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Clarke MIG PRO-90 - User Manual

Clarke MIG PRO-90
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OPERATING & MAINTENANCE
INSTRUCTIONS
0904
MIG PRO-90 • MIG 100E • MIG 150TE
MIG PRO-90 • MIG 100E • MIG 150TE

Table of Contents

Questions and Answers

  • R
    rodriguezkellyAug 14, 2025
    Why does my Clarke MIG PRO-90 Welding System produce poor quality welds?
    • A
      amunozAug 14, 2025
      Poor quality welds with the Clarke Welding System can result from several factors. First, ensure sufficient gas is reaching the weld area and that drafts aren't blowing it away; increase the gas supply if needed. Second, verify you're using the correct gas and wire combination, consulting your MIG welding manual for the proper setup. Also, the workpiece should be clean and dry, free from rust, paint, dampness, oil, or grease. The wire should also be clean and dry. Finally, check the earth clamp and workpiece connection to ensure good contact.
  • W
    William MillerAug 18, 2025
    What to do if my Clarke Welding System welder cuts out while in use?
    • A
      Amanda Carter PhDAug 18, 2025
      If your Clarke Welding System cuts out during use, it's likely that the duty cycle has been exceeded, activating the auto cut-out. To resolve this, allow the welder to cool for 15-30 minutes before resuming operation. Be aware that repeatedly exceeding the duty cycle can damage the welder, and it might indicate that the welder's output is too small for the application.
  • T
    Tammy ThorntonAug 21, 2025
    Why is the wire feed erratic on my Clarke MIG PRO-90?
    • D
      Derrick VanceAug 21, 2025
      Erratic wire feed in your Clarke Welding System can stem from several causes. First, slightly loosen the drum brake if it's too tight. Second, inspect the feed roller for wear and replace it if necessary. Third, increase the pressure on the feed roller, but avoid over-tightening. Fourth, ensure the wire is clean and free from dirt, rust, dampness, or bends; re-cut the wire to ensure cleanliness. Lastly, clean the liner with compressed air if it's partially blocked.
  • C
    Cindy AshleyAug 25, 2025
    What to do if the wire welds itself to the tip on my Clarke MIG PRO-90?
    • D
      David EvansAug 25, 2025
      If the wire welds itself to the tip of your Clarke Welding System, it's likely due to one of two reasons. First, the wire feed speed might be too low. To fix this, unscrew the tip, cut the wire, fit a new tip, and increase the wire speed before operating again. Second, you might be using the wrong size tip. Ensure you fit the correct size tip for your wire.
  • A
    April ReedAug 28, 2025
    Why does the wire feed into a ‘birds nest’ tangle in my Clarke MIG PRO-90 Welding System?
    • D
      Dave PriceAug 28, 2025
      If the wire feeds into a 'birds nest' tangle with your Clarke Welding System, it could be due to a couple of reasons. First, the wire might be welded to the tip. Address this as described above, and also reduce the feed roller pressure so that if a blockage occurs, the wire slips on the roller, preventing further feed. Second, the wire liner may be damaged, preventing smooth operation. If so, renew the wire liner.
  • E
    Emily PadillaAug 31, 2025
    What to do if the feed motor operates but wire will not feed on my Clarke MIG PRO-90 Welding System?
    • J
      James JonesAug 31, 2025
      If the feed motor operates but the wire won't feed in your Clarke Welding System, check the following: Increase roller pressure. Re-cut wire square with no burr. Clean with compressed air or replace liner. Use only good “clean” wire and replace roller.
  • G
    Gary MooreSep 3, 2025
    Why are there loose coils of wire tangling around the wire drum inside my Clarke MIG PRO-90 Welding System?
    • J
      Jeffery SteeleSep 3, 2025
      If loose coils of wire tangle around the wire drum inside your Clarke Welding System, the drum brake is likely too slack. Tighten the drum brake, but be careful not to over-tighten it.
  • M
    Michael DuffySep 6, 2025
    Why does the wire jam in the tip when welding aluminum with my Clarke Welding System?
    • K
      kimberlymurraySep 6, 2025
      If the wire jams in the tip when welding aluminum with your Clarke Welding System, the tip might be too small. Use a slightly oversized tip; for example, use a 1mm tip for 0.8mm wire. Note that this applies to aluminum only.
  • L
    laurataylorSep 10, 2025
    How to troubleshoot no 'life' from Clarke MIG PRO-90 Welding System?
    • G
      Gloria PorterSep 10, 2025
      To solve the problem with your Clarke Welding System, start by checking the fuses and mains lead. Replace fuses as necessary. If the problem persists return welder to your local dealer and check fuse size.

Summary

Guarantee and Service Contacts

Parts and Service Contacts

Contact information for obtaining spare parts and technical service.

Electromagnetic Interference (EMC) Management

Area Assessment and Emission Reduction

Assess potential electromagnetic problems and methods to reduce emissions.

Equipment Maintenance and Cable Management

Covers equipment maintenance, cable handling, bonding, earthing, and shielding.

Comprehensive Safety Precautions

General Precautions and Warnings

Covers burn prevention, toxic fumes, general warnings, and fire/explosion prevention.

Electric Arc Welding Safety

Details protective clothing, eye/head protection, and personnel safety for arc welding.

Hazard Prevention: Fumes, Fire, and Shock

Addresses fume hazards, fire/explosion risks, electric shock, and pacemaker safety.

Component and Cable Safety Guidelines

Covers safety related to electrode holders, connectors, cables, terminals, and safety devices.

MIG Welding Preparation and Safety

Working Area Preparation

Ensures the working area is spacious, dry, and well-ventilated.

MIG Welding Safety Guidelines

Specific safety checks and precautions for MIG welding operations.

Critical Welder Safety Warnings

Emphasizes critical warnings like not using damaged parts, avoiding shock, and never pointing the torch at people.

MIG Welding Overview and Benefits

Principles of Operation

Explains the MIG welding process: wire feed, arc, shielding gas.

Benefits of MIG Welding

Lists advantages like speed, no slag, and less distortion.

Electrical Connections and Setup

Model-Specific Electrical Connections

Details electrical connection requirements for PRO-90/100E, 150TE, and general models.

Extension Cable Guidelines

Recommendations for using extension cables with the welding equipment.

Unpacking and Parts Identification

PRO MIG-90 & MIG100 E Parts Identification

Lists and identifies components included with PRO MIG-90 and MIG 100E models.

MIG150 TE Parts Identification

Lists and identifies components included with the MIG 150TE model.

Assembly and Installation Procedures

Loose Components Assembly

Instructions for assembling wheels, foot, handle, and securing gas bottle.

Installing the Welding Wire

Step-by-step guide for loading the wire spool and feeding the wire.

Wire Feed Adjustment and Preparation

Adjusting wire feed pressure and preparing the wire for feeding.

Selecting the Correct Drive Roller Groove

Guide on choosing the appropriate groove on the feed roller for different wire sizes.

Gas Supply Setup and Recommendations

Mini Gas Bottle Connection

Instructions for connecting the mini gas bottle and regulator.

Gas Type Recommendations

Lists recommended gases for different welding materials.

Welding Shield Assembly and Safety

Shield Assembly Instructions

Steps for assembling the welding shield with glass panels.

Critical Eye Protection Warning

Emphasizes the importance of using a welding helmet for eye safety.

Preparation for Use and Control Settings

Preparing the Workpiece

Importance of cleaning the workpiece for a good weld.

Setting the Controls Overview

Overview of control functions: ON/OFF, Wire Feed Speed, Welding Current.

Model-Specific Control Settings

Details control switch configurations for MIG PRO-90, MIG 100E, and MIG 150TE.

Operation Procedures

Wire Trimming and Earth Connection

Steps to trim wire and attach the earth lead before welding.

Welding Operation Steps

How to approach the workpiece, strike an arc, and maintain the weld.

Thermal Overload and Welding Tips

Thermal Overload Protection

Explains the thermal overload function and when the welder will shut off.

Welding Tips for Quality

Advice on torch angle, movement, environment, and cleaning for better welds.

Maintenance Procedures and Shield Care

General Maintenance Safety Warnings

Critical safety warnings before performing any maintenance.

Welding Shield Maintenance

Guidelines for cleaning and maintaining the welding shield and its lenses.

Wire Liner Replacement

Wire Liner Replacement Procedure

Step-by-step guide to replace a damaged or kinked wire liner.

Control Settings Reference Tables

MIG PRO-90 Control Settings

Reference table for steel and aluminium welding parameters for the PRO-90.

MIG 100 E Control Settings

Reference table for steel and aluminium welding parameters for the 100E.

MIG 150 TE Control Settings

Reference table for steel and aluminium welding parameters for the 150TE.

Specifications and Wiring Diagrams

Welder Specifications Comparison

Technical specs for PRO-90, 100E, and 150TE models.

MIG PRO-90 Wiring Diagram

Electrical schematic for the MIG PRO-90 model.

MIG 100 E Wiring Diagram

Electrical schematic for the MIG 100E model.

MIG 150 TE Wiring Diagram

Electrical schematic for the MIG 150TE model.

Parts List and Diagrams

Comprehensive Parts List by Model

Detailed list of parts for PRO-90, 100E, and 150TE models.

Parts Diagram

Visual representation of welder components with numbering.

Troubleshooting Common Issues

Problem Identification and Solutions

Identifies common welding issues and provides remedies.

Available Accessories

Clarke MIG PRO-90 Specifications

General IconGeneral
BrandClarke
ModelMIG PRO-90
CategoryWelding System
LanguageEnglish

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