Autojack Mig Master MIG100 Installation manual

MIG100/MIG130
Mig Master
MIG100/MIG130
ORIGINAL INSTRUCTIONS
SAFETY AND OPERATING MANUAL

MIG100/MIG130
TABLE OF CONTENTS
Welcome to Auto
j
ack!
Dear customer, Congratulations on your purchase. Before using the
Product for the first time please be sure to read these instructions for use.
They provide you with all information necessary for using the product safely and to
ensure its long service life.
Closely observe all safety information in these instructions!
General Power Tool Safety Warnings………………………………….…......01
Symbols & Cable Rating Chart ……….…………………………………….………05
Machine Details and Product features……….…………………………….….06
Assembly……………………………………………………………………………………..07
Operation, Maintenance and Service…………………………………………..08
Autojack Guarantee…………………………………………………………………….09
Declaration of conformity……………………………………………………………11
Parts list……………………………………………………………………………………...12
Parts Diagram………………………………………………………………………………13

MIG100/MIG130 01
WARNING Read all safety warnings and
all instructions.
Failure to follow the warnings
and instructions may result in electric shock, fire
and/or serious injury.
Save all warnings and instructions for
future reference.
The term "power tool" in
the warnings refers to your electric (corded)
power tool or battery-operated (cordless) power
tool.
1. Work area safety
a) Keep work area clean and well lit. Cluttered
or dark areas invite accidents.
b) Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools
create sparks which may ignite the dust or
fumes.
c) Keep children and bystanders away while
operating a power tool. Distractions can cause
you to lose control.
2. Electrical safety
a) Power tool plugs must match the outlet.
Never modify the plug in any way. Do not use
any adapter plugs with grounded power tools.
Unmodified plugs and matching outlets will
reduce risk of electric shock.
b) Avoid body contact with grounded surfaces,
such as pipes, radiators, ranges and
refrigerators
.
There is an increased risk of
electric shock if your body is grounded.
c) Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords
increase the risk of electric shock.
e) When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of a
cord suitable for outdoor use reduces the risk of
electric shock.
f) If operating a power tool in a damp location is
unavoidable, use a residual current device (RCD)
protected supply. Use of an RCD reduces the risk
of electric shock.
3. Personal safety
a) Stay alert, watch what you are doing and use
common sense when operating a power tool. Do
not use a power tool while you are tired or under
the influence of drugs, alcohol or medication. A
moment of inattention while operating power
tools may result in serious personal injury.
b) Use personal protective equipment. Always
wear eye protection. Protective equipment such
as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions
will reduce personal injuries.
c) Prevent unintentional starting. Ensure the
switch is in the off position before connecting to
power source and/or battery pack, picking up or
carrying the tool. Carrying power tools with your
finger on the switch or energising power tools that
have the switch on invites accidents.
d) Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may
result in personal injury.
GENERAL POWER TOOL SAFETY WARNINGS

e) Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
away from moving parts. Loose clothes,
jewellery or long hair can be caught in moving
parts.
g) If devices are provided for the connection of
dust extraction and collection facilities, ensure
these are connected and properly used. Use of
dust collection can reduce dust-related hazards.
4. Power tool use and care
a) Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at the
rate for which it was designed.
b) Do not use the power tool if the switch does
not turn it on and off. Any power tool that
cannot be controlled with the switch is
dangerous and must be repaired.
c) Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
d) Store idle power tools out of the reach of
children and do not allow persons unfamiliar
with the power tool or these instructions to
operate the power tool. Power tools are
dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts and
any other condition that may affect the power
tool’s operation. If damaged, have the power tool
repaired before use. Many accidents are caused
by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier
g) Use the power tool, accessories and tool bits
etc. in accordance with these instructions, taking
into account the working conditions and the work
to be performed. Use of the power tool for
operations different from those intended could
result in a hazardous situation.
5. Service
a) Have your power tool serviced by a qualified
repair person using only identical replacement
parts. This will ensure that the safety of the power
tool is maintained.
b) If the replacement of the supply cord is
necessary, this has to be done by the
manufacturer or its agent in order to avoid a
safety hazard.
6. Battery Tool Use and Care
a) Recharge only with the charger specified by
the manufacturer. A charger that is suitable for
one type of battery pack may create a risk of fire
when used with another battery pack.
b) Use power tools only with specifically
designated battery packs. Use of any other
battery packs may create a risk of injury or fire.
GENERAL POWER TOOL SAFETY WARNINGS
MIG100/MIG130 02

c) When Battery pack is not in use, keep it away
from other metal objects, like paper clips, coins,
keys, nails, screws or other small metal object
that can make a connection from one terminal
to another. Shorting the battery terminals
together may cause burns or a fire.
d) User abusive conditions, liquid may be
ejected from the battery; Avoid contact. If
contact accidentally occurs, flush with copious
amounts of water. If liquid contacts eyes, seek
medical help immediately. Liquid ejected from
the batter may cause irritation or burns.
7 Additional Safety Instructions for
welders
Welders have many sources of danger. It is
therefore particularly important for the welder
to comply with the following rules so as not to
place themselves or others in danger and to
avoid endangering people and equipment.
a) Have all work on the mains voltage system, for
example on cables, plugs, sockets, etc.,
performed only by trained electricians. This
particularly applies to configuring intermediate
cables.
b) If an accident occurs, disconnect the welding
power source from the mains immediately.
c) If electric touch voltages occur, switch off the
welding set immediately and have it checked by
an expert.
d) Always check for good electrical contacts on
the welding current side.
e) Wear insulating gloves on both hands for
welding. These offer protection from electric
shocks (idling voltage in the welding circuit),
harmful radiation (Heat and UV radiation) and
from glowing metal and slag spatter.
f) Wear firm, insulated footwear. Your shoes
should also protect you in wet conditions. Open-
toed footwear is not suitable since falling droplets
of glowing metal will cause burns.
g) Wear suitable clothing, do not wear synthetic
clothes.
h) Do not look into the arc with unprotected eyes,
use only a welding safety shield with the proper
safety glass in compliance with DIN standards. In
addition to light and heat, which may cause
dazzling and burns, the arc also gives off UV
radiation. Without proper protection, this invisible
ultraviolet radiation causes very painful
conjunctivitis, which will only be noticeable
several hours later. In addition, UV radiation will
cause sunburn-type symptoms on unprotected
parts of the body.
i) Personnel or assistants in the vicinity of the arc
must also be notified of the dangers and provided
with the required protection; if necessary install
safety walls.
j) Ensure adequate ventilation for welding,
particularly in small rooms since the process
causes smoke and harmful gases.
k) Do not carry out any welding work on tanks that
have been used to store gases, fuels, mineral oil or
the like, even if they have been empty for a
lengthy period of time, since any residue will result
in a danger of explosion.
GENERAL POWER TOOL SAFETY WARNINGS
MIG100/MIG130 03

l) Special regulations apply in areas where there
is a potential risk of fire and/or explosion.
m) Welds that are exposed to large stresses and
must comply with safety requirements may only
be completed by specially trained and approved
welders. Examples of such welds include
pressure vessels, rails, trailer hitches, etc.
n) It must be noted that the protective
conductor in electrical systems of appliances
may be destroyed by the welding current in the
event of negligence, for example if the earth
terminal is placed on the welding set casing to
which the protective conductor of the electrical
system is connected. The welding work is
completed on a machine with a protective
conductor connection. It is therefore possible to
weld on the machine without having connected
the earth terminal to it. In this case the welding
current will flow from the earth terminal
through the protective conductor to the
machine. The high welding current may cause
the protective conductor to melt.
o) The fuses on the supply cables to the mains
sockets must comply with the relevant
regulations (VDE 0100). To comply with these
regulations, only fuses or circuit breakers
suitable for the cross-section of the cables may
be used (for earthing contact sockets max. 16 A
fuses or 16 A circuit breakers). The use of too
high a fuse may result in the cable burning and
fire damage to the building.
8 Additional Safety Instructions for
Constricted and wet areas
When working in constricted, wet or hot areas,
use insulating supports and intermediate layers as
well as slip-on gloves made of leather or other
non-conductive materials to insulate your body
against the floor, walls, conductive parts of the
machine and the like.
If you use small welding transformers for welding
in places with an increase electrical risk, for
example in constricted areas with conductive
walls, (tanks, pipes, etc.), in wet areas (which
make work clothes wet) and in hot areas
(perspiration on work clothes), the output voltage
of the welding set when idling must not exceed 48
V (effective value). Therefore, the appliance may
not be used for these purposes because its output
voltage is higher than this.
9 Additional Safety Instructions for Safety
clothing
a) While working, the welder must protect his
entire body from radiation and burns by wearing
suitable clothing and a face guard.
b) Slip-on gloves made of a suitable material
(leather) must be worn on both hands. They must
be in perfect condition.
c) Suitable aprons must be worn to protect
clothing from sparks and burns. A safety suit and,
if necessary, head protection must be worn if
required by the type of work in question, e.g.
overhead welding.
d) The safety clothing used as well as all
accessories must comply with the “Personal Safety
Equipment“ directive.
GENERAL POWER TOOL SAFETY WARNINGS
MIG100/MIG130 04

10 Additional Safety Instructions for
Protection from radiation and burns
a) Provide information about the risk to eyes at
the working site in the form of a poster with the
wording “Caution – do not look at the flames”.
Workplaces are to be screened off wherever
possible so that personnel in the vicinity are
protected. Unauthorized persons are to be kept
away from the welding work.
b) The walls in the immediate vicinity of
stationary workplaces should not have a light
color or a sheen. Windows up to head height are
to be protected against radiation passing
through them or reflecting off them, for example
by coating them with a suitable paint.
Do not store or use the equipment in wet
conditions or in the rain. Use the equipment only
indoors.
11. Using an Extension Cable
.
a) If an extension cable is required, use an
approved triple core extension cable suitable for
the power input of the tool.
b) Grounded tools always require a three wire
extension cable.
c) As the distance from the supply outlet increases
you must use a heavier gauge extension cable.
Using extension cables with inadequately sized
wire causes a serious drop in voltage, resulting in
loss of power and possible tool damage.
d) The smaller the gauge number of the wire the
greater the capacity of the cord.
e) When using a cable reel, always unwind the
cable completely.
GENERAL POWER TOOL SAFETY WARNINGS
MIG100/MIG130 05

SYMBOLS AND POWER RATING CHART
Danger!
–
Read the operating
instructions to reduce the risk of
injury.
Caution! Wear safety goggles.
Caution! Wear ear defenders. The
impact of noise can cause damage
to hearing.
Amperes 7.5M 15M 25M 30M 45M 60M
0 – 2.0 6 6 6 6 6 6
2.1 – 3.4 6 6 6 6 6 6
3.5 - 5.0 6 6 6 6 10 15
5.1 – 7.1 10 10 10 10 15 15
7.1 – 12.0 15 15 15 15 20 20
12.1 – 20.0 20 20 20 20 25 -
Caution! Risk of Injury! Do
not reach into the running
saw blade
.
Caution! Wear a dust mask.
MIG100/MIG130 06

MACHINE DETAILS AND PRODUCT FEATURES
Machine Details
Specifications:
Specifications: MIG100 MIG130
Mains Voltage - 230V / 50Hz
Rated Max. Supply Current - 13A 16A
Output Amperage Range @
Duty Cycle –
48A@60% 50A@60%
90A @10% 120A@10%
No Load Voltage - 27.5V 33V
Suitable Size Flux Cored - 0.6-0.9mm
Wire Spool Capacity - Up to 1Kg
Gross Weight - 15kg 17kg
Nett Weight - 13kg 15kg
Package Contents:
Welding Machine Earth Clamp Welding Torch Brush Mask Welding Spool
Intended Use
The flux cored welding set is designed for self-shielding flux cored welding using suitable wire.
The additional application of gas is not required.
The equipment is to be used only for its prescribed purpose. Any other use is deemed to be a
case of misuse. The user / operator and not the manufacturer will be liable for any damage or
injuries of any kind caused as a result of this.
Please note that our equipment has not been designed for use in commercial, trade or
industrial applications. Our warranty will be voided if the equipment is used in commercial,
trade or industrial businesses or for equivalent purposes.
MIG100/MIG130 07

MACHINE DETAILS AND PRODUCT FEATURES
Product Features
1. Handle
2. Thermostat control lamp
3. Housing cover
4. ON/OFF switch
5. Welding wire speed controller
6. Switch for welding current adjustment
7. Mains plug
8. Earth terminal
9. Hose package
10. Welding nozzle
11. Torch
12. Wire brush
13. Welding screen
14. Torch switch
15. Welding nozzle core
16. Flux core wire
16
MIG100/MIG130 08

Assembly
1.Fitting the welding screen
1.Place the welding glass (A) over it in the frame
for welding screen(B).
2. Insert the handle welding mask hole.
2.Fitting the wire spool
1Wire types
Various welding wires are required for different
applications. The welding set can be used with
welding wires with a diameter of 0.9 mm. The
appropriate feed rollers and contact tubes are
supplied with the set. The feed roller, contact
tube and wire cross-section must always match
each other.
2Wire spool capacity
Wire spools with a maximum weight of 0.45 kg
can be fitted in the welding set.
3Inserting the wire spool
1.Unlock the housing cover by turning the
fastening screw through 90°and flip open the
cover.
2.Check that the windings on the spool do not
overlap so as to ensure that the wire can be
unwound evenly.
3.Place the wire spool on the spool holder .
Ensure that the end of the welding wire is
unwound on the side of the wire guide, see
arrow.
4 Inserting the welding wire and adjusting the
wire guide
1.Pull the pressure roller spring and swing it
upward.
2.Pull the pressure roller holder(E) downwards .
MIG100/MIG130 09

Assembly
4.Swing the screws (F) 90 °and pull off
upwards.
5.Check the feed roller (G). The appropriate wire
thickness must be specified on the top of the
feed roller (G). The feed roller (G) is fitted with
two guide grooves. Turn the feed roller (G) over
if necessary or replace it.
5.Position the feed roller holder (G) again and
secure it.
6.Remove the gas nozzle (10) from the torch (11)
by turning it clockwise, unscrew the contact tube
(15). Place the hose package (9) on the floor as
straight as possible pointing away from the
welding set. (See page 8)
7.Cut off the first 10 cm of the welding wire to
produce a straight cut with no shoulders,
warping or dirt. Deburr the end of the welding
wire.
8.Push the welding wire through the guide tube
(C) between the pressure and feed rollers (G)
into the hose package mounting (H).
Carefully push the welding wire by hand into the
hose package until it projects out of the hose
package by approx. 1 cm at the torch (11).
9. Push the pressure roller holder(E) upwards and
Pull the pressure roller spring(D) and swing it
downward.
10. Screw the appropriate contact tube (15) for
the welding wire diameter on to the torch (Fig. 11)
and fit the gas nozzle(10), turning it clockwise.
11.Set the adjusting screw for the roller brake (I)
so that the wire can still be moved and the roller
stops automatically after the wire guide has been
braked.
F
G
C
H
I
ED
MIG100/MIG130 10

OPERATION
Operation
Before any work on the machine itself, remove
the mains plug from outlet.
Setting
Since the welding set must be set to suit the
specific application, we recommend that the
settings be made on the basis of a test weld.
Setting the welding current
-The welding current can be set to 2 different
levels using the welding current adjustment
switch (6). The required welding current
depends on the material thickness, the required
penetration depth and the welding wire
diameter.
Setting the wire feed speed
-The wire feed speed is automatically adjusted to
the current setting. The final wire feed speed
setting can be made on the welding wire speed
controller (5). It is advisable to start with the
medium setting and to re-adjust the speed as
necessary. The required quantity of wire
depends on the material thickness, the
penetration depth, the welding wire diameter
and also the size of the gap to be bridged
between the workpieces you wish to weld.
Electrical connection
-Before you connect the equipment to the mains
supply make sure that the data on the rating plate
are identical to the mains data.
-The equipment may only be operated from
properly earthed and fused shock-proof sockets.
Connecting the earth terminal
-Connect the welding set’s earth terminal (8) in
the immediate vicinity of the welding position if
possible. Ensure that the contact point is bare
metal.
Welding
-When all the electrical connections for the power
supply and welding current circuit have been
made, you can proceed as follows:
-The workpieces for welding must be clear of
paint, metallic coatings, dirt, rust, grease and
moisture in the area where they are to be welded.
-Set the welding current and wire feed
-Hold the welding screen (13) in front of your face
and move the welding nozzle to the point on the
workpiece where you wish to complete the weld.
Now press the torch switch (14).
-When the arc is burning, the welding set will feed
wire into the weld pool. When the weld nugget is
large enough, move the torch slowly along the
required edge. Move it to and fro if necessary to
enlarge the weld pool a little.
-Find the ideal setting of the welding current and
wire feed speed by carrying out a test weld. Ideally
an even welding noise will be audible. The
penetration depth should be as deep as possible,
but the weld pool must not be allowed to fall
through the workpiece.
MIG100/MIG130 11

OPERATION /MAINTENANCE AND SERVICE
-Do not remove the slag until the weld has
cooled. If you want to continue a welding job on
an interrupted weld seam, the slag from your
initial attempt must first be removed.
Safety equipment
Thermostat
The welding set is fitted with an overheating
guard that protects the welding transformer
from overheating. If the overheating guard trips,
the control lamp (2) on your set will be lit. Allow
the welding set to cool for a time.
Maintenance and Service
Always pull out the mains power plug before
starting any cleaning work.
Cleaning
-Keep all safety devices, air vents and the motor
housing free of dirt and dust as far as possible.
Wipe the equipment with a clean cloth or blow it
down with compressed air at low pressure.
-We recommend that you clean the equipment
immediately after you use it.
-Clean the equipment regularly with a damp cloth
and some soft soap. Do not use cleaning agents or
solvents; these may be aggressive to the plastic
parts in the equipment. Ensure that no water can
get into the interior of the equipment.
Servicing
There are no parts inside the equipment
which require additional maintenance.
MIG100/MIG130 12

AUTOJACK GUARANTEE
1. Guarantee
1.1 Autojack guarantees that for a period of 12
months from the date of purchase the
components of qualifying products (see clauses
1.2.1 to 1.2.8) will be free from defects caused
by faulty construction or manufacture
1.2 During this period, Autojack, will repair or
replace free of charge any parts which are
proved to be faulty in accordance with
paragraph 1.1 providing that:
1.2.1 You follow the claims procedure set out in
clause 2.
1.2.2 Autojack and its Authorised Dealers are
given reasonable opportunity after receiving
notice of the claim to examine the product.
1.2.3 If asked to do so by Autojack or its
Authorised Dealer, you return the product at
your own cost to Autojack’s or the supplying
Authorised Dealer’s Premises, For the
examination to take place clearly stating the
Returns Material Authorisation Number given by
Autojack or an Authorised Dealer.
1.2.4 The fault in question is not caused by
industrial use, accidental damage, fair wear and
tear, wilful damage,
neglect, incorrect electrical
connection, misuse, alteration or repair of the
product without approval.
1.2.5 The product has been used in a domestic
environment only.
1.2.6 The fault does not relate to consumable
items such as blades, bearings, drive belts or other
wearing parts which can reasonably be expected
to wear at different rates depending on usage.
1.2.7 The product has not been used for hire
purposes.
1.2.8 The product has been purchased by you, as
the guarantee is not transferable from a private
sale.
2. Claims Procedure
2.1 In the first instance please contact the
Authorised Dealer who supplied the product to
you. In our experience many initial problems with
machines that are thought to be fault due to faulty
parts are actually solved by correct setting up or
adjustment of the machine. A good Authorised
Dealer should be able to resolve the majority of
these issues much more quickly than processing a
claim under the guarantee. If a return is requested
by the Authorised Dealer or Autojack, you will be
provided with a Returns Material Authorisation
Number which must be clearly stated on the
returned package, and any accompanying
correspondence. Failure to provide a Returns
Material Authorisation Number may result in item
being refused delivery.
MIG100/MIG130 13

AUTOJACK GUARANTEE
2.2 Any issues with the product resulting in a
potential claim under the guarantee must be
reported to the Authorised Dealer from which it
was purchased within 48 hours of receipt.
2.3 If the authorised Dealer who supplied the
product to you has been unable to satisfy your
query, any claims made under this guarantee
should be made directly to Autojack. The claim
itself should be made in a letter setting out the
date and place of purchase, giving a brief
explanation of the problem which has led to the
claim. This letter should be then sent with proof
of purchase to Autojack. If you include a contact
number with this it will speed your claim up.
2.4 Please note that it is essential that the letter
of claim reaches Autojack on the last day of this
guarantee at the latest. Late claims will not be
considered.
3. Limitation of Liability.
3.1 We only supply products for domestic and
private use. You agree not to use the product for
any commercial, business or resale purposes and
we have no liability to you for any loss of profit,
loss of business, business interruption or loss of
business opportunity.
3.2 This guarantee does not confer any rights
other than these expressly set out above and does
not cover any claims for consequential loss or
damage. This guarantee is offered as an extra
benefit and does not affect your statutory rights as
a consumer.
4. Notice
This guarantee applies to all product purchased
from an Authorised Dealer of Autojack within the
United Kingdom. Terms of guarantee may vary in
other countries.
MIG100/MIG130 14

CE DECLARATION OF CONFORMITY
TOOLSAVE
Unit C, Manders Ind. Est.,
Old Heath Road, Wolverhampton,
WV1 2RP.
Tel: [phone]
Declares that the Welding Maching Mig Master (MIG100/MIG130)
Is in compliance with the regulations included in the Directives:2006/42/EC
EC DECLARATION OF CONFORMITY
Certificate for EC-type examination delivered by AV Technology Ltd. Unit 2 Easter Court,
Europa Boulevard, Warrington, Cheshire, WA5 7ZB (Certificate No.:GB/1067/5862/16 )
Person who declares: Bill Evans
01.03.2017
The Director
MIG100/MIG130 15

No. Description No. Description
1 Screw 18 Nut
2 Handle 19 Potentionmeter
3 Top panel 20 PC board
4 Left panel 21 Welding torch
5 Middle panel 22 Kickstand
6 Wire feed 23 Knob
7 Screw 24 Fan
8 Wire spool holder 25 Overheating indicator light
9 Screw 26 Power switch
10 Spacer 27 Adjustment switch
11 Nut 28 Water joint
12 Rivet 29 Earth clamp
13 Guard ring of torch 30 Plug
14 Transformer 31 Screw
15 Bottom panel 32 Plastic foot
16 Thermal protection 33 Screw spacer
17 Screw 34 Right panel
Parts List
MIG100/MIG130 16

Parts Diagram
MIG100/MIG130 17