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6E / ARS . WARRANTY o INTRODUCTION • SAFETY SUMMARY o SPECIFICATIONS CRRFTSMRK o INSTALLATION o OPERATION Operator's Guide ° MAINTENANCE o SCHEMATIC • WIRING DIAGRAM WIRE FEED ° REPLACEMENT PARTS • ESPANOL MIG WELDER Model No . 934.20511 1 CAUTION : Read and follow all Safety Rules and Operating Instructions before First Use of this Product . Sears , Roebuck and Co . , Hoffman Estates , IL 60179 USA 811 - 635 - 000 Rev , A ( , January 2001 )
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On Welding Gun or Cables , Welder , and Welder's Transformer WARRANTY SERVICE IS AVAILABLE Full One Year Warranty for Craftsman BY SIMPLY CONTACTING THE Welding Gun or Cables . For one year NEAREST SEARS SERVICE CENTER . from the date of purchase , when the This warranty applies only while this welding gun or cables are operated and product is in use in the United States ° maintained according to the owner's manual instructions , if the welding gun This warranty gives you specific legal or cables fail due to a defect in material rights , and you may also have other or workmanship , Sears will repair or rights which vary from state to state . replace the welding gun or cables free of charge . This warranty does not cover Sears Roebuck and Co . , Dept . 817WA , parts consumed in normal operation , Hoffman Estates , IL 60179 . such as contact tips , nozzles , gun liners , and drive rollers Full Three . . _ ear Warranty on Craftsman Welder For three years from the date of purchase , when the welder is operated and maintained according to the owner's manual instructions , if the welder fails due to a defect in material or workmanship , Sears will repair or replace the welder free of charge . This warranty does not cover the welding gun , cables , or normal consumable parts . _ 2
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CRAFTSMAN FULL WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SHOCK HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FIRE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FLASH HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FUME HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . COMPRESSED GASSES AND EQU1PMENT HAZARDS . . . . . . . . . . . . . . . . . . 6 BURN HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ADDITIONAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 WELDER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WELDER OPERATING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . DUTY CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INTERNAL THERMAL PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WELDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 POWER SOURCE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 POWER REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CONNECT TO POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 EXTENSION CORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ASSEMBLING THE WELDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . UNPACKING THE WELDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALL THE GROUND CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . INSTALL THE TANK TRAY AND BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALL THE SHIELDING GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CHECK THE GAS FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . 1 . . . . . ALIGN AND SET THE DRIVE ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 t STANDARD DRIVE ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 NEOPRENE DRIVE ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALL THE WELDING WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . 3 SET THE WIRE DRIVE TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CHANGE POLARITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 REPLACE A GUN LINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 MAINTAINING THE CONTACT TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 MAINTAINING THE NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t9 TESTING FOR A SHORTED NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3
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Where information is shown that does This Welder User's Guide provides not necessarily apply to all models or specific information about your wire feed brands of welder , it will be marked as welder ° It is to be used together with the either optional on some welder models Welding Instruction Guide to provide all or does not apply to all models , of the information needed to safely and effectively use your wire feed welder . The information in this book applies to your specific model of wire feed welder and gives instruction on set - up , installation , and actual use of the welder . 4
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safety messages in this Every craftsman respects the tools with manual , . which they work . They know that the tools represent years of constantly When you see one of the symbols improved designs and developments . shown here , be alert to the possibility of The true craftsman also knows that tools personal injury and carefully read the are dangerous if misused or abused . message that follows . Reading this Operator's Guide and the This symbol indicates that the Welding Instruction Guide before using possibility of electric shock the welder will enable you to do a better , hazard exists during the safer job . Learn the welder's operation of the step ( s ) that applications and limitations as well as follow . the specific potential hazards peculiar to welding This symbol indicates that the SAFETY INFORMATION possibility of fire hazard exists during the operation of the The following safety information is step ( s ) that follow . provided as guidelines to help you operate your new welder under the This symbol indicates that the safest possible conditions Any helmet must be worn during equipment that uses electrical power the step ( s ) that follow to can be potentially dangerous to use protect against eye damage when safety or safe handling instructions and bums due to flash are not known or not followed . The hazard , following safety information is provided to give you the information necessary for This symbol indicates that the safe use and operation ° possibility of toxic gas hazard When a procedure step is preceded by exists during operation of the a WARNING , it is an indication that the step ( s ) that follow . step contains a procedure that might be injurious to a person if proper safety This symbol indicates that the precautions are not heeded , possibility of being burned by hot slag exists during When a procedure step is preceded by operation of the step ( s ) that a CAUTION , it is an indication that the follow . step contains a procedure that might damage the equipment being used . This symbol indicates that the A NOTE may be used before or after a eye protection should be worn procedure step to highlight or explain to protect against flying debris something in that step , in the following step ( s ) READ ALL SAFETY INSTRUCTIONS This symbol indicates that the CAREFULLY before attempting to possibility of injury or death install , operate , or service this welder . exists due to improper Failure to comply with these instructions handling and maintenance of could result In personal injury and / or compressed gas cylinders or property damage . regulators RETAIN THESE INSTRUCTIONS Full explanations of the specific hazards FOR FUTURE REFERENCE . are shown in the WELDING INSTRUCTION GUIDE . Make sure you Note : The following safety alert have read and understand all of the symbols identify important 5
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FLASH HAZARDS information before proceeding with any of the instructions contained in this user's guide _ Published standards on safety are available . They are listed in WARNING ADDITIONAL SAFETY INFORMATION at the end of this SAFETY SUMMARY , , ARC RAYS CAN INJURE EYES AND BURN SKIN ! To reduce risk of The National Electrical Code , injury from arc rays , read , Occupational Safety and Health Act understand , and follow the following regulations , local industrial codes and local inspection requirements also safety instructions ° In addition , make certain that anyone else that uses provide a basis for equipment installation , use , and service this welding equipment , or is a bystander in the welding area , SHOCK HAZARDS understands and follows these safety instructions as well , FUME HAZARDS WARNING ELECTRIC SHOCK CAN KILL ! To WARNING reduce the risk of death or serious injury from shock , read , understand , and follow the following safety FUMES , GASSES , AND VAPORS instructions , tn addition , make CAN CAUSE DISCOMFORT , certain that anyone else who uses ILLNESS , AND DEATH ! To reduce this welding equipment , or who is a risk of discomfort , illness , or death , bystander in the welding area read , understand , and follow the understands and follows these safety following safety instructions . In instructions as welt , addition , make certain that anyone else that uses this welding equipment FIRE HAZARDS or is a bystander in the welding area , understands and follows these safety instructions as well COMPRESSED GASSES AND WARNING EQUIPMENT HAZARDS FIRE OR EXPLOSION CAN CAUSE DEATH , INJURY , AND PROPERTY DAMAGE ! To reduce risk of death , WARNING injury , or property damage from fire or explosion , read , understand , and follow the following safety IMPROPER HANDLING AND instruction & tn addition , make MAINTENANCE OF COMPRESSED certain that anyone else that uses GAS CYLINDERS AND this welding equipment , or is a REGULATORS CAN RESULT IN bystander in the welding area , SERIOUS INJURY OR DEATH ! To understands and follows these safety reduce risk of injury or death from instructions as well . REMEMBER ! compressed gasses and equipment Welding by nature produces sparks , hazards , read understand and follow hot spatter , molten metal drops , hot the following safety instructions , In slag , and hot metal parts that can addition , make certain that anyone start fires , burn skin , and damage else who uses this welding eyes , 6
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o NFPA Standard 51B - - - CUTTING equipmentor a bystanderin the AND WELDING PROCESS - - weldingarea understandsand obtainable from the National Fire followsthesesafety instructionsas well . Protection Association , t Batterymarch Park , P . O . Box 9t01 , Do not useflammablegasseswith Quincy , MA 02269 - 9101 Telephone MIGwelders . Only inertor ( 617 ) 770 - 3000 , Fax ( 617 ) 770 - 0700 nonflammablegassesare suitablefor . - - - www . nfpa . . org MIGwelding . Examplesare Carbon * CGA Pamphlet Pq - - SAFE Dioxide , Argon , Helium , etc . or HANDLING OF COMPRESSED mixturesof morethanone of these GASSES IN CYLINDERS - - gasseso obtainable from the Compressed Gas BURN HAZARDS Association , 1725 Jefferson Davis Highway , Suite 1004 , Arlington , VA 22202 - 4102 Telephone ( 703 ) 412 - 0900 Fax ( 703 ) 412 - 0128 - www cagneLcom WARNING . OSHA Standard 29 CFR , Part 1910 , Subpart Q . , WELDING , CUTTING Hot slag can cause fires and AND BRAZING - - - obtainable from serious injury from burns . To your state OSHA office or U . S . Dept . reduce the risk of discomfort or of Labor OSHA , Office of Public serious injury due to burns always Affairs , Room N3647 , 200 Constitution wear heavy protective clothing , eye Ave Washington , DC 20210 - - and face protection , and gloves wwwoshagov designed for welding . To prevent the risk of fires starting , use a metal plate . CSA Standard W1172 - - Code for or some other material with a high SAFETY IN WELDING AND CUTTING ° w obtainable from flash point to catch and shield combustibles from the hot slag Canadian Standards Association , 178 Rexdale Btvd . Etobicoke , Ontario ADDITIONAL SAFETY M9W 1R3 - - wwwcs & ca INFORMATION o American Welding Society Standard A60 . WELDING AND CUTTING For additional information concerning CONTAINERS WHICH HAVE HELD welding safety , refer to the following COMBUSTIBLES . - - obtainable from standards and comply with them as the American Welding Society , 550 applicable . NW Le Jeune Road , Miami , FL 33126 o ANSl Standard Z49 . 1 - - SAFETY IN Telephone ( 800 ) 443 - 9353 , Fax ( 305 ) WELDING AND CUTTING - - 443 - 7559 - - wwwoamweldorg or obtainable from the American Welding www . awsoorg Society , 550 NW Le Jeune Road , Miami , FL 33126 Telephone ( 800 ) 443 - 9353 , Fax ( 305 ) 443 - 7559 www , amweldoorg or www aws . org ° ANSI Standard Z87 . 1 - - SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION - - obtainable from the American National Standards Institute , 11 West 42 _ Sto , New York , NY t0036 Telephone ( 212 ) 642 - 4900 , Fax ( 212 ) 398 - 0023 - - - www . ansi . org
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represents the maximum welding time DESCRIPTION allowed . The balance of the 10 - minute Your new wire feed welder is designed cycle is required for cooling _ for maintenance and sheet metal Your new welder has a duty cycle rating fabrication . The welder consists of a of 20 % at the rated output . This means single - phase power transformer , that you can weld for two ( 2 ) minutes out stabilizer , rectifier , and a unique built - in of 10 with the remaining eight ( 8 ) minutes control / feeder _ required for cooling . ( See Table 2 ) . Now you can weld sheet metal from 26 Table 2 . Duty Cycle Ratings gauge up to 3 / 16 inch thick with a single pass , . You can weld thicker steel with Duty Maximum Required beveling and multiple pass techniques . . Cycle Welding Resting Table 1 lists your MIG welder Rating Time Time specifications . 20 % 2 minutes 8 minutes Table 1 . Welder Specifications 40 % 4 minutes 6 minutes Primary ( input ) volts 120 Vac 60 % 6 minutes 4 minutes Primary ( inputs ) Amps 20 80 % 8 minutes 2 minutes Phase Single 100 % 10 minutes 0 minutes Frequency 60 Hz INTERNAL THERMAL Secondary ( output ) volts 18 _ 5 PROTECTION Secondary ( UL output ) amps 90 Open Circuit Volts ( Max . ) 28 Vdc CAUTION Duty Cycle Rating 20 % Do not constantly exceed the duty cycle or damage to this welder can result . If you exceed the duty cycle of your welder , an internal thermal MIG welders equipped with gas are protector will open , shutting off all capable of welding with 0 _ 024 ( 0.6mm ) welder functions except the cooling and 0.030 ( 0 . Smm ) solid steel wire on dc fan If this happens , DO NOT SHUT reverse polarity and with 0 _ 030 ( 0 . Smm ) OFF THE WELDER . Leave the self - shielding flux - core wire on dc welder turned on with the fan running . straight polarity . Larger , 0.035 inch After cooling , the thermal protector will ( 0 . gmm ) diameter solid steel wire , on dc automatically reset and the welder will reverse polarity may also be used on function normally again . However , this welder . The use of larger diameter you should wait at least 10 minutes wire makes welding difficult and the after the thermal protector opens results cannot be guaranteed . The before resuming welding . You must manufacturer does not recommend the do this even if the thermal protector use of larger diameter wire . resets itself before the t0 minutes is up or you may experience tess than WELDER OPERATING specified duty cycle performance . CHARACTERISTICS If you find that your welder will not weld DUTY CYCLE for 2 minutes without stopping , reduce the wire speed slightly and tune the The duty cycle rating of a welder defines welder in at the lowest wire speed how long the operator can weld and how setting that still produces a smooth arc _ long the welder must be rested and Welding with the wire speed set too high cooled . Duty cycle is expressed as a causes excessive current draw and percentage of 10 minutes and shortens the duty cycle °
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EXTENSION CORDS POWER SOURCE CONNECTION For optimum welder performance , an extension cord should not be used POWER REQUIREMENTS unless absolutely necessary , . If necessary , care must be taken in This welder is designed to operate on a selecting an extension cord appropriate properly grounded 120 Volt , 60 Hz , for use with your specific welder . single - phase alternating current ( ac ) power source fused with a 20 amp time - Select a properly grounded extension delayed fuse or circuit breaker , tt is cord that will mate directly with the ac recommended that a qualified electrician power source receptacle and the welder verify the ACTUAL VOLTAGE at the power cord without the use of adapters ° receptacle into which the welder will be Make certain that the extension is properly plugged and confirm that the receptacle wired and in good electrical condition . is properly fused and grounded . The Extension cords must be at the smallest use of the proper circuit size can a # 12 gauge cord . . Do not use an eliminate nuisance circuit breaker extension cord over 25 ft . . in length . . tripping when welding ASSEMBLING THE DO NOT OPERATE THIS WELDER if WELDER the ACTUAL power source voltage is less than 105 Volts ac or greater than The following procedures describe the ! 32 Volts ac . Contact a qualified process required to assemble , install , electrician if this problem exists . . maintain , and prepare to weld with your Improper performance and / or damage to new wire feed welder ° the welder will result if operated on UNPACKING THE WELDER inadequate or excessive power ' . CONNECT TO POWER SOURCE 1 Remove any cartons or bags containing parts / accessories 2 Open the cartons or bags packed with your welder and inspect their WARNING contents for damage . Report any missing or damaged items High voltage danger from power immediately source ! Consult a qualified electrician 3 Grasp the top handle of the welder for proper installation of receptacle at and lift the welder out of the carton . the power source INSTALL THE GROUND CLAMP This welder must be grounded while in use to protect the operator from Connect the ground clamp to the ground electrical shock . If you are not sure if cable ( coming out the front of the your outlet is properly grounded , have it welder ) according to the instructions checked by a qualified electrician Do packaged with the ground clamp . not cut off the grounding prong or alter INSTALL THE TANK TRAY the plug in any way and do not use any AND BRACKET adapters between the welder's power cord and the power source receptacle . Make sure the POWER switch is OFF then connect your welder's power cord The tank tray bracket is installed on the to a properly grounded I20 Vac , 60 Hz , back of the welder , see Figure 1 . single phase , 20 amp power source . 9
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IMPORTANT - GAS CYLINDER SIZE Align the tank tray bracket ( 1 ) to fit between the legs at the back of the RESTRICTION ! The tank tray you have cart ( 2 ) ( as shown in Figure 2 ) so just installed on the back of tile welder that the mounting holes are aligned will handle gas cylinders no larger than with the four staked nuts on the rear 20 cubic feet . , tf you select a cylinder of the cart . larger than 20 cubic feet , it must be chained to a wall or other fixed support . 2 Start one ¼ inch split lock washer ( 3 ) and a ¼ - 20 x Y2 inch hex bolt ( 4 ) 2 in one of the top tank tray bracket ( 1 ) mounting holes then start each of the other three split lock washers ( 2 ) and ¼ inch hex bolts ( 3 ) through the remaining mounting holes . 3 Tighten all four inch hex bolts ° " 3 INSTALL THE SHIELDING GAS Figure 1 , Mount Tank Tray Bracket - Ib Welder 1 . Align the four tank tray bracket ( 1 ) WARNING mounting holes ( as shown in Figure 1 ) with the four staked nuts on the IMPROPER HANDLING AND rear of the welder MAINTENANCE OF COMPRESSED 2 _ Start one 1.4inch split lock washer GAS CYLINDERS AND REGULATORS ( 2 ) and a 1A - 20 x 1 / 2inch hex bolt ( 3 ) CAN RESULT IN SERIOUS INJURY in one of the top tank tray bracket OR DEATH ! Always secure gas ( 1 ) mounting holes , then start each cylinders to the tank bracket kit , a wail , of the other three split lock nuts ( 2 ) or other fixed support to prevent the and ¼ - 20 x 1 / 2inch hex bolts ( 3 ) cylinder " from falling over and rupturing ° through the remaining mounting Read , understand , and follow all the holes . COMPRESSED GASSES AND 3 . . Tighten all four hex bolts . . EQUIPMENT HAZARDS in the SAFETY SUMMARY at the front of this manual . Secure your gas cylinder to the tank bracket kit , a wall , or other fixed support , . If you have an optional cart with the welder , the tank tray bracket is installed 1 Remove the protective cap from the at the rear of the cart , below the welder , cylinder and inspect the regulator see Figure 2 connecting threads for dust , dirt oil , and grease . Remove any dust or dirt with a clean cloth . DO NOT 2 ATTACH THE REGULATOR IF OIL , / GREASE , OR DAMAGE ARE / 1 PRESENT . 2 Open the cylinder valve FOR JUST AN INSTANT to blow out any foreign matter inside the valve port I • : 1 to reduce the risk of plugging or \ damaging the regulator ° Never aim the open cylinder valve port at t yourself or bystanders . ' 3 4 3 Screw the preset regulator supplied with this welder ( see Figure 3 ) into Figure 2 . Mount Tank Tray Bracket the cylinder valve and tighten with a To Cart wrench . . 10
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Slowly crack open the cylinder valve , then turn open ALL THE WAY . Pull the trigger on the gun to allow the gas to flow . . KEEP THE Q TRIGGER PULLED . Listen and feel for gas flowing from the end of the welding gun . If your regulator has no adjustment , it has been pre - set at the factory for a flow of 20 cubic feet per hour ° If your gas regulator has an adjustment to control the gas flow rate , turn the Figure 3 . Preset Regulator adjustment key clockwise to increase gas flow ; counterclockwise 4 . Insert the gas hose into the outlet to reduce flow _ For most welding , port of the gas regulator The hose the gas flow should be set at 15 - 20 locks in place in the fitting when cubic feet per hour . . If no gas is pressed into the port heard or felt , verify all steps 5 . To remove the gas hose , press involved in connecting the ga & down on the ring at the rear of the Refease the trigger gas fitting , and pull the hose out of Note : If welding outside or in a draft , it the fitting . may become necessary to set CHECK THE GAS FLOW up a windbreak to keep the shielding gas from being blown from the weld area ° MAKE SURE TO TURN OFF WARNING THE GAS CYLINDER VALVE WHEN DONE WELDING , , IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED ALIGN AND SET THE DRIVE GAS CYLINDERS AND REGULATORS ROLLER CAN RESULT IN SERIOUS INJURY OR DEATH ! To reduce tile risk of injury Before installing any welding wire into the unit , the proper sized groove must or death , always stand to the side of the be placed into position on the wire drive cylinder opposite the regulator when mechanism Change to a neoprene opening the cylinder valve , keeping the drive roller when welding with aluminum cylinder valve between you and the wire regulaton Never aim the open cylinder valve port at yourself or bystanders . STANDARD DRIVE ROLLER Failure to comply with this warning could Change the standard drive roller result in serious personal injury . according to the following steps : Note : If the cylinder you have is 1 Remove the drive tension by equipped with male regulator unscrewing the tension adjusting connecting threads hqstead of screw ( ALL THE WAY in a counter - female , you will need to obtain clockwise direction ) The drive a special compressed gas tension screw will come loose , cylinder adapter from your gas allowing you to pull the drive supplier to install between your tension arm up away from the drive gas cylinder and regulator , , roller Make sure to keep the screw • The gas control function does and the spring in place with the not require the welder to be drive tension arm turned on or plugged in 11
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, 5 . Slide the roller onto the shaft so that If there is wire already installed in the welder , roll it back onto the wire the groove in the roller lines up with spool by hand - turning the spool the inlet tube and the welding gun counter - clockwise . Be careful not liner . You can look at the alignment to allow the wire to come out of the from the top of the welder . rear end of the gun without holding 6 Tighten the setscrew , while holding onto it or it will unspool itself . Put tlqe drive roller in place . the end of the wire into the hole on NEOPRENE DRIVE ROLLER the outside edge of the wire spool and bend it over to hold the wire in place . Remove the spool of wire from the welder . Change to the neoprene drive ro ! ler 3 _ Loosen the drive roller setscrew according to the following steps : and pull the drive roller off the drive 1 Remove the drive tension by shaft . unscrewing the tension adjusting Note : The drive roller has two wire screw ( ALL THE WAY in a counter - size grooves built into it . . When clockwise direction ) . The drive installing the drive roller the tension screw will come loose , number stamped on the drive allowing you to pull the drive roller for the wire size you are tension arm up away from the drive using should be facing away roller Make sure to keep the screw from you . If you can read the and the spring in place with the wire size you are using on the drive tension arm drive roller , it is installed If there is wire already installed in backwards . Use only the the welder , roll it back onto the wire proper size drive roller when spool by hand - turning the spool using your welder _ counter - clockwise _ Be careful not 4 _ Find the side of the drive roller that to allow the wire to come out of the is stamped with the same wire rear end of the gun without holding diameter as that of the wire being onto it or it will unspoot itself . . Put installed ( see Figure 4 , and if in the end of the wire into the hole on metric , see DESCRIPTtON ) _ Make flqe outside edge of the wire spool certain the spacing wast _ er is still on and bend it over to hold the wire in the motor shaft and push the drive place , Remove the spool of wire roller onto the motor shaft , aligning from the welder . the setscrew with the flat side of the 3 Loosen the setscrew in the drive shaft . Make sure the side standard drive roller and remove it stamped with the desired wire and the spacing washer from the diameter is away from you drive shaft . Drive Roller 4 Do not use the spacing washer ° The spacing washer is for use with the standard drive roller only . Save the spacing washer with the standard drive roller While holding the side of the neoprene drive roller that has the Shaft setscrew toward you ( see Figure 5 ) , push the neoprene drive roller onto the motor shaft as far as it will go . . Spacing Align the setscrew with the flat side Washer of the drive shaft Figure 4 . Drive Roller 12
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2 . Make sure the proper groove on the drive roller is in place for the wire being installed , if the proper groove is not in place , change the drive roller as described above , 3 Unwrap the spool of wire then find the leading end of the wire ( it goes Motor Shat { through a hole in the outer edge of time spool and is bent over the spool edge to prevent the wire from unspooling ) BUT DO NOT Figure 5 . Drive Assembly & UNHOOK IT YET , Neoprene Drive Roller 4 Place the spool on the spindle in such a manner that when the wire 6 . Tighten the setscrew , while holding the drive roller inplace comes off the spool , it will look like the top illustration in Figure 6 . The 7o Remove the screws that retain the welding wire should always come inlet guide tube . Replace the off the top of the spool into the drive plastic inlet guide tube with the mechanism . supplied brass inlet guide tube Secure screws . Note : The tapered side of the brass inlet guide tube should be as close to the rollers as possible without touching , It is not necessary to reinstall the plastic inlet guide tube when switching back to the standard drive roller . However , if you experience some binding , readjust the brass inlet guide Figure 6 , Right and Wrong Way To tube slightly away from the Feed Wire From Spool drive roller . 5 tf you are installing a fourqnch INSTALL THE WELDING spool of wire , install the drive brake hardware on the top of the spool of WIRE wire according to Figure 7Ao If you are installing an eight - inch spool , install the spindle adapter and WARNING drive brake hardware as shown in Figure 7B . The purpose of the drive brake is to cause the spool of wire Electric shock can kill ! Always turn to stop turning at nearly the same the POWER switch OFF and unplug the moment that wire feeding stops . power cord from the ac power source 6 Once the drive brake hardware is before installing wire . , installed , set the spool tension ° Be very careful when removing the With one hand , turn the wire spool welding nozzle . The contact tip on this and continue turning it while welder is electrically hot as long as adjusting the tension on the spool . POWER is turned ON , Make certain With your free hand , tighten ( turn POWER is turned OFF , clockwise ) the wing nut that holds time spool in place Stop tightening t . Remove the nozzle and contact tip when drag is felt on the wire spool from the end of the gun assembly . . that you are turning , then stop hand turning the wire spool . 13
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direction . If this should happen , the A wire could feed inside the cable casing or take a right angle and follow the wires and gas hose inside the welder . It could also feed back on itself jamming up the mechanism . 11 Line the wire up in the inside groove of the drive roller , then allow the drive tension arm to drop onto the drive roller _ . 12 Tighten ( turn clockwise ) the drive 4 " Spool . . . : . tension adjusting screw until the 8 " Spool tension roller is applying enough Figure 7 . Drive Brake Assemblies force on the wire to prevent it from with Four Inch and Eight Inch Wire slipping out of the drive assembly , Spools 13 Let go of the wire . tf TOO MUCH tension is t4 Connect the welder power cord to Note : the ac power source . Turn the applied to the wire spool , the welder ON by setting the VOLTAGE wire will slip on the drive roller or will not be able to feed at all . switch to the voltage ( heat ) setting If TOO LITTLE tension is recommended for the gauge metal applied , the spool of wire will that is to be welded Refer to the want to unspool itself Readjust label mounted on the cover , inside the drive brake tension as the drive compartment , for necessary to correct for either recommended voltage ( heat ) problem , settings for your welding job . The VOLTAGE selector controls the weld , , After checking to make sure that heal There is an OFF and four your welder is disconnected from voltage ( heat ) selections the ac power source , free the leading end of the wire from the ( numbered 1 through 4 ) available spool , but do not let go of it until told on this welder . Numbered position to do so , or the wire will unspool t provides the lowest voltage itself . ( heat ) and position 4 the highest aN voltage ( heat ) . Using a wire cutter , cut the bent end off the leading end of the wire so 15 Set the WIRE SPEED control to the that only a straight leading end rniddfe of the wire speed range , remains . 16 Pull the trigger on the welding gun . Loosen the tension adjusting screw to feed the wire through the gun holding the drive tension arm in assembly place and lift the tension arm up off 17 When at least an inch of wire sticks the drive roller . out past the end of the gun , release 10 . Insert the leading end of the wire the trigger into the inlet guide tube Then push 18 Select a contact tip stamped with it across the drive roller and into the tile same diameter as the wire gun assembly about six inches , being used . If stamped in metric , see DESCRIPTION , . CAUTION 19 , Slide the contact tip over the wire Make certain that the welding wire is ( protruding from the end of the actually going into the gLm liner Be gun ) Thread the contact tip into the very sure it has not somehow been end of the gun and hand - tighten accidentally been routed alongside securely , the liner or even in some other 14
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20 _ Installthe nozzleon the gun stainless steel , flux cored hardfacing of steel , and silicon bronze wetding of assembly . For best results , coat the insideof the nozzle withantFstick steel , select dc Reverse Polarity ( dc + MIG ) . When using self - shielding , flux - sprayor gel ( part # 4312 , not core steel wire , use dc Straight Polarity supplied ) . ( dc - FkJx Cored ) . L 21 _ Cutoff the excesswire that extends Change the polarity of your welder pastthe end of the nozzle according to the following procedure steps ° SET THE WIRE DRIVE Figure 8 shows what the polarity block should took like for each polarity setting , TENSION WARNING WARNING Electric shock can kill ! Always turn the To reduce the risk of arc flash , make power OFF and unplug the power cord certain that the wire coming out of from the ac power source before the end of the gun does not come in changing polarity . contact with the workpiece clamp or any grounded material during the CAUTION drive tension setting process or Do not use a ratchet , crescent or other arcing will occur _ lever type wrench to tighten the nuts 1 . Pull the trigger on the gun on the polarity bus . The nuts must be hand tightened with a 7 / 16 inch nut 2o Turn the drive tension adjustment driver only . . Too much torque applied knob clockwise , increasing the drive to the one of the nuts could cause the tension until the wire seems to feed threaded post to break off . smoothly without slipping Tools Required : 3 . Block the end of the nozzle by o 7 / 16 inch nut driver holding it up against something that doesn't conduct electricity , such as With a 7 / 16 inch nut driver , remove a block of wood or a concrete floor , all four nuts and pull out the then trigger the gun again The vertically mounted copper straps . wire should slip at the drive roller . 2 Replace the copper straps However , if the wire bird - nests at horizontally in the dc Straight the drive roller , rethread the drive Polarity ( dc - . Flux Cored ) system using less drive tension and configuration shown in Figure & try again ° OC , DC - 4 . When the drive tension is set MIG FLUX CORED correctly , there should be no slippage between the wire and the drive roller . However , if an obstruction occurs along the wire feed path , the wire should then slip on the drive roller . CHANGE POLARITY Figure 8 . Welder Polarity Selections This welder allows you the capability to 3 , Start the four nuts on the four change the welding current polarity . connecting posts and hand snug You may select either dc Straight ( dc - each nut with the 7 / 16 nut driver . Flux Cored ) or dc Reverse Polarity ( dc + Do not use a ratchet , crescent or MIG ) . For welding steel with solid wire , other lever type wrench . 15
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Position 4 on the Voltage Selector Operation of this welder consists of produces the rated output of 90 amps , selecting and adjusting operating controls for optimum voltage ( welding The duty cycle at 90 amps is 20 % , but will increase as the heat setting is heat ) and wire speed settings decreased . CONTROLS AND The position to the left of number t is INDICATORS the OFF position . In this position , no power is provided to the welder - the drive motor and welding power are turned off . . However , as long as the WARNING voltage selector is in one of the four numbered voltage positions , welding circuit is HOT ( there is voltage on the Electric shock can kill ! To remove contact tip ) . the risk of electric shock , be aware WIRE SPEED CONTROL - The WIRE that the VOLTAGE selector , when SPEED CONTROL adjusts the speed at OFF , does not remove power from all which the wire is fed out of the welding internal circuitry in the welder . gun The wire speed needs to be Whenever the VOLTAGE selector is closely matched ( tuned - in ) to the rate at in any position except OFF , the wtlich it is being melted off ( see welding circuit is activated , Under TUNING IN THE WIRE SPEED , in the this condition , an arc will occur if the WELDING INSTRUCTION GUIDE ) . welding wire or any part of the Some things that affect wire speed welding circuit comes in contact with selection are the type and diameter of welding ground . the wire being used , the heat setting VOLTAGE SELECTOR - The voltage selected , and the welding position to be selector controls the welding heat The used voltage selector is numbered 1 - 4 NOTE : The wire will feed faster without Number 1 is the lowest heat and an arc . When an arc is being number 4 the highest . , Refer to the label drawn , the wire speed will slow under the welder hood for down _ recommended heat settings for your welding job , 16
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GENERAL This welder has been engineered to give WARNING many years of trouble - free service providing that a few very simple steps are taken to properly maintain it . ELECTRIC SHOCK CAN KILL ! To reduce the risk of electric shock , always 1 _ Keep the wire drive compartment lid unplug the welder from its ac power closed at all times unless the wire source before removing side panels . needs to be changed or the drive tension needs adiusting IT IS VERY IMPORTANT TO MAINTAIN THE CONSUMABLES TO AVOID THE 2o Keep all consumables ( contact tips , NEED FOR PREMATURE nozzles , and gun liner ) clean and REPLACEMENT OF THE GUN replace when necessary . See ASSEMBLY CONSUMABLE MAINTENANCE AND TROUBLESHOOTING later in The GUN LINER is intended to provide this section for detailed information _ an unrestricted path for the welding wire 3 , Replace power cord , ground cable , to flow through the gun assembly . Over time it will accumulate dust , dirt , and ground clamp , or gun assembly when damaged or worn otller debris . RepIacement is necessary when these accumulations begin to 4 . Periodically clean dust , dirt , grease , restrict the free flow of wire through the etco from your welder Every six gun assembly months or as necessary , remove the side panels from time welder and REPLACE A GUN LINER air - blow any dust and dirt that may When removing or installing a gun liner , have accumulated inside the care must be taken not to kink or welder . otherwise damage the gun liner or replacernent wilt be necessary . See Figure 9 for the drive assembly and Figure 10 for the gun assembly . Ddve Drive Guner " { besion Tension Lin Adiustmenl Arm t / 4 " Hex Head Screws Irfle ! nGuided Tube E PMllips Pan Strain , Gun llet _ e ! \ Head Screw Clamp nAssemblyd ) bdInletee Drive ( Taii E uGui Rotter T Drive Assembly Figure 9 . Drive Assembly 17
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Live Wire Conduct . or Terminal PlasticTie lGasve Cable Va Tube Insulation Gasse Gun Cable Ho Gas Cable Hose Fitting internalStar Switch Lockwasher Handle Head End Case Gun Liner Gun Assembly Figure 10 . gun assembly can be laid out Tools Required : straight on a table or workbench or • 5 / 16 inch open end wrench similar flat surface . • Crescent Wrench ( 6 or 8 inch ) 7 Unscrew and remove the nozzle , 8 With a crescent wrench ( six or eight • 9 mm open end wrench ( or 3 inch inch ) , turn the gas diffuser crescent ) clockwise ( has left hand threads ) and remove the gas diffuser ( and • Phillips Screwdriver contact tip together ) from the ° Straight Blade Screwdriver or _ A inch conductor tube on the end of the hex driver gun , g , , Remove the four Phillips head Turn OFF welder POWER SWtTCH screws that hold the handle case 2 , Open the welder side panel , together , With the exception of the 3 . Loosen the tension arm and lift it trigger , completely remove the up off the drive roller . contents of the handle case , 4 , Turn the wire spool counter - 10 Cut the plastic cable tie away from clockwise ( be sure to hold onto the the cable covering ( tubing ) . wire itself while turning the spool or Note : In the following procedure step , the wire will unspool itself when it it may be necessary to remove becomes free of the gun liner ) , the gas fitting from the gas removing wire from gun assembly . valve in order to make room to 5 , . Remove two _ A inch hex head turn out the head end of the screws ( may also be removed with gun liner . . a straight blade screwdriver ) and 11 With a 5 / 16 inch open end wrench , one pan head Phillips screw ( inlet unscrew the head end of the liner guide tube end ) from the drive from the gas valve Save the roller and lift away the strain relief internal star lock _ washer and note clamp that holds the tail end of the the orientation of the live wire gun in the drive assembly . terminal . If you find it necessary to 6 , , Leave the gun assembly ( consists remove the gas hose connector , of nozzle , gas diffuser , goosemeck , press down on the ring at the rear handle and cable containing gas of the gas fitting to release the gas tubing electrical cable and liner ) lnose and pull out the gas hose . attached to the welder but move the welder to a place where the Remove the gas fitting with a 9 mm open end wrench or three inch crescent . 18
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12 , Pull the liner out of the cable 20 Make sure the cable covering covering ( tubing ) from the handle ( tubing ) is far enough in the end and push the small piece of machine so that it is covered by the liner out of the conductor tube wire - feed torch clamp . 13 , Carefully insert the new liner into 21 Tighten the two 1,4inch hex head screws ( may also be tightened by a the cable taking particular care to keep the liner straight ( especially at straight blade screwdriver ) and one the terminal end ) to ease its pan head Phillips screw to the passage through cable covering . . It drive roller securing the gun in may be desirable , perhaps even place . necessary , to apply some silicon 22 Re - install the wedding wire grease to the outside of the new according to INSTALL THE liner so that it will slide easily WELDING WIRE . through the cable . MAINTAINING THE CONTACT TIP 14 . Insert the new piece of liner into the The purpose of the CONTACT TIP is to conductor tube . transfer welding current to the welding Note : If you found it necessary to wire while allowing the wire to pass remove the gas and hose through it smoothly . . connector at step 9 , remember Always use a contact tip stamped with to reconnect it after completing the same diameter as the wire it wil ! be step t2 The gas hose can be used with reconnected by simply pushing it into the back of the connector . t if the wire burns back into the tip , remove the tip from the gun and t5o Insert the head of the gun liner clean the hole running through it through the internal star lock with an oxygen - acetylene torch tip washer and the live wire terminal cleaner or tip drill ( repeat the orientation noted in 2 Over time , the hole in the contact tip step 9 ) , With a 5 ! 16 inch open end will become worn by the wire wrench , screw the head end of the passing through it . The more worn new liner into the gas valve ti ] is hole becomes , the less efficient 16 Insert a new plastic cable tie in is the transfer of welding current to place around the cable and tighten tl _ e wire and eventually arc it in approximately the same breakage and difficult arc starting location as the plastic cable tie that wilt result Replace contact tips was cut in step 8 . when signs of wear become apparent . 17 , Return all components to the MAINTAINING THE NOZZLE handle casing and realign them as they were originally . . The nozzle directs the shielding gas to 18 . With both halves of the handle the weld puddle , determines the size of case in place , tighten the four the shielding area , and prevents the electrically hot contact tip from Philips pan head screws making contacting the work piece . . sure the trigger remains seated in place . CAUTION 19 . Push the cable into the welder far KEEP THE NOZZLE CLEAN ! During enough so that the end of the gun the welding process , spatter and slag liner protrudes through the inlet wilt build up inside the nozzle and guide tube end of the wire - feed must be cleaned out periodically . . torch clamp far enough so that it is Failure to clean and / or replace the within approximately 1 / 16 inch of nozzle in a timely fashion WILL touching the drive roller . . CAUSE DAMAGE TO THE FRONT - END OF THE GUN ASSEMBLY ° 19
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For best results , coat the inside of a new TESTING FOR A SHORTED or freshly cleaned nozzle with anti - stick NOZZLE spray or gel Arcing between the nozzle and the work 1 . Stop welding and clean any piece ALWAYS means the nozzle is accumulated slag or spatter from shorted , but this can be hard to detect the nozzle every 5 to I0 minutes of through the lens of a welding helmet . welding time . The following testing method is another 2 . When weeding overhead , if any way to tell if a nozzle is shorted . , molten metal drips from the weld With the welder unplugged from the ac puddle and falls into the nozzle , power source , touch the probes of an STOP WELDING IMMEDIATELY ohmmeter or continuity tester to the end and clean the nozzle of the contact tip and the outside of the 3 . If the slag cannot be thoroughly nozzle . If there is any continuity at all , cleaned from the nozzle , REPLACE the nozzle IS shorted . . Clean or replace THE NOZZLE ! as needed . Failure to keep the nozzle adequately PREVENTIVE MAINTENANCE cleaned can result in the following Except for internal and external problems : cleaning , cleaning the nozzle , and A SHORTED nozzle results when occasionally retightening screws , there spatter buildup bridges the insulation in is no periodic maintenance the nozzle allowing welding current to recommended for your welder . flow through it as welt as the contact tip . When shorted , a nozzle wilt steal TROUBLESHOOTING welding current from the wire whenever The following TROUBLESHOOTING it contacts the grounded work piece information is provided as a guide to This causes erratic welds and reduced help resolve some of the more common penetration . problems that could be encountered ° In addition , a shorted nozzle overheats Table 3 is a troubleshooting table the end of the gun , which can DAMAGE provided to help you determine a the front _ end of the gun . . possible remedy when you are having a A RESTRICTED nozzle is created when probtem with your welder This table enough slag builds up in the nozzle to does not provide all possible solutions , affect the direction , concentration , and only tlqose possibilities considered to or rate of the shielding gas flow . This likely be common faults The table problem can cause porous , brittle welds consists of a TROUBLE or symptom , a and reduce penetration POSSIBLE CAUSE for that symptom , and a POSSIBLE REMEDY for that symptorn _ 2O
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Table 3 . Troubleshooting TROUBLE POSSIBLE CAUSE POSSIBLE REMEDY . , , , , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dirty , porous brittle 1 . Plugged welding nozzle 1 . Clean or replace nozzle weld 2 No shielding gas 2 Tank empty , flow restricted , or regulator set too tow 3 , See SELECTING SHIELDING & Wrong Type of Gas GAS in the WELDING INSTRUCTION GUIDE for proper selection 4 . Dirty or rusty welding wire 4 . , Replace spool of wire I Check ground and connections 1 . Bad ground or loose Wire feed works but connection tighten as necessary no arc 2 , Bad connection to gun or 2 , Check connection to gun or faulty gun replace gun Arc works but not 1 . , Faulty wire speed control I Replace wire speed control assembly feeding wire assembly 2 . No tension on the drive roller 2 , Adjust the drive tension 3 . Faulty drive motor ( very rare ) 3 . Replace drive motor I Replace trigger Nothing works 1 Faulty trigger on gun except fan 2 . Faulty transformer ( rare ) 2 Replace transformer 3 Allow welder to cool at least 10 3 Exceeded duty cycle ; thermal protector opened minutes ( observe and maintain proper duty cycle 1 Loose connection inside I , Blow inside of machine out with machine compressed air , clean and tighten Low output or all connections non - penetrating weld 2 See EXTENSION CORD USE in 2 Too tong or improper extension cord this manual 3 Use correct size welding wire 3 Wrong type or size wire 4 Poor ground connection 4 Reposition clamp and check cable to clamp connection 5 , Wrong size contact tip 5 Use correct size contact tip 6 . Loose gun connection or 6 Tighten gun or replace gun 7 Change polarity to proper for faulty gun assembly 7 Wrong welding polarity set wire beil _ j used 8 . Dirty or rusty welding wire 8 . Replace spool of wire 1 Too much tension on drive 1 , Adjust the drive tension roller ( see INSTALLING THE WELDING Wire is birdnesting at the drive roller WIRE ) 2 . Gun liner worn or damaged 2 Replace gun liner i3 Contact tip is clogged or 3 Replace conlact tip Idamaged 4 Liner is stretched or is too 4 Trim liner to proper length t Replace gun liner Wire burns back 1 Gun liner is worn or damaged to contact tip 2 . Liner stretched or is too long 2 Trim liner for proper length 3 . Wrong size contact tip 3 Use correct size contact tip 4 contact tip clogged or 4 Replace contact tip damaged Bad connection from cable to Ground clamp andlor lighten connection or replace cable cable gets hot , € ! arnp Gun nozzJe arcs Slag buildup inside nozzle or Clean or replace nozzle as needed to work surface nozzle is shorted 21
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Model 205111 24
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ITEM DESCRIPTION PART NO , 117 - 076 - 002 ¥ 20511 Sears 90 amp MIG Welder 1 Heat Control Switch 242 - 422 - 666 2 Fan 216 - 100 - 666 410 _ 900 - 010 3 Front Panel 541 _ 057 - 666 4 Strain Relief 238 - 223 - 666 5 Cable Assembly 6 Knob 246 - 107 - 666 238 - 592 _ 000 7 6 ' MfG gun 8 Control Panel 4t0 - 868 - 040 880 - 418 - 666 9 Wire Speed control W / Circuit Board t0 Transformer 880 - 410 - 666 11 Left Side Panel 410 - 865 - 020 312 - 295 - 666 12 Side Latch WtClip 13 Terminal Block 246 - 414 - 666 14 Wire Feed Motor 880 - 406 - 666 131 - 419 - 000 15 Tension Hardware 312 - 076 - 666 t6 Spindle 410 - 960 - 010 17 Center Panel t8 Rectifier 880 - 402 - 666 253 _ 333 _ 666 19 Fitting 248 - 327 - 666 20 Power Cord 512 - 215 - 666 21 Bushing 239 - 074 - 666 22 Strain Relief 23 Handle W / Hardware 312 - 296 - 666 410 - 864 - 020 24 Right Side Panel 25 Base 410 - 866 - 010 26 Thermo Breaker 880 - 415 - 666 27 Tank Bracket 412 - 635 - 010 238 - 592 - 000 ¥ Tweco MIG Gun ( 6 foot cable ) 238 - 593 - 000 ¥ Tweco MIG Gun ( 10 foot cable ) 28 Contact Tip 0 024 ' ( 0,6 mm ) 43090 43100 Contact Tip 0 030 " ( 0,8 mm ) 29 Nozzle 43480 334 - 440 - 000 30 Trigger ( MIG Gun ) 334 - 465 - 000 31 Gun Cable . Complete 334 - 495 - 666 32 Handle ( With Trigger ) 059 - 217 _ 040 33 Gas Hose 334 - 468 - 666 34 Liner 35 Gas Hose Quick Connector 334 - 467 - 000 ¥ Gun Head : Gas Valve , Conductor Tube . Conductor Tube 334 - 490 - 666 Insulation , Gas Diffuser 36 Gas Valve 334 - 491 - 666 37 Conductor Tube Insulation 334 - 493 - 666 38 Conductor Tube 334 ° 492 - 666 39 Gas Diffuser ( M ] G Gun ) 334 - 494 - 666 334 - 438 - 000 t Regulator 312 - 110 - 666 t " Wire Spool Adaptor ( for 8 " ) 880 - 427 - 666 1 " Urelhane Drive Roller 239 - 010 _ 102 I " Giound Clamp 332 - 239 _ 666 l " Welding Face Shield ¥ Complete Assembly 1 Not Shown In Drawing 25
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For the repair or replacement parts you need delivered directly to your home Call 7 am - 7 pro , 7 days a week 1 - 800 - 366 - PART ( 1 - 800 - 366 - 7278 ) For in - home major brand repair service Call 24 hours a day , 7 days a week 1 - 800 - 4 - REPAIR ( 1 - 800 - 473 - 7247 ) The model number of your product is located on the welder nameplate . If the parts you need are not stocked locally , your order will be electronically transmitted to a Sears Repair Parts Distribution Center for expedited handling . When requesting service or ordering parts , always give the following information : • Product Name • Model Number • Part Number • Part Description America's Repair Specialists
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