Craftsman 934.205111 Operator'S Manual Download | Manualshive

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Summary of Contents for 934.205111

Page 1: ...FETY SUMMARY o SPECIFICATIONS o INSTALLATION o OPERATION MAINTENANCE o SCHEMATIC WIRING DIAGRAM REPLACEMENT PARTS ESPANOL 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 ...

Page 2: ...ive 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 _ WARRANTY SERVI...

Page 3: ...T 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 11 ALIGN AND SET THE DRIVE ROLLER 1 t STANDARD DRIVE ROLLER 11 NEOPRENE DRIVE ROLLER 12 INSTALL THE WELDING WIRE 13 SET THE WIRE DRIVE TENSION 15 CHANGE POLARITY t 5 OPERATION 16 CONTROLS AND INDICATORS 1...

Page 4: ... 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 Where information is shown that does not necessarily apply to all models or brands of welder it will be marked as either optional on some welder models or does not apply to all models 4 ...

Page 5: ...at step READ ALL SAFETY INSTRUCTIONS CAREFULLY before attempting to install operate or service this welder Failure to comply with these instructions could result In personal injury and or property damage RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE Note The following safety alert symbols identify important safety messages in this manual When you see one of the symbols shown here be alert to the ...

Page 6: ...y instructions as welt FIRE HAZARDS WARNING FIRE OR EXPLOSION CAN CAUSE DEATH INJURY AND PROPERTY DAMAGE To reduce risk of death injury or property damage from fire or explosion read understand and follow the following safety instruction tn addition make certain that anyone else that uses this welding equipment or is a bystander in the welding area understands and follows these safety instructions...

Page 7: ...CUPATION 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 o NFPA Standard 51B CUTTING AND WELDING PROCESS obtainable from the National Fire Protection Association t Batterymarch Park P O Box 9t01 Quincy MA 02269 9101 Telephone 617 770 3000 Fax 617 770 0700 www nf...

Page 8: ...nutes and represents the maximum welding time allowed The balance of the 10 minute cycle is required for cooling_ Your new welder has a duty cycle rating of 20 at the rated output This means that you can weld for two 2 minutes out of 10 with the remaining eight 8 minutes required for cooling See Table 2 Table 2 Duty Cycle Ratings Duty Maximum Required Cycle Welding Resting Rating Time Time 20 2 mi...

Page 9: ...d the power source receptacle Make sure the POWER switch is OFF then connect your welder s power cord to a properly grounded I20 Vac 60 Hz single phase 20 amp power source EXTENSION CORDS For optimum welder performance an extension cord should not be used unless absolutely necessary If necessary care must be taken in selecting an extension cord appropriate for use with your specific welder Select ...

Page 10: ...h split lock washer 3 and a 20 x Y2 inch hex bolt 4 in one of the top tank tray bracket 1 mounting holes then start each of the other three split lock washers 2 and inch hex bolts 3 through the remaining mounting holes 3 Tighten all four inch hex bolts INSTALL THE SHIELDING GAS WARNING IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEAT...

Page 11: ...o allow the gas to flow KEEP THE 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 adjustment key clockwise to increase gas flow counterclockwise to reduce flow_ For most welding the ga...

Page 12: ...t the groove in the roller lines up with the inlet tube and the welding gun liner You can look at the alignment from the top of the welder 6 Tighten the setscrew while holding tlqe drive roller in place NEOPRENE DRIVE ROLLER Change to the neoprene drive ro ler according to the following steps 1 Remove the drive tension by unscrewing the tension adjusting screw ALL THE WAY in a counter clockwise di...

Page 13: ...roove 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 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 UNHOOK IT YET 4 Place the spool on the spindle in such a manner that when the wire comes off the spool it will look like the top illustr...

Page 14: ...e 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 tension adjusting screw until the tension roller is applying enough force on the wire to prevent it from slipping out of the drive assembly 1...

Page 15: ... roller However if the wire bird nests at the drive roller rethread the drive system using less drive tension and try again 4 When the drive tension is set 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 WARNING Electric shock can kill Always turn the power OFF and un...

Page 16: ...lding job Position 4 on the Voltage Selector produces the rated output of 90 amps The duty cycle at 90 amps is 20 but will increase as the heat setting is decreased The position to the left of number t is 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 voltage selector is in one of the four numbered voltag...

Page 17: ...sion Tension Liner Adiustmenl Arm WARNING ELECTRIC SHOCK CAN KILL To reduce the risk of electric shock always unplug the welder from its ac power source before removing side panels IT IS VERY IMPORTANT TO MAINTAIN THE CONSUMABLES TO AVOID THE NEED FOR PREMATURE REPLACEMENT OF THE GUN ASSEMBLY The GUN LINER is intended to provide an unrestricted path for the welding wire to flow through the gun ass...

Page 18: ...aining gas tubing electrical cable and liner attached to the welder but move the welder to a place where the 18 Gun Assembly 7 8 g 10 Note 11 gun assembly can be laid out straight on a table or workbench or similar flat surface Unscrew and remove the nozzle With a crescent wrench six or eight inch turn the gas diffuser clockwise has left hand threads and remove the gas diffuser and contact tip tog...

Page 19: ...f the wire feed torch clamp far enough so that it is within approximately 1 16 inch of touching the drive roller 20 Make sure the cable covering tubing is far enough in the machine so that it is covered by the wire feed torch clamp 21 Tighten the two 1 4inch hex head screws may also be tightened by a straight blade screwdriver and one pan head Phillips screw to the drive roller securing the gun in...

Page 20: ... This problem can cause porous brittle welds and reduce penetration TESTING FOR A SHORTED NOZZLE Arcing between the nozzle and the work piece ALWAYS means the nozzle is shorted but this can be hard to detect through the lens of a welding helmet The following testing method is another way to tell if a nozzle is shorted With the welder unplugged from the ac power source touch the probes of an ohmmet...

Page 21: ... machine 2 Too tong or improper extension cord 3 Wrong type or size wire 4 Poor ground connection 5 Wrong size contact tip compressed air clean and tighten all connections 2 See EXTENSION CORD USE in this manual 3 Use correct size welding wire 4 Reposition clamp and check cable to clamp connection 5 Use correct size contact tip Wire is birdnesting at the drive roller Wire burns back to contact tip...

Page 22: ...Model 205111 J 5 o 0 t_rr 1 kL__ 0 _ WZ m CO CC n _ 0 o m o i g N cc kU i O2 b Z C12 C 2 22 kl l if V 0 LU Z _j W _ rr QZ W j EL LL_ 0 _J I w j I 0 X j o 0a D Z ...

Page 23: ...rr _IlHM Model 205111 rr tll 09 Z rr 6 23 ...

Page 24: ...Model 205111 24 ...

Page 25: ...e Quick Connector Gun Head Gas Valve Conductor Tube Conductor Tube Insulation 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 ...

Page 26: ...0 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 Re...

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