Related Manuals for Sears Craftsman 934.20105
Summary of Contents for Sears Craftsman 934.20105
- Page 1 811-309-000 MANUAL . EAR$ OWNERS MANUAL WIRE FEED MODEL No. MIG WELDER 934.20105 Operation Repair Parts CAUTION: Read Rules for Safe Operation and Instructions Carefully 811-309-000 SEARS ROEBUCK AND CO., CHICAGO, IL 60684 U.S.A.
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Page 2: Table Of Contents
Table of Contents IMPORTANT SAFETY INSTRUCTIONS Changing the Drive Roller ....INSTALLING ALUMINUM WIRE ....SHOCK HAZARDS ......FLASH HAZARDS ......PREPARING TO WELD FIRE HAZARDS ......PREPARING A SAFE WELDING WORK AREA.. FUME HAZARDS ......PREPARING THE WORK PIECE ..... COMPRESSED GASSES AND EQUIPMENT HAZ- ALUMINUM WELDING PREPARATION .. -
Page 3: Important Safety Instructions
IMPORTANT SAFETY INSTRUCTIONS Page 1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS! DO NOT OPERATE YOUR WELDER UNTIL YOU HAVE READ AND UNDERSTAND THESE INSTRUCTIONS (welding rod or welding wire). Any metal parts on the electrode holder or MIG gun. ELECTRIC SHOCK CAN KILL! NEVER weld in a damp area or come in contact with a moist or wet surface when welding. -
Page 4: Flash Hazards
IMPORTANT SAFETY INSTRUCTIONS P age2 ALWAYS keep containers of water or other liquids the inside of your helmet or shield, then into your far enough away from welder and work area so that eyes. If a reflective background exists in your weld- if spilled, the liquid could not possibly come in contact ing area, either remove it or cover it with something with the welder, welding cables (or MIG gun assem-... -
Page 5: Fume Hazards
IMPORTANT SAFETY INSTRUCTIONS Page)3 NEVER weld or cut in an area where the air may nized steel, unless the coating is removed, the contain flammable dust (such as grain dust), gas, area is well ventilated, or the operator and _all' or liquid vapors (such as gasoline). -
Page 6: Additional Safety Information
IMPORTANT SAFETY INSTRUCTIONS Page 4 NEVER use flammable gasses with MIG welders. ALWAYS protect cylinder, especially valve, from Only inert or non-flammable gasses are suitable bumps, falls, falling objects, and weather. for MIG welding. Examples are Carbon Dioxide, Argon, Helium, etc. or mixtures of more than one ALWAYS make sure cylinder cap is securely in of these gasses. -
Page 7: Product Description
PRODUCT DESCRIPTION Page. 5 PRODUCT DESCRIPTION WIRE SPEED - This control adjusts the speed at Your new Metal Inert Gas (MIG) wire feed welder which the wire is fed out of the gun. The wire speed is designed for maintenance, and sheetmetal fab- needs to be closely matched... -
Page 8: Assembly And Installation
ASSEMBLY ANDINSTALLATION Page6 ASSEMBLY AND INSTALLATION 4. Lay out the parts and compare to following illus- trations to familiarize yourself with the parts and what they are called. This will help you when ELECTRIC SHOCK CAN KILL! To re- reading the manual. duce risk of electric shock,... -
Page 9: Install Welding Gun Assembly
ASSEMBLY AND INSTALLATION Page 7 Knob DRIVE ASSEMBLY INSTALL WELDING ASSEMBLY On Gun On Welder 1. Insert the brass tail piece of the welding gun through hole in the front of the welder. 2. Align the gun's tail-piece with the hole in the brass conductor block on the front of the drive Female Plug... -
Page 10: Connect Welder To Power Source
ASSEMBLY AND INSTALLATION Page 8 ance and/or damage to the welder will result if tabs of the tank tray with the two holes in the operated on inadequate or excessive power. welder. Reinstall the two sheetmetal screws that were removed and TIGHTEN ONLY. -
Page 11: Select Shielding Gas
ASSEMBLY ANDINSTALLATION Page9 SELECT SHIELDING GAS Gas Selection For Aluminum Gas Welding The shielding gas plays an extremely important role in the MIG welding process. As with most welding processes, it is critical that the molten weld puddle be "shielded" from the atmosphere. -
Page 12: Gas Selection For Steel Welding With Silicon-Bronze Wire
ASSEMBLY ANDINSTALLATION Page 10 Gas Selection For Steel Welding With Silicon- PRESSED GASSES EQUIPMENT HAZ- bronze Wire ARDS in the SAFETY INSTRUCTION section of this manual. 1. Secure gas cylinder to the tank bracket kit, a wall or other fixed support. 2. -
Page 13: Checking Gas Flow
ASSEMBLY AND INSTALLATION Page 11 clamp with a pliers, slide it up the gas hose, and 3. Pull the trigger on the gun to allow the gas to release clamp when it is positioned on a portion flow. KEEP PULLED. Listen for gas to flow from of the hose that is over the brass fitting. -
Page 14: Select The Spool Size
ASSEMBLY AND INSTALLATION Page 12 dation for self-shielding, flux-core, steel wire is that on an 8" spool. However, welding wire oxi- AWS classification number E71T-GS. dizes over time, so it is important to select a spool size that will be used up within the times recom- NOTE: With flux core wire you will bum through mended... -
Page 15: Wire Spool Storage
ASSEMBLY ANDINSTALLATION Page19 INSTALL THE WELDING WIRE Wire Spool Storage ELECTRIC SHOCK KILL! Always turn the The above recommended spool storage times are POWER SWITCH to its OFF position and unplug rules-of-thumb and can be impacted by many fac- tors such as length of time in distribution prior to the welder's powercord from the AC power source retail sale, warehouse conditions, time of year (ie:... - Page 16 ASSEMBLY AND INSTALLATION Page 14 d. Remove the drive roller by pulling it straight 8. Place the spool on the spindle in such a manner out and off the drive motor shaft. that when the wire comes off the spool it will look like this: Find side of the...
- Page 17 ASSEMBLY AND INSTALLATION Page,_15_ a. With one hand, turn the wire spool and con- rying welding current whenever the welder, is, turned on -- WHETHER THE TRIGGER tinue turning it while adjusting the tension. PULLED OR NOT! b. With your free hand, tighten (turn clockwise) the wing-nut.
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Page 18: Installing Aluminum Wire
ASSEMBLY AND INSTALLATION Page 16 When set correctly, there should be no slippage between the wire and the drive teller under normal conditions, but if an obstruction occurs along the wire feed path, the wire should then slip on the drive roller. -
Page 19: Preparing To Weld
PREPARING TO WELD Page .17 PREPARING TO WELD PREPARING A SAFE WELDING bystanders in the welding area. It is a must that the WORK AREA welding work area be cleared of all flammables and that a type ABC chemical fire extinguisher always close at hand. -
Page 20: Aluminum Welding Preparation
PREPARING TO WELD Page 18 600PLATE 450 PLATE BUTT WELD JOINTS 37.5 ° SINGLE V JOINT SINGLE BEVELJOINT 6O 0 BUTT JOINT DOUBLEV JOINT DOUBLE BEVEL JOINT 3/32" TO 1/8" 60-- "-_N '_''r 1/16" TO 1/8" _ VEE JOINT CLOSED JOINT OPEN JOINT SHOUI.._ER EDGE 1/4"... -
Page 21: Operation
OPERATION Page 19 OPERATION GETTING TO KNOW YOUR NEW "TUNING IN" THE WIRE SPEED is one of the WELDER most important parts of MIG welder operation and must be done before starting each welding job or whenever of the following variables Whether you have welded before or not, it is impor- changed: heat setting, wire diameter, or wire type. -
Page 22: Holding The Gun
OPERATION Page 20 2. Angle "B" can be varied for two reasons: to REPEAT THIS TUNE-IN PROCEDURE if you se- improve the ability to see the arc in relation to lect a new heat setting, a different diameter _vire, the weld puddle and to directthe force of the arc. or a different type wire. -
Page 23: Distance From The Work Piece
OPERATION Page 21 Distance from the Work Piece Once you have the gun in position with the wire lined up on the weld joint, lower your helmet, pull The end of the welding gun is designed with the the trigger and the arc will start. In a second or contact tip recessed from the end of the nozzle and two, you will notice a weld puddle form and the... -
Page 24: Welding Techniques
WELDING TECHNIQUES Page 22 WELDING TECHNIQUES As you become more familiar with your new welder TRAVEL SPEED is the rate at which the gun is and better at laying some simple weld beads, you being "pushed" or "pulled" along the weld joint. can begin to try some different welding techniques For a fixed heat setting, the faster... -
Page 25: Welding Positions
WELDING TECHNIQUES Page 23 WELDING POSITIONS VERTICAL POSITION is the next most difficult position. "Pulling" the gun from top to bottom may be easier for many people, but in There are four basic welding positions: fiat, hori- some instances it can be difficult to prevent the zontal, vertical, and overhead. -
Page 26: Multiple Pass Welding
WELDING TECHNIQUES Page 24 MULTIPLE PASS WELDING ,,,,,,,,,,, ,,,,,, 1. Butt Weld Joints In PREPARING THE WORK PIECE, we discussed First or Root Pass the need for edge preparation on thicker materials by grinding a bevel on the edge of one or both pieces of the metal being joined. -
Page 27: Special Welding Methods
SPECIAL WELDING METHODS Page 25 SPECIAL WELDING METHODS SPOT WELDING and the arc is directed through this hole to pene- trate into the bottom piece. The puddle is al- lowed to fill up the hole leaving a spot weld that is smooth and flush with the surface of the top... -
Page 28: Maintenance And Trou- Bleshooting
MAINTENANCE AND TROUBLESHOOTING Page 26 MAINTENANCE AND TROUBLESHOOTING GENERAL MAINTENANCE b. Remove wire from gun assembly and gun assembly from welder. This welder has been engineered to give many years of trouble-free service providing that a few c. Remove nozzle and contact tip from gun very simple steps are taken to properly maintain d. -
Page 29: Testing For A Shorted No72'Le
MAINTENANCE AND TROUBLESHOOTING Page 27 TESTING FOR A SHORTED NOZZLE 2. The CONTACT TIP's purpose is to transfer welding current to the welding wire while allow- ing the wire to pass through it smoothly. Arcing between the nozzle and the work piece ALWAYS means the nozzle is shorted, but this can a. - Page 30 MAINTENANCE AND TROUBLESHOOTING Page 28 In the following TROUBLESHOOTING table, POSSIBLE CAUSE, listed for certain problems, INSUFFICIENT SHIELDING COVERAGE. IMPROPER HANDLING AND MAINTE- This "cause" itself can be the result of many differ- NANCE OF COMPRESSED CYLINDERS ent causes. Below, and preceeding the TROU- AND REGULATORS...
- Page 31 MAINTENANCE AND TROUBLESHOOTING Page 29 Gas flow rate too low DIRTY, POROUS, BRITTLE Increase flow rate from WELD regutator/flowmeter Try Increasing flow rate or set Wind or draft blowing gas up wind break away from weld puddle Wrong type of gas See select shielding gas WIRE FEED AND GAS Check ground or tighten all...
- Page 32 MAINTENANCE AND TROUBLESHOOTING Page 30 ii ir Allow welder to cool at least 10 NOTHING WORKS Exceeded duty cycle; thermal FAN IS ON minutes with fan running protector opened circuit (observe duty cycle) Replace rectifier Faulty rectifier Replace transformer Faulty transformer (extremely rare) Blow inside of machine LOW OUTPUT...
- Page 33 MAINTENANCE AND TROUBLESHOOTING Page 31 ..i lllllll iii ..WIRE "BIRDNESTING" Gun liner worn or damaged Replace liner DRIVE ROLLER Replace contact tip Contact tip is clogged or damaged Trim liner to proper length Liner stretched or too long Using aluminum wire with a Replace liner with teflon liner steel liner...
- Page 34 MAINTENANCE AND TROUBLESHOOTING Page 32 = = =llll, Check connections and FAN MOTOR DOES NOT RUN Loose connection or replace fan motor if needed faulty motor Bad connection from GROUND CLAMP AND/OR Tighten connection CABLE GETS HOT cable to clamp replace cable GUN NOZZLE ARCS TO...
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Page 35: Replacement Parts List
REPLACEMENT PARTS LIST Page 33 REPLACEMENT PARTS LIST ii i iin PART No. ITEM DESCRIPTION ITEM DESCR|!_TION PART No. Rectifier 410-694-020 860-905-666 Faceplate Fan Motor Kit 216-087-666 880-094-666 Wire Speed Control Fan Blade 316-009-666 Knob 246-041-666 312-076-666 Power Switch Sjoindle 246-177-6_ 312-077-666 433t... -
Page 36: Warranty
WARRANTY Page 34 WARRANTY FULL 1-YEAR WARRANTY If, within 1-year from the date of purchase, this Welder fails due to a defect in material or work- manship, simply return it to the nearest Sears store throughout the United States, and Sears wilt repair or replace it, free of charge.