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NO GAS/GAS MIG WELDER
MODEL NO: MIG107
PART NO: 6014012
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC03/24
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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.
MACHINE SPECIFICATIONS
Model MIG 107
Part No 6014012
Weight 22.1 kg
Dimensions (l x w x h) 460 x 260 x 380 mm
Power Supply 230 V @ 50Hz
Ingress Protection Rating IP21S
Insulation Class H
Output Min/Max Amps 40 /100 Amps
Open Circuit Voltage 16 - 19 V DC
Rated Max Input Current (A) 18 Amps
Maximum welding Capacity (Mild Steel) 4 mm
Output power settings Mini1, Max1, Min2, Max 2
Welding wire diameters MSW 0.6, 0.8, 0.9 (flux cored)
Material Flux (no gas) / MSW (gas)
Spool capacity 1kg/5kg
Feed speed 11m/min
Max material welding thickness Aluminium - No
Steel;- MIG 0.8 - 4mm
Others;-MIG 0.8 - 4mm
Earth cable length 1600mm
Torch cable length 1800mm
CLARKE International reserve the right to change specifications at any time
without prior notice.
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SAFETY PRECAUTIONS FOR ALL TYPES OF WELDING
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
GENERAL PRECAUTIONS
A) BURN PREVENTION
Wear protective clothing - gauntlet gloves designed for use in welding, apron,
and protective shoes. Button shirt collars and pocket flaps and wear cuffless
trousers to avoid entry of sparks and slag. Wear a helmet with safety goggles
or glasses with side shields underneath, incorporating 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 the cover glass
when broken, pitted, or spattered. Avoid oily or greasy clothing as a spark may
ignite them. Hot metal 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 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.
NOTE: ALL protective wear including masks & head shields MUST comply
with PPE Directive 89/686/EEC.
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 air-supplied respirator. For beryllium, both must be
used. Metals coated with or containing materials that emit toxic fumes should
not be heated unless any 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 force 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
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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.
C) FIRE AND EXPLOSION PREVENTION
Causes of fire and explosion are:
• Combustibles reached by the arc, flame, flying sparks, hot slag or
heated material.
• Misuse of compressed gases and cylinders.
•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 goggle wearing operator.
To prevent fire and explosion, keep equipment clean and free of oil, grease,
and (in electrical parts) of metallic particles that can cause short circuits. If
combustibles are in area, do NOT weld. Move the work, if practicable, to an
area free of combustibles.
Avoid working in paint spray rooms, dip tanks, storage areas and ventilators. If
the work cannot be moved, move any combustibles away from sparks and
heat or protect against ignition with suitable fire-resistant covers or shields.
Walls, ceilings and floors near the work should be protected by heat resistant
covers or shields. A Fire Watcher must be standing by with suitable fire
extinguishing equipment during and for some time after welding or cutting if:
• appreciable combustibles (including building construction) are
within 10m.
• appreciable combustibles are further than 10m, but could be ignited
by sparks.
• openings (concealed or visible) in floors or walls exist, which could
expose combustibles to flying sparks.
• combustibles adjacent to walls, ceilings, roofs or metal partitions
could be ignited by radiant or conducted heat.
After work, check that the 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 the
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 the working level may substitute for inerting.
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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 as they can explode.
In explosive atmospheres, never weld or cut where the air may contain
flammable dust, gas, or liquid vapours.
ELECTRIC ARC (MIG) WELDING
Comply with precautions in the 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 and work pieces
are hot. The wise operator avoids unnecessary risks and protects himself and
others from accidents.
A) BURN PROTECTION
The welding arc is intense and visibly bright. It’s 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! FOLLOW ALL SAFETY PRECAUTIONS!
PROTECTIVE CLOTHING
Wear long sleeved clothing (particularly for gas shielded arc) in addition to
gloves, apron and strong shoes. As necessary, use additional protective
clothing such as leather jacket or sleeves, flameproof apron, and fire-resistant
leggings. Avoid outer garments of untreated cotton. For bare skin protection,
wear dark substantial clothing. Button all collars closed to protect the chest
and neck and button any pockets to prevent entry of sparks.
EYE AND HEAD PROTECTION
Protect the eyes from exposure to an arc. NEVER look at any electric arc
without the protection of a welding helmet or shield containing an
appropriate filter plate (Refer to the section ‘Welding Shield). Place over the
face before striking an arc. Protect the filter plate with a clear cover plate. A
cracked or broken helmet or face shield should NOT be worn as radiation can
pass through and cause burns.
Cracked, broken, or loose filter plates must be replaced IMMEDIATELY.
Replace a 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
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may leave a permanent dark area in the field of vision. Before welding whilst
wearing contact lenses, seek advice from your optician.
PROTECTION OF NEARBY PERSONNEL
For production welding, a separate, well vented 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.
B) FIRE AND EXPLOSION PREVENTION
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.
C) 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.
PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPORT DEVICES
(PACEMAKERS).
Magnetic fields from high currents can affect pacemaker operation. Persons
wearing pacemakers should consult with their doctor before going near arc
welding or spot welding operations.
D) PROTECTION AGAINST SHOCK
Keep your body and clothing dry. NEVER work in a damp area without
adequate insulation against electric shock. Stay on a dry duckboard or rubber
mat when dampness or sweat cannot be avoided. Sweat, sea water, or
moisture between the 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
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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 an electrical conduit or to a pipe carrying ANY gas or a flammable
liquid such as oil or fuel.
2) TORCH
A fully insulated torch should be used without protruding screws or other
damage.
3) CONNECTORS
Fully insulated lock-type connectors should be used to join a 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 bare 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) SAFETY DEVICES
Safety devices such as interlocks and circuit breakers should not be
disconnected or shunted out. Before installation, inspection, or servicing 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 the
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. A 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 danger to the operator.
Avoid welding storage tanks which may contain flammable residuals.
WARNING: 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.
ADDITIONAL PRECAUTIONS FOR MIG WELDING
1. ALWAYS ensure that there is full free air circulating around the outer casing
of the machine and that the louvres are unobstructed.
2. The 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.
3. ALWAYS check that the pressure regulator and gauges (where fitted), are
working correctly. DO NOT lubricate the regulator.
4. ALWAYS use the correct regulator. Regulators are designed to be used with
specific gases.
5. ALWAYS inspect the torch hose before use to ensure it is in good condition.
6. ALWAYS keep the free length of the torch hose outside the work area.
7. ALWAYS remove all flammable materials from the welding area.
8. NEVER remove any of the cover panels unless the machine is
disconnected from the power supply and never use the machine with any
of the panels removed.
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9. 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.
10. NEVER use or store in a damp environment. DO NOT EXPOSE TO RAIN.
11. ALWAYS keep a fire extinguisher handy. (Dry Powder, C02 or BCF, NOT
Water)
12. 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.
13. 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.
14. NEVER point the MIG torch at any person or animal.
15. NEVER touch the MIG torch nozzle until the welder is switched OFF and the
nozzle has been allowed to cool.
16. NEVER connect, disconnect, or attempt to service the welding torch, until
the machine is switched OFF and disconnected from the power supply.
17. NEVER allow the earth cable or torch hose to become wrapped around
the operator or any person in the vicinity.
A comprehensive range of CLARKE safety equipment for use when welding is
available from your local dealer.
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.
The welding equipment should be maintained according to the
manufacturer’s recommendations. All access and service doors and covers
should be closed and properly fastened when the equipment is in operation.
The welding equipment should not be modified in any way except for those
changes and adjustments covered in the manufacturer’s instructions. In
particular, the spark gaps of arc striking and stabilizing devices should be
adjusted and maintained according to the manufacturers recommendations.
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ELECTRICAL CONNECTIONS
Plug must be BS1363/A approved.
Always fit
make sure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
a 13 Amp
the cable is firmly held by the clamp
fuse.
Earth
(Green and
Yellow)
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS FULLY
BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY.
This product is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug,
for connection to a standard, domestic electrical supply. Should the plug
need changing, make sure that a plug of identical specification is used.
WARNING: THE WIRES IN THE CABLE ARE COLOURED AS FOLLOWS:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH
If the colours of the wires in the power cable do not correspond with the
markings on the terminals of your plug, proceed as follows.
• Connect the blue
wire to the terminal
marked N.
• Connect the brown
wire to the terminal
marked L.
• Connect the
Yellow and Green
wire to the terminal
marked E or .
We recommend that this machine is connected to the mains supply via a
Residual Current Device (RCD)
If in doubt, consult a qualified electrician. DO NOT attempt any repairs
yourself.
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SAFETY SYMBOLS
The following symbols may be displayed on the machine or its packaging.
Read this instruction
booklet carefully
before use.
Wear welding mask Recycle unwanted
Wear protective gloves General Hazard
Wear a dust mask Warning;- Magnetic
Caution:- Hot surface Danger! Harmful fumes
Risk of Electric Shock Do not weld near
Do not expose to rain.
materials under WEEE
Directive
field created (
flammable or
combustible materials
Do not weld near
flammable or
combustible materials
May interfere with
pacemakers
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Danger:- Arc Rays
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OVERVIEW
INVENTORY
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 100 Amp Mig Welder (No Gas / Gas)
• 1 x 0.9 mm tip for no gas welding in the torch
• 1 x 0.9 mm tip
• 1 x 0.8 mm tip
• 1 x 0.6 mm tip
• 1 x 0.9 mm 0.45 kg mini spool flux cored wire (no gas welding)
• 1 x 0.6 mm 0.7 kg mini spool MSW (gas welding)
• 1 x Welding shield
• 1 x Hammer / brush tool
• 2 x Fixing brackets for gas bottle
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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 switches MIN-MAX & 1-2. Used together, these two switches
provide 4 increasing power levels as follows:
•MIN-1
•MIN-2
•MAX-1
•MAX-2
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 plug should be disconnected
from the mains 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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PREPARATION FOR USE
ASSEMBLING THE WELDING SHIELD
1. The welding shield 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 should be
replaced if it becomes badly
pitted.
4. Secure the handle in
position using the plastic
nuts provided.
• The handle will be on the inside of
the shield.
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.
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FITTING THE GAS BOTTLE HOLDER
WARNING: NEVER OPERATE THIS MACHINE WITH THE SIDE PANELS
PARTIALLY OPENED OR REMOVED.
IMPORTANT: Ensure that the welder is
not connected to the mains supply
before opening.
1. Open the side panel by pushing
the latch down and allowing the
side panel to drop down.
2. Remove any loose items that
have been transported inside.
3. Place the lower bottle bracket
into position and secure in place
using the 2 screws provided.
4. Secure the top clip in place using
the screw provided.
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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 wingnut and
retaining disc.
3. Place a spool of welding wire 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 in the correct orientation otherwise it will not
feed correctly.
SETTING THE DRIVE ROLLER SIZE
1. Loosen the tensioning knob and
pivot it towards you.
2. Lift up the arm.
3. Take hold of the triangular knob
on the drive roller cover and
rotate it 90°anticlockwise to
release it.
4. Pull the roller retainer off the drive
spindle to reveal the roller.
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 cover back onto the drive spindle with the opening
facing right.
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7. Ensure that the flanges at the base of the drive roller cover, seat fully into
the circular recess in the main moulding and then rotate the drive roller
cover through 90° to lock it in place.
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.
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.
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10. Release the trigger and switch off the welder and disconnect the machine
from the mains supply.
11. Refit the appropriate size contact tip (the 0.9 mm tip, for no gas welding is
supplied fitted) to suit your wire and replace the shroud.
• A spare 0.8 mm tip is supplied loose and should be used when using
0.6/0.8 mm mild steel solid wire.
12. Trim the welding wire so that it protrudes no more than 5 mm from the end
of the contact tip.
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)
WELDING WITHOUT GAS
1. If using 0.9mm flux cored wire,
connect the terminal as shown.
• The earth cable (Thicker Lead)
should be connected to the
positive (Red) terminal.
• The cable from torch (Thinner
Lead) should be connected to
the Negative (Black) terminal.
WELDING WITH GAS
1. If using solid cored wire 0.6/0.8mm
wire, connect the terminal as
shown.
• The earth cable (Thicker Lead)
should be connected to the
negative (Black) terminal.
• The cable from torch (Thinner
Lead) should be connected to
the positive (Red) terminal.
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CONNECTING THE GAS SUPPLY
2. Connect a bottled gas supply to
the small tube at the back of the
welder.
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 No
Mild Steel Carbon Dioxide (CO2) 6000643
Stainless Steel Argon 6000661
Thin Sheet Metal/Mild Steel Carbon Dioxide (CO2)/Argon Mix 6000660
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.
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OPERATING THE WELDER
PREPARING THE WORKPIECE
The area being welded should be perfectly clean. Any coating, plating or
corrosion must be removed, otherwise a good weld will be impossible to
achieve.
Attach the earth clamp to the workpiece as close to the point of weld as
possible, without it being intrusive.
OPERATION
CAUTION: THE DUTY CYCLE MUST BE ADHERED IN ORDER TO PREVENT
THE THERMAL OVERLOAD PROTECTION FROM ACTIVATING
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. Cover your face with a welding mask or welding helmet.
• 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 satisfactory weld, the controls may 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.
NOTE: The Wire Feed control is for fine tuning the wire speed. The speed
of wire delivery will increase automatically as the current is
o
and pull the torch trigger fully.
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increased. 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.
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 light up. Allow the welder
to cool until the amber light
extinguishes before resuming work.
DUTY CYCLE
This welder is covered by regulations 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.
e.g. when welding at 40 amps the machine may be used for 6 minutes (60%)
in any 10 minute period.
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 adhered to, to
prevent the thermal cutout protection from activating.
Duty Cycle (%) 10 60
Rated Welding Current (A) 100 40
Conventional Load Voltage (V) 19 16
Do not exceed the stated duty cycle for this machine. Failure to heed this
warning may invalidate your warranty.
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WELDING TECHNIQUE
• 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.
• Try to maintain a constant speed of movement with the torch.
• DO NOT weld in windy conditions or in an area where ventilation is a
problem, or where air flow fluctuates.
• ALWAYS keep the wire and nozzle clean. NEVER use rusted wire.
• Avoid sharp bends or kinks in the welding hose.
• Whenever possible, clean out the wire liner with compressed air when
replacing the wire spool.
• Periodically remove the dust using LOW PRESSURE compressed air within
the casing. Adequate heat dissipation is essential during the welders
operation.
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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.
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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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.
Wire welds itself
to tip.
Wire feeds into
‘birds nest’
tangle.
Check fuses, power switch
and mains lead.
Feed motor has
malfunctioned.
Insufficient Feed Roller
pressure.
Burr on end of wire. Re-cut wire square with no burr.
Liner blocked or damaged. Clean with compressed air or
Inferior wire Use only good “clean” wire.
Roller worn out. Replace roller.
Wire feed speed too low. Unscrew tip, cut wire and fit
Wrong size tip. Fit correct size tip.
Wire welded to tip. As above plus reduce feed
Wire liner damaged
preventing smooth
operation.
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.
replace liner.
new tip.
Increase wire speed before
operating again.
roller pressure.
Renew wire liner.
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PROBLEM CAUSE SOLUTION
Loose coils of
wire tangle
around wire
drum inside
machine.
Erratic wire
feed.
Poor quality
welds.
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.
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 no 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.
Welder cuts out
whilst in use.
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.
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MACHINE RATING PLATE
1 Manufacturer name and address 11 Protect from rain
2 Model number, part number 12 Class of protection
3 Batch number 13 Rated supply voltage
4 Single phase transformer-rectifier 14 Rated maximum supply current
5 British Standards applied 15 Load voltage symbol
6 Welding process (MIG) 16 Rated maximum supply current
7 Min+max welding current and
corresponding load voltages
8 Welding Current symbol - DC. 18 Class of protection
9 Rated no-load voltage 19 Rated maximum welding time in
10 Energy Input symbol 20 Rated maximum welding time in
17 Maximum effective supply current
continuous modeat the maximum
welding current at an ambient
o
temperature of 20
C, expressed
in minutes and seconds.
intermittent mode at therated
maximumwelding current at an
o
ambient temperature of 20
C,
expressed in minutes & seconds.
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ACCESSORIES
The following are some of the accessories 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 steel
Welding Tips 0.6 mm (pack of 5) 8132260
Arc Welding
Rods
Regulator Argon Gas Regulator 8134140
Welding Apron 6000920
Gauntlets Leather (EN407 rated) 8133494
Welding
screen
Flux cored mild steel (mini
spool) 0.9mm
Mild steel (mini) - 0.6mm 8132100 Use for gas welding
Mild steel (mini) - 0.8mm 8132070 Use for gas welding
Stainless Steel 0.8mm
(mini spool)
CO2 (600g) 6000643 For welding mild steel
CO2/Argon Mix 6000660 For welding stainless/
0.8 mm (pack of 5) 8132270
1.0 mm (pack of 5) 8132275
1.6 x 300mm 3050590
2.0 x 350mm 3050592
2.5 x 350mm 3050594
3.25 x 350mm 3050596
WSC2 and replacement
screen
8132110 Use for no gas welding
8132090
6000945
6000910
Comment
thin sheet mild steel
A Gas Regulator, Arc Activated Headshields, Anti-spatter Spray, Swan Necks,
Torch Shrouds and Torch Liner are also available from your CLARKE dealer or
our parts division.
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ARC ACTIVATED HEADSHIELDS
These highly popular headshields activate instantly when the arc is struck and
allow you to have both hands free when welding.
Model Arc
Activated
GWH4 ✔✔✔ 6000706
GWH7 ✔✔✔ 6000709
GWH5 ✔✔✔ 6000707
GWH6 ✔✔✔ 6000708
GWH3 ✔✔✔ 6000698
GWH2 ✔✔✔ 6000697
GWH8 ✔✔✔ 6000714
PG4 ✔✔✔ 6000716
HS1 ✔✔6000700
HSF1 ✔✔6000705
Grinding
function
Solar
Powered
Fixed
Shade
Flip Up Part
Number
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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COMPONENT PARTS
1 Welding torch 18 Rear panel
2 Potentiometer knob 19 Side opening door
3 Power switch 20 Door hinge
4 Overheat LED 21 Middle panel
5 Power cable & plug 22 Cooling fan
6 Earth clamp & cable 23 Wire spool retainer
7 Plastic front panel 24 Wire spool carrier
8 Transformer 25 Rectifier bridge
9 Insulated mounting base 26 Thermal cut-out 1 (rectifier)
10 Insulated mounting base 27 Thermal cut-out 2 (transformer)
11 Rubber foot 28 Main transformer
12 Base panel 29 Control board base
13 Cover panel 30 Control board
14 Handle rubber support 31 Wire feeder
15 Handle 32 Selection switch
16 Gas bottle support 33 Potentiometer
17 Gas bottle bracket 34 Manual reset fuse in transformer
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DECLARATION OF CONFORMITY-UK
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DECLARATION OF CONFORMITY-EU
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