brake slightly

8. Poor quality welds a) Insufficient gas at weld area a) Check that gas is not being blown

9. Wire jams in tip when Tip too small Use slightly oversize tip ie., for .8mm welding aluminium wire use 1mm tip. (Note: Applies to

10. Welder cuts out Duty cycle exceeded Allow welder to cool 15-30 mins whilst in use (auto cut-out operates) before continuing

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.

c) Liner blocked or damaged c) Clean with compressed air or

d) Inferior wire d) Use only good “clean” wire e) Roller worn out e) Replace roller

b) Wrong size tip b) Fit correct size tip

b) Wire liner damaged preventing

smooth operation b) Renew wire liner

b) Feed roller worn b) Check and replace if necessary c) Insufficient pressure on feed roller c) Increase pressure on feed roller

d) Wire dirty, rusty, damp or bent d) Re-cut wire and ensure it is clean e) Liner partially blocked e) Clean with compressed air

b) Incorrect gas/wire combination b) Consult your MIG welding manual

c) Rusty, painted, damp, oil or c) Ensure workpiece is clean and dry

greasy workpiece d) Rusty/dirty wire d) Ensure wire is clean and dry e) Poor earth contact e) Check earth clamp/workpiece conn

problem persists return welder to your local dealer

b) Check fuse size

replace liner.

Increase wire speed before operating again

wire slips on roller i.e. no feed

Caution: Do not over-tighten

away by draughts and if so move to more sheltered weld area. If not increase gas supply

for correct set-up

aluminium only)

Note: If duty cycle is continually exceeded, damage to the welder may result, and welder output is probably too small for application

Page 43

ACCESSORIES

The following accessories are available from your Clarke dealer. Please quote the part numbers shown below:

Welding Wire Spools

Mild Steel Stainless Steel Aluminium

Mini - 0.6mm 6000641 - -

Mini - 0.8mm 6000481 6000498 6000483

Mini - 9mm (FLUX Core) 6000664 - -

5kg - 0.6mm 6000476 - -

5kg - 0.8mm 6000475 - -

4.5-5kg - 9mm (FLUX Core) 6000666 - -

2. Welding Gas

CO2 (250g) 6000642 For welding Mild Steel

(600g) 6000643 For welding Mild Steel

Argon 6000661 For welding Aluminium

CO2/Argon Mix 6000660 For welding Stainless/Thin Sheet MS

3. Welding Tips

0.6mm (pack of 5) 8132260

0.8mm (pack of 5) 8132270

4. Gas Regulator 8132000

In addition to the above, your Clarke dealer can provide you with a wide range of welding accessories, safety equipment etc., to increase productivity where necessary and to simplify and assist in the welding process.

PARTS AND SERVICE CONTACTS

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400

PARTS & SERVICE FAX: 020 8558 3622

or e-mail as follows:

PARTS: [email protected]

SERVICE: [email protected]

Page 44