6E/ARS

CRRFTSMRKOperator's Guide

WIRE FEEDMIG WELDERModel No.934.20511 1

. WARRANTYo INTRODUCTION• SAFETY SUMMARYo SPECIFICATIONS

o INSTALLATIONo OPERATION° MAINTENANCEo SCHEMATIC• WIRING DIAGRAM° REPLACEMENT PARTS• ESPANOL

CAUTION: Read and follow

all Safety Rules andOperating Instructions beforeFirst Use of this Product.

Sears, Roebuck and Co., Hoffman Estates, IL 60179 USA

811-635-000 Rev, A (,January 2001)

On Welding Gun or Cables, Welder, and Welder's Transformer

Full One Year Warranty for CraftsmanWelding Gun or Cables. For one yearfrom the date of purchase, when thewelding gun or cables are operated andmaintained according to the owner'smanual instructions, if the welding gunor cables fail due to a defect in material

or workmanship, Sears will repair orreplace the welding gun or cables free ofcharge. This warranty does not coverparts consumed in normal operation,such as contact tips, nozzles, gun liners,and drive rollers

Full Three.._ear Warranty on CraftsmanWelder For three years from the date ofpurchase, when the welder is operatedand maintained according to the owner'smanual instructions, if the welder failsdue to a defect in material or

workmanship, Sears will repair orreplace the welder free of charge. Thiswarranty does not cover the weldinggun, cables, or normal consumableparts._

WARRANTY SERVICE IS AVAILABLEBY SIMPLY CONTACTING THENEAREST SEARS SERVICE CENTER.

This warranty applies only while thisproduct is in use in the United States°

This warranty gives you specific legalrights, and you may also have otherrights which vary from state to state.

Sears Roebuck and Co., Dept. 817WA,Hoffman Estates, IL 60179.

2

CRAFTSMAN FULL WARRANTY ......................................................... 2TABLE OF CONTENTS ......................................................................... 3INTRODUCTION .................................................................................... 4SAFETY SUMMARY ............................................................................... 5

SAFETY INFORMATION ......................................................................... 5SHOCK HAZARDS ............................................................................... 6FIRE HAZARDS .............................................................................................. 6FLASH HAZARDS ............................................................................................ 6FUME HAZARDS .......................................................................................................6COMPRESSED GASSES AND EQU1PMENT HAZARDS .................. 6BURN HAZARDS .... ..........................................................................................7

ADDITIONAL SAFETY INFORMATION ................................................... 7WELDER SPECIFICATIONS .................................................................. 8

DESCRIPTION .................................................................................................... 8WELDER OPERATING CHARACTERISTICS .................................................8

DUTY CYCLE ..................................................................................... 8INTERNAL THERMAL PROTECTION .................................................. 8

WELDER INSTALLATION ..................................................................... 9POWER SOURCE CONNECTION .......................................................... 9

POWER REQUIREMENTS ........................................................................... 9CONNECT TO POWER SOURCE .............................................................. 9EXTENSION CORDS ................................................................................. 9

ASSEMBLING THE WELDER ............................................................................9UNPACKING THE WELDER ..................................................................... 9INSTALL THE GROUND CLAMP ......................................................................9INSTALL THE TANK TRAY AND BRACKET ............................................. 9INSTALL THE SHIELDING GAS .............................................................. 10

CHECK THE GAS FLOW ........................................................................................11ALIGN AND SET THE DRIVE ROLLER ............................................. 1 t

STANDARD DRIVE ROLLER ..................................................................... 11NEOPRENE DRIVE ROLLER ..................................................................... 12

INSTALL THE WELDING WIRE ......................................................................13SET THE WIRE DRIVE TENSION ............................................................ 15CHANGE POLARITY .................................................................................... t 5

OPERATION ......................................................................................... 16CONTROLS AND INDICATORS .............................................................. 16

MAINTENANCE .................................................................................... 17GENERAL ............................................................................................................ 17

REPLACE A GUN LINER .......................................................................... 17MAINTAINING THE CONTACT TIP ...................................................... 19MAINTAINING THE NOZZLE ..................................................................... t9TESTING FOR A SHORTED NOZZLE ............................................ 20PREVENTIVE MAINTENANCE ......................................................... 20

TROUBLESHOOTING ......................................................................... 20SCHEMATIC ......................................................................................... 22WIRING DIAGRAM ............................................................................... 23REPLACEMENT PARTS LIST ............................................................. 24

3

This Welder User's Guide providesspecific information about your wire feedwelder° It is to be used together with theWelding Instruction Guide to provide allof the information needed to safely and

effectively use your wire feed welder.The information in this book applies toyour specific model of wire feed welderand gives instruction on set-up,installation, and actual use of thewelder.

Where information is shown that does

not necessarily apply to all models orbrands of welder, it will be marked aseither optional on some welder modelsor does not apply to all models,

4

Every craftsman respects the tools withwhich they work. They know that thetools represent years of constantlyimproved designs and developments.The true craftsman also knows that tools

are dangerous if misused or abused.

Reading this Operator's Guide and theWelding Instruction Guide before usingthe welder will enable you to do a better,safer job. Learn the welder'sapplications and limitations as well asthe specific potential hazards peculiar towelding

SAFETY INFORMATION

The following safety information isprovided as guidelines to help youoperate your new welder under thesafest possible conditions Anyequipment that uses electrical powercan be potentially dangerous to usewhen safety or safe handling instructionsare not known or not followed. The

following safety information is providedto give you the information necessary forsafe use and operation°

When a procedure step is preceded bya WARNING, it is an indication that thestep contains a procedure that might beinjurious to a person if proper safetyprecautions are not heeded,

When a procedure step is preceded bya CAUTION, it is an indication that the

step contains a procedure that mightdamage the equipment being used.

A NOTE may be used before or after aprocedure step to highlight or explainsomething in that step,

READ ALL SAFETY INSTRUCTIONSCAREFULLY before attempting toinstall, operate, or service this welder.Failure to comply with these instructionscould result In personal injury and/orproperty damage.

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE.

Note: The following safety alertsymbols identify important

safety messages in thismanual,.

When you see one of the symbolsshown here, be alert to the possibility ofpersonal injury and carefully read themessage that follows.

This symbol indicates that thepossibility of electric shockhazard exists during theoperation of the step(s) thatfollow.

This symbol indicates that thepossibility of fire hazard existsduring the operation of thestep(s) that follow.

This symbol indicates that thehelmet must be worn duringthe step(s) that follow toprotect against eye damageand bums due to flashhazard,

This symbol indicates that thepossibility of toxic gas hazardexists during operation of thestep(s) that follow.

This symbol indicates that thepossibility of being burned byhot slag exists duringoperation of the step(s) thatfollow.

This symbol indicates that theeye protection should be wornto protect against flying debrisin the following step(s)

This symbol indicates that thepossibility of injury or deathexists due to improperhandling and maintenance ofcompressed gas cylinders orregulators

Full explanations of the specific hazardsare shown in the WELDING

INSTRUCTION GUIDE. Make sure youhave read and understand all of the

5

information before proceeding with anyof the instructions contained in this

user's guide_

Published standards on safety areavailable. They are listed inADDITIONAL SAFETY INFORMATIONat the end of this SAFETY SUMMARY,,

The National Electrical Code,

Occupational Safety and Health Actregulations, local industrial codes andlocal inspection requirements alsoprovide a basis for equipmentinstallation, use, and service

SHOCK HAZARDS

WARNING

FLASH HAZARDS

WARNING

ARC RAYS CAN INJURE EYESAND BURN SKIN! To reduce risk of

injury from arc rays, read,understand, and follow the followingsafety instructions° In addition, makecertain that anyone else that usesthis welding equipment, or is abystander in the welding area,understands and follows these safetyinstructions as well,

FUME HAZARDS

ELECTRIC SHOCK CAN KILL! Toreduce the risk of death or serious

injury from shock, read, understand,and follow the following safetyinstructions, tn addition, make

certain that anyone else who usesthis welding equipment, or who is abystander in the welding areaunderstands and follows these safetyinstructions as welt,

FIRE HAZARDS

WARNING

FIRE OR EXPLOSION CAN CAUSE

DEATH, INJURY, AND PROPERTYDAMAGE! To reduce risk of death,

injury, or property damage from fireor explosion, read, understand, andfollow the following safetyinstruction& tn addition, makecertain that anyone else that usesthis welding equipment, or is abystander in the welding area,understands and follows these safetyinstructions as well. REMEMBER!

Welding by nature produces sparks,hot spatter, molten metal drops, hotslag, and hot metal parts that canstart fires, burn skin, and damage

eyes,6

WARNING

FUMES, GASSES, AND VAPORSCAN CAUSE DISCOMFORT,ILLNESS, AND DEATH! To reducerisk of discomfort, illness, or death,read, understand, and follow thefollowing safety instructions. Inaddition, make certain that anyoneelse that uses this welding equipmentor is a bystander in the welding area,understands and follows these safetyinstructions as well

COMPRESSED GASSES AND

EQUIPMENT HAZARDS

WARNING

IMPROPER HANDLING ANDMAINTENANCE OF COMPRESSEDGAS CYLINDERS ANDREGULATORS CAN RESULT INSERIOUS INJURY OR DEATH! To

reduce risk of injury or death fromcompressed gasses and equipmenthazards, read understand and follow

the following safety instructions, Inaddition, make certain that anyoneelse who uses this welding

equipmentor a bystander in theweldingarea understandsandfollowsthesesafety instructionsaswell.

Do not use flammablegasseswithMIGwelders. Only inert ornonflammablegassesare suitableforMIGwelding. Examplesare CarbonDioxide,Argon,Helium,etc. ormixturesof more thanone of thesegasseso

BURN HAZARDS

WARNING

Hot slag can cause fires andserious injury from burns. Toreduce the risk of discomfort or

serious injury due to burns alwayswear heavy protective clothing, eyeand face protection, and glovesdesigned for welding. To prevent therisk of fires starting, use a metal plateor some other material with a highflash point to catch and shieldcombustibles from the hot slag

ADDITIONAL SAFETYINFORMATION

For additional information concerningwelding safety, refer to the followingstandards and comply with them asapplicable.

o ANSl Standard Z49.1 -- SAFETY INWELDING AND CUTTING --obtainable from the American Welding

Society, 550 NW Le Jeune Road,Miami, FL 33126 Telephone (800)443-9353, Fax (305) 443-7559www,amweldoorg or www aws.org

° ANSI Standard Z87.1 -- SAFEPRACTICE FOR OCCUPATION ANDEDUCATIONAL EYE AND FACEPROTECTION -- obtainable from theAmerican National Standards Institute,11 West 42 _ Sto, New York, NYt0036 Telephone (212) 642-4900,Fax (212) 398-0023 --- www.ansi.org

o NFPA Standard 51B --- CUTTINGAND WELDING PROCESS --obtainable from the National Fire

Protection Association, tBatterymarch Park, P.O. Box 9t01,Quincy, MA 02269-9101 Telephone(617) 770-3000, Fax (617) 770-0700.--- www.nfpa..org

* CGA Pamphlet Pq -- SAFEHANDLING OF COMPRESSEDGASSES IN CYLINDERS --

obtainable from the Compressed GasAssociation, 1725 Jefferson DavisHighway, Suite 1004, Arlington, VA22202-4102 Telephone (703) 412-0900 Fax (703) 412-0128-www cagneLcom

. OSHA Standard 29 CFR, Part 1910,Subpart Q., WELDING, CUTTINGAND BRAZING --- obtainable from

your state OSHA office or U. S. Dept.of Labor OSHA, Office of PublicAffairs, Room N3647, 200 Constitution

Ave Washington, DC 20210--wwwoshagov

. CSA Standard W1172 -- Code forSAFETY IN WELDING ANDCUTTING° w obtainable from

Canadian Standards Association, 178Rexdale Btvd. Etobicoke, OntarioM9W 1R3 -- wwwcs&ca

o American Welding Society StandardA60. WELDING AND CUTTINGCONTAINERS WHICH HAVE HELDCOMBUSTIBLES. -- obtainable from

the American Welding Society, 550NW Le Jeune Road, Miami, FL 33126Telephone (800) 443-9353, Fax (305)443-7559 -- wwwoamweldorg orwww. awsoorg

DESCRIPTION

Your new wire feed welder is designedfor maintenance and sheet metalfabrication. The welder consists of a

single-phase power transformer,stabilizer, rectifier, and a unique built-incontrol/feeder_

Now you can weld sheet metal from 26gauge up to 3/16 inch thick with a singlepass,. You can weld thicker steel withbeveling and multiple pass techniques..Table 1 lists your MIG welderspecifications.

Table 1. Welder Specifications

Primary (input) volts 120 VacPrimary (inputs) Amps 20Phase SingleFrequency 60 HzSecondary (output) volts 18_5Secondary (UL output) amps 90Open Circuit Volts (Max.) 28 VdcDuty Cycle Rating 20%

MIG welders equipped with gas arecapable of welding with 0_024 (0.6mm)and 0.030 (0.Smm) solid steel wire on dcreverse polarity and with 0_030 (0.Smm)self-shielding flux-core wire on dcstraight polarity. Larger, 0.035 inch(0.gmm) diameter solid steel wire, on dcreverse polarity may also be used onthis welder. The use of larger diameterwire makes welding difficult and theresults cannot be guaranteed. Themanufacturer does not recommend the

use of larger diameter wire.

WELDER OPERATINGCHARACTERISTICS

DUTY CYCLE

The duty cycle rating of a welder defineshow long the operator can weld and howlong the welder must be rested andcooled. Duty cycle is expressed as apercentage of 10 minutes and

represents the maximum welding timeallowed. The balance of the 10-minute

cycle is required for cooling_

Your new welder has a duty cycle ratingof 20% at the rated output. This meansthat you can weld for two (2) minutes outof 10 with the remaining eight (8) minutesrequired for cooling. (See Table 2).

Table 2. Duty Cycle Ratings

Duty Maximum RequiredCycle Welding RestingRating Time Time

20% 2 minutes 8 minutes

40% 4 minutes 6 minutes60% 6 minutes 4 minutes80% 8 minutes 2 minutes

100% 10 minutes 0 minutes

INTERNAL THERMALPROTECTION

CAUTION

Do not constantly exceed the dutycycle or damage to this welder canresult. If you exceed the duty cycle ofyour welder, an internal thermalprotector will open, shutting off allwelder functions except the coolingfan If this happens, DO NOT SHUTOFF THE WELDER. Leave the

welder turned on with the fan running.After cooling, the thermal protector willautomatically reset and the welder willfunction normally again. However,you should wait at least 10 minutesafter the thermal protector opensbefore resuming welding. You mustdo this even if the thermal protectorresets itself before the t0 minutes is

up or you may experience tess thanspecified duty cycle performance.

If you find that your welder will not weldfor 2 minutes without stopping, reducethe wire speed slightly and tune thewelder in at the lowest wire speedsetting that still produces a smooth arc_Welding with the wire speed set too highcauses excessive current draw and

shortens the duty cycle°

POWER SOURCECONNECTION

POWER REQUIREMENTS

This welder is designed to operate on aproperly grounded 120 Volt, 60 Hz,single-phase alternating current (ac)power source fused with a 20 amp time-delayed fuse or circuit breaker, tt isrecommended that a qualified electrician

verify the ACTUAL VOLTAGE at thereceptacle into which the welder will beplugged and confirm that the receptacleis properly fused and grounded. Theuse of the proper circuit size caneliminate nuisance circuit breaker

tripping when welding

DO NOT OPERATE THIS WELDER if

the ACTUAL power source voltage isless than 105 Volts ac or greater than!32 Volts ac. Contact a qualifiedelectrician if this problem exists..Improper performance and/or damage tothe welder will result if operated oninadequate or excessive power'.

CONNECT TO POWER SOURCE

WARNING

High voltage danger from powersource! Consult a qualified electricianfor proper installation of receptacle atthe power source

This welder must be grounded while inuse to protect the operator fromelectrical shock. If you are not sure ifyour outlet is properly grounded, have itchecked by a qualified electrician Donot cut off the grounding prong or alterthe plug in any way and do not use anyadapters between the welder's powercord and the power source receptacle.

Make sure the POWER switch is OFF

then connect your welder's power cordto a properly grounded I20 Vac, 60 Hz,single phase, 20 amp power source.

EXTENSION CORDS

For optimum welder performance, anextension cord should not be used

unless absolutely necessary,. Ifnecessary, care must be taken inselecting an extension cord appropriatefor use with your specific welder.

Select a properly grounded extensioncord that will mate directly with the acpower source receptacle and the welderpower cord without the use of adapters°Make certain that the extension is properlywired and in good electrical condition.

Extension cords must be at the smallest

a #12 gauge cord.. Do not use anextension cord over 25 ft.. in length..

ASSEMBLING THEWELDER

The following procedures describe theprocess required to assemble, install,maintain, and prepare to weld with yournew wire feed welder°

UNPACKING THE WELDER

1 Remove any cartons or bagscontaining parts/accessories

2 Open the cartons or bags packedwith your welder and inspect theircontents for damage. Report anymissing or damaged itemsimmediately

3 Grasp the top handle of the welderand lift the welder out of the carton.

INSTALL THE GROUND CLAMP

Connect the ground clamp to the groundcable (coming out the front of thewelder) according to the instructionspackaged with the ground clamp.

INSTALL THE TANK TRAY

AND BRACKET

The tank tray bracket is installed on theback of the welder, see Figure 1.

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IMPORTANT - GAS CYLINDER SIZE

RESTRICTION! The tank tray you havejust installed on the back of tile welderwill handle gas cylinders no larger than20 cubic feet., tf you select a cylinderlarger than 20 cubic feet, it must bechained to a wall or other fixed support.

2

" 3

Figure 1, Mount Tank Tray Bracket-Ib Welder

1.

2_

Align the four tank tray bracket (1)mounting holes (as shown in Figure1) with the four staked nuts on therear of the welder

Start one 1.4inch split lock washer(2) and a 1A-20 x 1/2inch hex bolt (3)in one of the top tank tray bracket(1) mounting holes, then start eachof the other three split lock nuts (2)and ¼-20 x 1/2inch hex bolts (3)through the remaining mountingholes.

3.. Tighten all four hex bolts..

If you have an optional cart with thewelder, the tank tray bracket is installedat the rear of the cart, below the welder,

see Figure 2

t

Figure 2.

2

//

1

I• :1\

'3 4

Mount Tank Tray BracketTo Cart

10

Align the tank tray bracket (1) to fitbetween the legs at the back of thecart (2) (as shown in Figure 2) sothat the mounting holes are alignedwith the four staked nuts on the rearof the cart.

2 Start one ¼ inch split lock washer(3) and a ¼-20 x Y2 inch hex bolt (4)in one of the top tank tray bracket(1) mounting holes then start eachof the other three split lock washers(2) and ¼ inch hex bolts (3) throughthe remaining mounting holes.

3 Tighten all four inch hex bolts°

INSTALL THE SHIELDING GAS

WARNING

IMPROPER HANDLING ANDMAINTENANCE OF COMPRESSEDGAS CYLINDERS AND REGULATORSCAN RESULT IN SERIOUS INJURY

OR DEATH! Always secure gascylinders to the tank bracket kit, a wail,or other fixed support to prevent thecylinder" from falling over and rupturing°Read, understand, and follow all theCOMPRESSED GASSES ANDEQUIPMENT HAZARDS in the SAFETYSUMMARY at the front of this manual.

Secure your gas cylinder to the tankbracket kit, a wall, or other fixed support,.

1 Remove the protective cap from thecylinder and inspect the regulatorconnecting threads for dust, dirt oil,and grease. Remove any dust ordirt with a clean cloth. DO NOTATTACH THE REGULATOR IF OIL,GREASE, OR DAMAGE AREPRESENT.

2 Open the cylinder valve FOR JUSTAN INSTANT to blow out anyforeign matter inside the valve portto reduce the risk of plugging ordamaging the regulator° Never aimthe open cylinder valve port atyourself or bystanders.

3 Screw the preset regulator supplied

with this welder (see Figure 3) intothe cylinder valve and tighten with awrench..

Q

Figure 3. Preset Regulator

4. Insert the gas hose into the outletport of the gas regulator The hoselocks in place in the fitting whenpressed into the port

5. To remove the gas hose, pressdown on the ring at the rear of thegas fitting, and pull the hose out ofthe fitting.

CHECK THE GAS FLOW

WARNING

IMPROPER HANDLING ANDMAINTENANCE OF COMPRESSEDGAS CYLINDERS AND REGULATORSCAN RESULT IN SERIOUS INJURYOR DEATH! To reduce tile risk of injuryor death, always stand to the side of thecylinder opposite the regulator whenopening the cylinder valve, keeping thecylinder valve between you and theregulaton Never aim the open cylindervalve port at yourself or bystanders.Failure to comply with this warning couldresult in serious personal injury.

Note: If the cylinder you have isequipped with male regulatorconnecting threads hqstead offemale, you will need to obtaina special compressed gascylinder adapter from your gassupplier to install between yourgas cylinder and regulator,,

• The gas control function doesnot require the welder to beturned on or plugged in

Note:

Slowly crack open the cylindervalve, then turn open ALL THEWAY.

Pull the trigger on the gun to allowthe gas to flow.. KEEP THETRIGGER PULLED. Listen and

feel for gas flowing from the end ofthe welding gun. If your regulatorhas no adjustment, it has been pre-set at the factory for a flow of 20cubic feet per hour° If your gasregulator has an adjustment tocontrol the gas flow rate, turn theadjustment key clockwise toincrease gas flow; counterclockwiseto reduce flow_ For most welding,the gas flow should be set at 15-20cubic feet per hour.. If no gas isheard or felt, verify all stepsinvolved in connecting the ga&

Refease the trigger

If welding outside or in a draft, itmay become necessary to setup a windbreak to keep theshielding gas from being blownfrom the weld area°

MAKE SURE TO TURN OFFTHE GAS CYLINDER VALVEWHEN DONE WELDING,,

ALIGN AND SET THE DRIVEROLLER

Before installing any welding wire intothe unit, the proper sized groove mustbe placed into position on the wire drivemechanism Change to a neoprenedrive roller when welding with aluminumwire

STANDARD DRIVE ROLLER

Change the standard drive rolleraccording to the following steps:

1 Remove the drive tension byunscrewing the tension adjustingscrew (ALL THE WAY in a counter-clockwise direction) The drivetension screw will come loose,

allowing you to pull the drivetension arm up away from the driveroller Make sure to keep the screwand the spring in place with thedrive tension arm

11

,

3_

If there is wire already installed inthe welder, roll it back onto the wirespool by hand-turning the spoolcounter-clockwise. Be careful notto allow the wire to come out of therear end of the gun without holdingonto it or it will unspool itself. Putthe end of the wire into the hole on

the outside edge of the wire spooland bend it over to hold the wire in

place. Remove the spool of wirefrom the welder.

Loosen the drive roller setscrew

and pull the drive roller off the driveshaft.

Note:

4_

The drive roller has two wire

size grooves built into it.. Wheninstalling the drive roller thenumber stamped on the driveroller for the wire size you areusing should be facing awayfrom you. If you can read thewire size you are using on thedrive roller, it is installedbackwards. Use only theproper size drive roller whenusing your welder_

Find the side of the drive roller that

is stamped with the same wirediameter as that of the wire beinginstalled (see Figure 4, and if inmetric, see DESCRIPTtON)_ Makecertain the spacing wast_er is still onthe motor shaft and push the driveroller onto the motor shaft, aligningthe setscrew with the flat side of thedrive shaft. Make sure the side

stamped with the desired wirediameter is away from you

Drive Roller

Shaft

SpacingWasher

5. Slide the roller onto the shaft so that

the groove in the roller lines up withthe inlet tube and the welding gunliner. You can look at the alignmentfrom the top of the welder.

6 Tighten the setscrew, while holdingtlqe drive roller in place.

NEOPRENE DRIVE ROLLER

Change to the neoprene drive ro!leraccording to the following steps:

1 Remove the drive tension byunscrewing the tension adjustingscrew (ALL THE WAY in a counter-clockwise direction). The drivetension screw will come loose,allowing you to pull the drivetension arm up away from the driveroller Make sure to keep the screwand the spring in place with thedrive tension arm

If there is wire already installed inthe welder, roll it back onto the wirespool by hand-turning the spoolcounter-clockwise_ Be careful notto allow the wire to come out of the

rear end of the gun without holdingonto it or it will unspoot itself.. Putthe end of the wire into the hole on

flqe outside edge of the wire spooland bend it over to hold the wire in

place, Remove the spool of wirefrom the welder.

3 Loosen the setscrew in thestandard drive roller and remove it

and the spacing washer from thedrive shaft.

4 Do not use the spacing washer°The spacing washer is for use withthe standard drive roller only. Savethe spacing washer with thestandard drive roller

While holding the side of theneoprene drive roller that has thesetscrew toward you (see Figure 5),push the neoprene drive roller ontothe motor shaft as far as it will go..Align the setscrew with the flat sideof the drive shaft

Figure 4. Drive Roller

12

MotorShat{

Figure 5. Drive Assembly &Neoprene Drive Roller

6. Tighten the setscrew, while holdingthe drive roller inplace

7o Remove the screws that retain the

inlet guide tube. Replace theplastic inlet guide tube with thesupplied brass inlet guide tubeSecure screws.

Note: The tapered side of the brassinlet guide tube should be asclose to the rollers as possiblewithout touching,

It is not necessary to reinstallthe plastic inlet guide tube whenswitching back to the standarddrive roller. However, if youexperience some binding,readjust the brass inlet guidetube slightly away from thedrive roller.

INSTALL THE WELDINGWIRE

WARNING

Electric shock can kill! Always turnthe POWER switch OFF and unplug thepower cord from the ac power sourcebefore installing wire.,

Be very careful when removing thewelding nozzle. The contact tip on thiswelder is electrically hot as long asPOWER is turned ON, Make certainPOWER is turned OFF,

t. Remove the nozzle and contact tipfrom the end of the gun assembly..

2. Make sure the proper groove onthe drive roller is in place for thewire being installed, if the propergroove is not in place, change thedrive roller as described above,

3 Unwrap the spool of wire then findthe leading end of the wire (it goesthrough a hole in the outer edge oftime spool and is bent over thespool edge to prevent the wire fromunspooling) BUT DO NOTUNHOOK IT YET,

4 Place the spool on the spindle insuch a manner that when the wire

comes off the spool, it will look likethe top illustration in Figure 6. Thewelding wire should always comeoff the top of the spool into the drivemechanism.

Figure 6, Right and Wrong Way ToFeed Wire From Spool

5 tf you are installing a fourqnchspool of wire, install the drive brakehardware on the top of the spool ofwire according to Figure 7Ao If youare installing an eight-inch spool,install the spindle adapter anddrive brake hardware as shown in

Figure 7B. The purpose of the drivebrake is to cause the spool of wireto stop turning at nearly the samemoment that wire feeding stops.

6 Once the drive brake hardware is

installed, set the spool tension°With one hand, turn the wire spooland continue turning it whileadjusting the tension on the spool.With your free hand, tighten (turnclockwise) the wing nut that holdstime spool in place Stop tighteningwhen drag is felt on the wire spoolthat you are turning, then stop handturning the wire spool.

13

A

4" Spool ....:8" Spool

Figure 7. Drive Brake Assemblieswith Four Inch and Eight Inch Wire

Spools

Note:

,,

aN

.

10.

tf TOO MUCH tension is

applied to the wire spool, thewire will slip on the drive rolleror will not be able to feed at all.If TOO LITTLE tension is

applied, the spool of wire willwant to unspool itself Readjustthe drive brake tension as

necessary to correct for eitherproblem,

After checking to make sure thatyour welder is disconnected fromthe ac power source, free theleading end of the wire from thespool, but do not let go of it until toldto do so, or the wire will unspoolitself.

Using a wire cutter, cut the bent endoff the leading end of the wire sothat only a straight leading endremains.

Loosen the tension adjusting screwholding the drive tension arm inplace and lift the tension arm up offthe drive roller.

Insert the leading end of the wireinto the inlet guide tube Then pushit across the drive roller and into the

gun assembly about six inches,

CAUTION

Make certain that the welding wire isactually going into the gLm liner Bevery sure it has not somehow beenaccidentally been routed alongsidethe liner or even in some other

14

direction. If this should happen, thewire could feed inside the cablecasing or take a right angle and followthe wires and gas hose inside thewelder. It could also feed back on

itself jamming up the mechanism.

11 Line the wire up in the insidegroove of the drive roller, then

allow the drive tension arm to droponto the drive roller_.

12 Tighten (turn clockwise) the drivetension adjusting screw until thetension roller is applying enoughforce on the wire to prevent it fromslipping out of the drive assembly,

13 Let go of the wire.

t4 Connect the welder power cord tothe ac power source. Turn thewelder ON by setting the VOLTAGE

switch to the voltage (heat) settingrecommended for the gauge metalthat is to be welded Refer to the

label mounted on the cover, insidethe drive compartment, for

recommended voltage (heat)settings for your welding job. TheVOLTAGE selector controls the weldheal There is an OFF and four

voltage (heat) selections(numbered 1 through 4) availableon this welder. Numbered positiont provides the lowest voltage(heat) and position 4 the highestvoltage (heat).

15 Set the WIRE SPEED control to the

rniddfe of the wire speed range,

16 Pull the trigger on the welding gunto feed the wire through the gunassembly

17 When at least an inch of wire sticks

out past the end of the gun, releasethe trigger

18 Select a contact tip stamped withtile same diameter as the wire

being used. If stamped in metric,see DESCRIPTION,.

19, Slide the contact tip over the wire

(protruding from the end of thegun) Thread the contact tip into theend of the gun and hand-tightensecurely,

20_ Installthe nozzleon the gunassembly. For best results,coat theinsideof the nozzle withantFsticksprayor gel (part#4312,notsupplied).

21_ Cutoff the excesswire that extendspast the end of the nozzle

SET THE WIRE DRIVETENSION

stainless steel, flux cored hardfacing ofsteel, and silicon bronze wetding ofsteel, select dc Reverse Polarity (dc +MIG). When using self-shielding, flux-core steel wire, use dc Straight Polarity(dc - FkJx Cored).L

Change the polarity of your welderaccording to the following procedure steps°Figure 8 shows what the polarity blockshould took like for each polarity setting,

WARNING

To reduce the risk of arc flash, make

certain that the wire coming out ofthe end of the gun does not come incontact with the workpiece clamp orany grounded material during thedrive tension setting process orarcing will occur_

1. Pull the trigger on the gun

2o Turn the drive tension adjustmentknob clockwise, increasing the drivetension until the wire seems to feed

smoothly without slipping

3. Block the end of the nozzle byholding it up against something thatdoesn't conduct electricity, such asa block of wood or a concrete floor,

then trigger the gun again Thewire should slip at the drive roller.However, if the wire bird-nests atthe drive roller, rethread the drive

system using less drive tension andtry again°

4. When the drive tension is set

correctly, there should be noslippage between the wire and thedrive roller. However, if anobstruction occurs along the wirefeed path, the wire should then slipon the drive roller.

WARNING

Electric shock can kill! Always turn thepower OFF and unplug the power cordfrom the ac power source beforechanging polarity.

CAUTION

Do not use a ratchet, crescent or otherlever type wrench to tighten the nutson the polarity bus. The nuts must behand tightened with a 7/16 inch nutdriver only.. Too much torque appliedto the one of the nuts could cause the

threaded post to break off.

Tools Required:

o 7/16 inch nut driver

2

With a 7/16 inch nut driver, removeall four nuts and pull out thevertically mounted copper straps.

Replace the copper strapshorizontally in the dc StraightPolarity (dc -. Flux Cored)configuration shown in Figure &

OC, DC-MIG FLUX CORED

CHANGE POLARITY

This welder allows you the capability tochange the welding current polarity.You may select either dc Straight (dc -Flux Cored) or dc Reverse Polarity (dc +MIG). For welding steel with solid wire,

Figure 8. Welder Polarity Selections

3, Start the four nuts on the four

connecting posts and hand snugeach nut with the 7/16 nut driver.

Do not use a ratchet, crescent orother lever type wrench.

15

Operation of this welder consists ofselecting and adjusting operatingcontrols for optimum voltage (weldingheat) and wire speed settings

CONTROLS ANDINDICATORS

WARNING

Electric shock can kill! To removethe risk of electric shock, be awarethat the VOLTAGE selector, whenOFF, does not remove power from allinternal circuitry in the welder.Whenever the VOLTAGE selector is

in any position except OFF, thewelding circuit is activated, Underthis condition, an arc will occur if thewelding wire or any part of thewelding circuit comes in contact withwelding ground.

VOLTAGE SELECTOR - The voltageselector controls the welding heat Thevoltage selector is numbered 1-4Number 1 is the lowest heat and

number 4 the highest., Refer to the labelunder the welder hood forrecommended heat settings for yourwelding job,

Position 4 on the Voltage Selectorproduces the rated output of 90 amps,The duty cycle at 90 amps is 20%, butwill increase as the heat setting isdecreased.

The position to the left of number t isthe OFF position. In this position, nopower is provided to the welder - thedrive motor and welding power areturned off.. However, as long as thevoltage selector is in one of the fournumbered voltage positions, weldingcircuit is HOT (there is voltage on thecontact tip).

WIRE SPEED CONTROL - The WIRE

SPEED CONTROL adjusts the speed atwhich the wire is fed out of the weldinggun The wire speed needs to beclosely matched (tuned-in) to the rate atwtlich it is being melted off (seeTUNING IN THE WIRE SPEED, in theWELDING INSTRUCTION GUIDE).Some things that affect wire speedselection are the type and diameter ofthe wire being used, the heat settingselected, and the welding position to beused

NOTE: The wire will feed faster withoutan arc. When an arc is beingdrawn, the wire speed will slowdown_

16

GENERAL

This welder has been engineered to givemany years of trouble-free serviceproviding that a few very simple stepsare taken to properly maintain it.

1_ Keep the wire drive compartment lidclosed at all times unless the wireneeds to be changed or the drivetension needs adiusting

2o Keep all consumables (contact tips,nozzles, and gun liner) clean andreplace when necessary. SeeCONSUMABLE MAINTENANCEAND TROUBLESHOOTING later inthis section for detailed information_

3, Replace power cord, ground cable,ground clamp, or gun assemblywhen damaged or worn

4. Periodically clean dust, dirt, grease,etco from your welder Every sixmonths or as necessary, removethe side panels from time welder andair-blow any dust and dirt that mayhave accumulated inside thewelder.

Ddve Drive Gun"{besion Tension Liner

Adiustmenl Arm

WARNING

ELECTRIC SHOCK CAN KILL! To

reduce the risk of electric shock, alwaysunplug the welder from its ac powersource before removing side panels.

IT IS VERY IMPORTANT TO MAINTAINTHE CONSUMABLES TO AVOID THENEED FOR PREMATUREREPLACEMENT OF THE GUNASSEMBLY

The GUN LINER is intended to providean unrestricted path for the welding wireto flow through the gun assembly. Overtime it will accumulate dust, dirt, andotller debris. RepIacement is necessarywhen these accumulations begin torestrict the free flow of wire through thegun assembly

REPLACE A GUN LINER

When removing or installing a gun liner,care must be taken not to kink or

otherwise damage the gun liner orreplacernent wilt be necessary. SeeFigure 9 for the drive assembly andFigure 10 for the gun assembly.

t/4" HexHead Screws

Irfle! GuideTube End

InletGuideTube

DriveAssembly

PMllips Pan Strain, Gunllet_e!

\ Head Screw Clamp AssemblyDrive (Taii End)Rotter

Figure 9. Drive Assembly17

Gun

Cable

PlasticCable Tie

Cable

Switch

HandleCase

Live WireTerminal

GasHose

GasHoseFitting

Conduct.orGas

Valve Tube Insulation

internalStarLockwasher

Head EndGun Liner

Figure 10.

Tools Required:

• 5/16 inch open end wrench

• Crescent Wrench (6 or 8 inch)

• 9 mm open end wrench (or 3 inchcrescent)

• Phillips Screwdriver

° Straight Blade Screwdriver or _A inchhex driver

2,

3.

Turn OFF welder POWER SWtTCH

Open the welder side panel,

Loosen the tension arm and lift it

up off the drive roller.

4, Turn the wire spool counter-clockwise (be sure to hold onto thewire itself while turning the spool orthe wire will unspool itself when itbecomes free of the gun liner),removing wire from gun assembly.

5,. Remove two _A inch hex head

screws (may also be removed witha straight blade screwdriver) andone pan head Phillips screw (inletguide tube end) from the driveroller and lift away the strain reliefclamp that holds the tail end of thegun in the drive assembly.

6,, Leave the gun assembly (consistsof nozzle, gas diffuser, goosemeck,handle and cable containing gastubing electrical cable and liner)attached to the welder but movethe welder to a place where the

18

Gun Assembly

7

8

g,,

10

Note:

11

gun assembly can be laid outstraight on a table or workbench orsimilar flat surface.

Unscrew and remove the nozzle,

With a crescent wrench (six or eightinch), turn the gas diffuserclockwise (has left hand threads)and remove the gas diffuser (andcontact tip together) from theconductor tube on the end of the

gun,

Remove the four Phillips headscrews that hold the handle case

together, With the exception of thetrigger, completely remove thecontents of the handle case,

Cut the plastic cable tie away fromthe cable covering (tubing).

In the following procedure step,it may be necessary to removethe gas fitting from the gasvalve in order to make room toturn out the head end of the

gun liner..

With a 5/16 inch open end wrench,unscrew the head end of the liner

from the gas valve Save theinternal star lock_washer and note

the orientation of the live wire

terminal. If you find it necessary toremove the gas hose connector,press down on the ring at the rearof the gas fitting to release the gaslnose and pull out the gas hose.

Remove the gas fitting with a 9 mmopen end wrench or three inchcrescent.

12,

13,

14.

Note:

Pull the liner out of the cable

covering (tubing) from the handleend and push the small piece ofliner out of the conductor tube

Carefully insert the new liner intothe cable taking particular care tokeep the liner straight (especially atthe terminal end) to ease itspassage through cable covering.. Itmay be desirable, perhaps evennecessary, to apply some silicon

grease to the outside of the newliner so that it will slide easily

through the cable.

Insert the new piece of liner into theconductor tube.

If you found it necessary toremove the gas and hoseconnector at step 9, rememberto reconnect it after completingstep t2 The gas hose can bereconnected by simply pushingit into the back of the connector.

t5o Insert the head of the gun liner

through the internal star lockwasher and the live wire terminal

(repeat the orientation noted instep 9), With a 5!16 inch open endwrench, screw the head end of the

new liner into the gas valve

16 Insert a new plastic cable tie inplace around the cable and tighten

it in approximately the samelocation as the plastic cable tie that

was cut in step 8.

17, Return all components to the

handle casing and realign them asthey were originally..

18. With both halves of the handle

case in place, tighten the fourPhilips pan head screws makingsure the trigger remains seated inplace.

19. Push the cable into the welder far

enough so that the end of the gunliner protrudes through the inlet

guide tube end of the wire-feedtorch clamp far enough so that it iswithin approximately 1/16 inch of

touching the drive roller..

20 Make sure the cable covering

(tubing) is far enough in themachine so that it is covered by thewire-feed torch clamp.

21 Tighten the two 1,4inch hex headscrews (may also be tightened by a

straight blade screwdriver) and onepan head Phillips screw to thedrive roller securing the gun inplace.

22 Re-install the wedding wireaccording to INSTALL THEWELDING WIRE.

MAINTAINING THE CONTACT TIP

The purpose of the CONTACT TIP is totransfer welding current to the weldingwire while allowing the wire to passthrough it smoothly..

Always use a contact tip stamped withthe same diameter as the wire it wil! beused with

t if the wire burns back into the tip,remove the tip from the gun andclean the hole running through itwith an oxygen-acetylene torch tipcleaner or tip drill

2 Over time, the hole in the contact tipwill become worn by the wirepassing through it. The more wornti]is hole becomes, the less efficientis the transfer of welding current totl_e wire and eventually arcbreakage and difficult arc startingwilt result Replace contact tipswhen signs of wear becomeapparent.

MAINTAINING THE NOZZLE

The nozzle directs the shielding gas tothe weld puddle, determines the size ofthe shielding area, and prevents theelectrically hot contact tip fromcontacting the work piece..

CAUTION

KEEP THE NOZZLE CLEAN! Duringthe welding process, spatter and slagwilt build up inside the nozzle andmust be cleaned out periodically..Failure to clean and/or replace thenozzle in a timely fashion WILLCAUSE DAMAGE TO THE FRONT-END OF THE GUN ASSEMBLY°

19

For best results, coat the inside of a new

or freshly cleaned nozzle with anti-stickspray or gel

1. Stop welding and clean anyaccumulated slag or spatter fromthe nozzle every 5 to I0 minutes ofwelding time.

2. When weeding overhead, if anymolten metal drips from the weldpuddle and falls into the nozzle,STOP WELDING IMMEDIATELYand clean the nozzle

3. If the slag cannot be thoroughlycleaned from the nozzle, REPLACETHE NOZZLE!

Failure to keep the nozzle adequatelycleaned can result in the followingproblems:

A SHORTED nozzle results when

spatter buildup bridges the insulation inthe nozzle allowing welding current toflow through it as welt as the contact tip.When shorted, a nozzle wilt stealwelding current from the wire wheneverit contacts the grounded work pieceThis causes erratic welds and reduced

penetration.

In addition, a shorted nozzle overheatsthe end of the gun, which can DAMAGEthe front_end of the gun..

A RESTRICTED nozzle is created when

enough slag builds up in the nozzle toaffect the direction, concentration, andor rate of the shielding gas flow. Thisproblem can cause porous, brittle weldsand reduce penetration

TESTING FOR A SHORTEDNOZZLE

Arcing between the nozzle and the workpiece ALWAYS means the nozzle isshorted, but this can be hard to detectthrough the lens of a welding helmet.The following testing method is anotherway to tell if a nozzle is shorted.,

With the welder unplugged from the acpower source, touch the probes of anohmmeter or continuity tester to the endof the contact tip and the outside of thenozzle. If there is any continuity at all,the nozzle IS shorted.. Clean or replaceas needed.

PREVENTIVE MAINTENANCE

Except for internal and externalcleaning, cleaning the nozzle, andoccasionally retightening screws, thereis no periodic maintenancerecommended for your welder.

TROUBLESHOOTING

The following TROUBLESHOOTINGinformation is provided as a guide tohelp resolve some of the more commonproblems that could be encountered°

Table 3 is a troubleshooting tableprovided to help you determine apossible remedy when you are having aprobtem with your welder This tabledoes not provide all possible solutions,only tlqose possibilities considered tolikely be common faults The tableconsists of a TROUBLE or symptom, aPOSSIBLE CAUSE for that symptom,and a POSSIBLE REMEDY for that

symptorn_

2O

Table 3. Troubleshooting

TROUBLE

Dirty, porous brittleweld

Wire feed works butno arc

Arc works but notfeeding wire

Nothing worksexcept fan

POSSIBLE CAUSE.,,,,,..............................

1. Plugged welding nozzle2 No shielding gas

& Wrong Type of Gas

4. Dirty or rusty welding wire1. Bad ground or looseconnection2, Bad connection to gun orfaulty gun

1.,Faulty wire speed controlassembly2. No tension on the drive roller3. Faulty drive motor (very rare)1 Faulty trigger on gun2. Faulty transformer (rare)3 Exceeded duty cycle; thermalprotector opened

1 Loose connection inside

POSSIBLE REMEDY

1. Clean or replace nozzle2 Tank empty, flow restricted, orregulator set too tow3, See SELECTING SHIELDING

GAS in the WELDING

INSTRUCTION GUIDE for properselection

4.,Replace spool of wireI Check ground and connectionstighten as necessary2, Check connection to gun orreplace gun

I Replace wire speed controlassembly2, Adjust the drive tension3. Replace drive motorI Replace trigger2 Replace transformer3 Allow welder to cool at least 10minutes (observe and maintainproper duty cycleI, Blow inside of machine out with

Low output ornon-penetrating weld

machine

2 Too tong or improperextension cord

3 Wrong type or size wire4 Poor ground connection

5, Wrong size contact tip

compressed air, clean and tightenall connections2 See EXTENSION CORD USE inthis manual3 Use correct size welding wire4 Reposition clamp and checkcable to clamp connection5 Use correct size contact tip

Wire is birdnestingat the drive roller

Wire burns backto contact tip

Ground clamp andlorcable gets hotGun nozzJe arcsto work surface

6. Loose gun connection orfaulty gun assembly7 Wrong welding polarity set8. Dirty or rusty welding wire1 Too much tension on driveroller

2. Gun liner worn or damagedi3 Contact tip is clogged orIdamaged4 Liner is stretched or is too

1 Gun liner is worn or damaged2. Liner stretched or is too long3. Wrong size contact tip4 contact tip clogged ordamaged

Bad connection from cable to

,€!arnpSlag buildup inside nozzle ornozzle is shorted

6 Tighten gun or replace gun7 Change polarity to proper forwire beil_j used8. Replace spool of wire

1, Adjust the drive tension(see INSTALLING THE WELDINGWIRE)2 Replace gun liner3 Replace conlact tip

4 Trim liner to proper length

t Replace gun liner

2 Trim liner for proper length3 Use correct size contact tip4 Replace contact tip

lighten connection or replace cable

Clean or replace nozzle as needed

21

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Model 205111

24

ITEM DESCRIPTION

¥ 20511 Sears 90 amp MIG Welder1 Heat Control Switch

2 Fan

3 Front Panel

4 Strain Relief

5 Cable Assembly

6 Knob

7 6' MfG gun

8 Control Panel

9 Wire Speed control W/Circuit Board

t0 Transformer

11 Left Side Panel

12 Side Latch WtClip

13 Terminal Block

14 Wire Feed Motor

15 Tension Hardware

t6 Spindle

17 Center Panel

t8 Rectifier

19 Fitting

20 Power Cord

21 Bushing

22 Strain Relief

23 Handle W/Hardware

24 Right Side Panel

25 Base

26 Thermo Breaker

27 Tank Bracket

¥ Tweco MIG Gun (6 foot cable)

¥ Tweco MIG Gun (10 foot cable)

28 Contact Tip 0 024' (0,6 mm)

Contact Tip 0 030" (0,8 mm)

29 Nozzle

30 Trigger (MIG Gun)

31 Gun Cable. Complete

32 Handle (With Trigger)

33 Gas Hose

34 Liner

35 Gas Hose Quick Connector

¥ Gun Head: Gas Valve, Conductor Tube. Conductor TubeInsulation, Gas Diffuser

36 Gas Valve

37 Conductor Tube Insulation

38 Conductor Tube

39 Gas Diffuser (M]G Gun)

t Regulator

t" Wire Spool Adaptor (for 8")

1" Urelhane Drive Roller

I" Giound Clamp

l" Welding Face Shield

¥ Complete Assembly

1 Not Shown In Drawing

PART NO,

117-076-002

242-422-666

216-100-666

410_900-010

541_057-666

238-223-666

246-107-666

238-592_000

4t0-868-040

880-418-666

880-410-666

410-865-020

312-295-666

246-414-666

880-406-666

131-419-000

312-076-666

410-960-010

880-402-666

253_333_666

248-327-666

512-215-666

239-074-666

312-296-666

410-864-020

410-866-010

880-415-666

412-635-010

238-592-000

238-593-000

43090

43100

43480

334-440-000

334-465-000

334-495-666

059-217_040

334-468-666

334-467-000

334-490-666

334-491-666

334-493-666

334°492-666

334-494-666

334-438-000

312-110-666

880-427-666

239-010_102

332-239_666

25

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Call 24 hours a day, 7 days a week1-800-4-REPAIR

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