WARNING: Read these instructions before using the machine NO GAS MIG WELDER MODEL NO: MIG102NG PART NO: 6015600 OPERATION & MAINTENANCE INSTRUCTIONS LS0214
INTRODUCTION Thank you for purchasing this CLARKE MIG Welder. Before attempting to operate the machine, it is essential that you read this manual thoroughly and carefully follow all instructions given. In doing so you will ensure the safety of yourself and that of others around you, and you can also look forward to the welder giving you long and satisfactory service. GUARANTEE This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase.
CONTENTS INTRODUCTION ............................................................... 2 GUARANTEE .................................................................... 2 ENVIRONMENTAL RECYCLING POLICY ......................... 2 CONTENTS ....................................................................... 3 GENERAL SAFETY INSTRUCTIONS ................................... 4 SAFETY SYMBOLS ............................................................ 7 THE WELDING SHIELD ......................................
GENERAL SAFETY INSTRUCTIONS WARNING: WHEN USING ELECTRICAL TOOLS, BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK AND PERSONAL INJURY WARNING: READ ALL THESE INSTRUCTIONS BEFORE ATTEMPTING TO OPERATE THIS PRODUCT AND KEEP THESE INSTRUCTIONS IN A SAFE PLACE. ELECTRIC SHOCK insulated for safety. - Keep all equipment well maintained.
• The welding arc can cause serious burns. Avoid contact with skin. one is looking before striking an arc. • Sparks and molten metal are ejected during welding. Take precautions to prevent fire. • Wear hearing protection if required. • Allow the weld to cool. Hot metal should never be handled without gloves. • Sparks and molten metal can pass through gaps. Be aware that fire can start out of sight.
from radiant energy and spatter. Replace cover glass when broken, pitted, or spattered. • Never touch the MIG torch nozzle until the welder is switched OFF and the nozzle has been allowed to cool off. NOTE: ALL protective wear inc. masks & head shields MUST comply with PPE Directive 89/686/EEC • NEVER allow the earth cable or hose to become wrapped around the operator or any person in the vicinity.
SAFETY SYMBOLS General Warning, indicates that failing to follow these instructions could result in injury or damage to the machine. Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to a recycling centre and disposed of in a manner which is compatible with the environment. Read Instruction Manual before use. THE WELDING SHIELD 1.
ELECTRICAL CONNECTIONS WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY. Before switching the product on, make sure that the voltage of your electricity supply is the same as that indicated on the rating plate. This product is designed to operate on 230VAC 50Hz. Connecting it to any other power source may cause damage. This product may be fitted with a non-rewireable plug.
UNPACKING Any damage or deficiency should be reported to your CLARKE dealer immediately. The components include the following: • 1 x Gasless MIG Welder (torch and earth clamp attached) • 2 x 0.9 mm Torch Tips (one installed in the torch) • 1 x Spool Of Flux Cored Wire • 1 x Combination Wire Brush / Hammer • 1 x Split Welding Mask • 1 x Instruction Manual WARNING: NEVER OPERATE THIS MACHINE WITH THE COVER OPENED OPENING THE COVER IMPORTANT: Ensure that the welder is not connected to the mains supply. 1.
OVERVIEW NO DESCRIPTION NO DESCRIPTION 1 Handle 4 Hammer/Brush Tool 2 Control Panel 5 Torch 3 Earth Clamp 6 Torch Hose 10 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.
THE CONTROL PANEL 1. Thermal overload light. If the duty cycle is exceeded as a result of welding too long with a high current, the amber overload light will illuminate and the welder will turn off. When the welder has cooled down (approx. 5 to 10 minutes), the light will go out, the power will be restored and welding can recommence. 2. Power ON/OFF switch. When the power is ON, the green switch will be illuminated.
PREPARATION FOR USE MOUNTING THE WELDING WIRE SPOOL Warning: Ensure that the welder is not connected to the mains supply. NOTE: Spools of welding wire are available from your Clarke Dealer. 1. Open the cover, by sliding the top back ,and then lift the cover open as shown on page 9. 2. Remove the locking knob and retaining disc. 3. Place the spool of welding wire (supplied) over the spindle so that it sits on the spring.
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. 7.
6. Lower the cover and slide it forward to close. 7. Pull off the torch shroud with a twisting movement, then unscrew the contact tip. 8. Connect the welder to the power supply and switch ON. 9. Set the ‘WIRE FEED’ rotary control on the front panel to position 7 or 8 and squeeze the trigger on the torch body. • The wire will feed through the hose until it appears at the torch tip. • Ensuring the hose is free from kinks during this process will assist the wire in its passage through the hose liner. 10.
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.
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.
DUTY CYCLE These welders are covered by regulations EN 60974-1 and EN 60974-10, where the duty cycle is expressed as a percentage of time the machine may be used in a given period for a specified welding current. Using the example shown, which is an illustration of the data plate;e.g. when welding at 35 amps the machine may be used for 6 minutes (60%) in any 10 minute period. ACCESSORIES The following are some of the accessories available from your CLARKE dealer.
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).
RATING PLATE 1 Name and address of manufacturer 13 Load Voltage symbol 2 Model number, part number 14 Energy Input symbol 3 Batch number 15 Rated supply voltage 4 Single phase transformer-rectifier 16 Rated maximum supply current 5 British Standards applied 17 Maximum effective supply current 6 Welding process 18 N/A 7 This symbol indicates that the unit is suitable for carrying out welding operations in an environment which has an increased risk of electric shock.
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 Erratic wire feed Locking Knob too tight Loosen Locking Knob slightly Feed roller worn Check and replace if necessary Insufficient pressure on feed roller Increase pressure on feed roller Caution: Do not over-tighten Wire dirty, rusty, damp or bent Re-cut wire and ensure it is clean Liner partially blocked Clean with compressed air Poor earth contact Check earth clamp/workpiece connection Rusty, painted, damp, oil or greasy workpiece Ensure workpiece is clean and dry
SPECIFICATIONS Model MIG102NG Part No 6015600 Weight 16.65 kg Dimensions (l x w x h) mm 420 X 192 X 362 Power Supply 230 V @ 50Hz IP Rating IP21S Output Min/Max Amps 35 / 90 A Open Circuit Voltage 20-30 V DC Rated Max Input Current 16 A 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.
DECLARATION OF CONFORMITY 23 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.
