Craftsman 934.205592 Operator's Manual

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Page 1

SEARS

CRRFTSMRN

Operator's Guide

WIRE FEED

MIG WELDER

Model No.

934.205592

CAUTION: Read and follow all Safety Rules and

Operating Instructions before First Use of this Product.

• WARRANTY

• INTRODUCTION

• SAFETY SUMMARY

• SPECIFICATIONS

• INSTALLATION

• OPERATION

• MAINTENANCE

• SCHEMATIC

• WIRING DIAGRAM

• REPLACEMENT PARTS

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

811-642-000 September 2001

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

Full One Year Warranty for Craftsman Welding Gun or Cables. For one year

from the date of purchase, when the

welding gun or cables are operated and maintained according to the owner's manual instructions, if the welding gun

or cables fail due to a defect in material or workmanship, Sears will repair or

replace the welding gun or cables free of charge. This warranty does not cover parts consumed in normal operation, such as contact tips, nozzles, gun liners,

and drive rollers. Full Three Year 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 SERVICE IS AVAILABLE BY SIMPLY CONTACTING THE NEAREST SEARS SERVICE CENTER.

This warranty applies only while this product is in use in the United States.

This warranty gives you specific legal rights, and you may also have other

rights which vary from state to state. Sears Roebuck and Co., Dept. 817WA,

Hoffman Estates, IL 60179.

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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 EQUIPMENT 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 .................................................................... 11

ALIGN AND SET THE DRIVE ROLLER ............................................. 11

STANDARD DRIVE ROLLER ............................................................ 11

INSTALL THE WELDING WIRE .......................................................... 12

SET THE WIRE DRIVE TENSION ...................................................... 14

PREPARATION .................................................................................... 15

CHANGE POLARITY ........................................................................ 15

OPERATION ......................................................................................... 16

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

MAINTENANCE .................................................................................... 17

GENERAL ........................................................................................... 17

REPLACE A GUN LINER .................................................................. 17

MAINTAINING THE CONTACT TIP .................................................. 20

MAINTAINING THE NOZZLE ........................................................... 20

TESTING FOR A SHORTED NOZZLE ............................................ 21

PREVENTIVE MAINTENANCE ......................................................... 21

TROUBLESHOOTING ........................................................................ 21

WIRING DIAGRAM ............................................................................... 23

REPLACEMENT PARTS LIST ............................................................. 24

SCHEMATIC ......................................................................................... 26

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This Welder User's Guide provides

specific information about your wire

feed welder. It is to be used together

with the Welding Instruction Guide to provide all 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.

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.

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Every craftsman respects the tools with which they work. They know that the

tools represent years of constantly

improved designs and developments.

The true craftsman also knows that tools

are dangerous if misused or abused. Reading this Operator's Guide and the

Welding Instruction Guide before using

the welder will enable you to do a better,

safer job. Learn the welder's applications and limitations as well as

the specific potential hazards peculiar to

welding.

SAFETY INFORMATION

The following safety information is

provided as guidelines to help you operate your new welder under the safest possible conditions. Any equipment that uses electrical power can be potentially dangerous to use when safety or safe handling instructions

are not known or not followed. The

following safety information is provided to give you the information necessary for

safe use and operation. When a procedure step is preceded by

a WARNING, it is an indication that the step contains a procedure that might be

injurious to a person if proper safety precautions are not heeded.

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

step contains a procedure that might damage the equipment being used.

A NOTE may be used before or after a procedure step to highlight or explain something in that 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 followingsafety alert

symbols identify important safety messages in this manual.

When you see one of the symbols shown here, be alert to the possibility of personal injury and carefully read the message that follows.

This symbol indicates that the

possibility of electric shock hazard exists during the operation of the step(s) that

follow.

This symbol indicates that the

possibility of fire hazard exists during the operation of the step(s) that follow.

This symbol indicates that the

helmet must be worn during

the step(s) that follow to

protect against eye damage and burns due to flash

hazard.

This symbol indicates that the

possibility of toxic gas hazard exists during operation of the step(s) that follow.

This symbol indicates that the

possibility of being burned by hot slag exists during operation of the step(s) that

follow.

This symbol indicates that the

eye protection should be worn

to protect against flying debris

in the following step(s).

This symbol indicates that the

possibility of injury or death exists due to improper handling and maintenance of compressed gas cylinders or regulators

Full explanations of the specific hazards are shown in the WELDING

INSTRUCTION GUIDE. Make sure you have read and understand all of the

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informationbeforeproceedingwithany oftheinstructionscontainedinthis

user'sguide. Publishedstandardsonsafetyare

available.Theyarelistedin ADDITIONALSAFETYINFORMATION

attheendofthisSAFETYSUMMARY.

TheNationalElectricalCode,

OccupationalSafetyandHealthAct regulations,localindustrialcodesand localinspectionrequirementsalso provideabasisforequipment

installation,use,andservice.

SHOCKHAZARDS

WARNING

ELECTRIC SHOCK CAN KILL! To

reduce the risk of death or serious injury from shock, read, understand,

and follow the following safety instructions. In addition, make

certain that anyone else who uses

this welding equipment, or who is a

bystander in the welding area understands and follows these safety

instructions as well.

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

instructions. In 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 as well. REMEMBER!

Welding by nature produces sparks, hot spatter, molten metal drops, hot

slag, and hot metal parts that can start fires, burn skin, and damage

eyes.

FLASH HAZARDS

WARNING

ARC RAYS CAN INJURE EYES AND BURN SKIN! To reduce risk of

injury from arc rays, read, understand, and follow the following safety instructions. In 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 as well.

FUME HAZARDS

WARNING

FUMES, GASSES, AND VAPORS CAN CAUSE DISCOMFORT, ILLNESS, AND DEATH! To reduce

risk of discomfort, illness, or death, read, understand, and follow the following safety instructions. In 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 as well.

COMPRESSED GASSES AND EQUIPMENT HAZARDS

WARNING

IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATH! To

reduce risk of injury or death from compressed gasses and equipment

hazards, read understand and follow the following safety instructions. In

addition, make certain that anyone else who uses this welding

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equipmentorabystanderinthe weldingareaunderstandsand

followsthesesafetyinstructionsas

well. Donotuseflammablegasseswith

MIGwelders.Onlyinertor nonflammablegassesaresuitablefor MIGwelding.ExamplesareCarbon Dioxide,Argon,Helium,etc.or

mixturesofmorethanoneofthese gasses.

BURN HAZARDS

WARNING

Hot slag can cause fires and serious injury from burns. To

reduce the risk of discomfort or serious injury due to burns always

wear heavy protective clothing, eye and face protection, and gloves designed for welding. To prevent the risk of fires starting, use a metal plate or some other material with a high

flash point to catch and shield

combustibles from the hot slag.

ADDITIONAL SAFETY INFORMATION

For additional information concerning welding safety, refer to the following standards and comply with them as applicable.

• ANSI Standard Z49.1 i SAFETY IN

WELDING AND CUTTING i obtainable from the American Welding

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

• ANSI Standard Z87.1 i SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION i obtainable from the

American National Standards Institute,

11 West 42ndSt., New York, NY 10036

Telephone (212) 642-4900, Fax (212) 398-0023 i www.ansi.org

• NFPA Standard 51B i CUTTING

AND WELDING PROCESS i obtainable from the National Fire

Protection Association, 1 Batterymarch Park, P.O. Box 9101,

Quincy, MA 02269-9101 Telephone

(617) 770-3000, Fax (617) 770-0700

i www.nfpa.org

• CGA Pamphlet P-I i SAFE HANDLING OF COMPRESSED

GASSES IN CYLINDERS i obtainable from the Compressed Gas

Association, 1725 Jefferson Davis

Highway, Suite 1004, Arlington, VA

22202-4102 Telephone (703) 412- 0900 Fax (703) 412-0128 i www.cagnet.com

• OSHA Standard 29 CFR, Part 1910,

Subpart Q., WELDING, CUTTING AND BRAZING i obtainable from

your state OSHA office or U. S. Dept. of Labor OSHA, Office of Public Affairs, Room N3647, 200 Constitution Ave. Washington, DC 20210 i www.osha.gov

• CSA Standard W117.2 i Code for

SAFETY IN WELDING AND CUTTING. i obtainable from

Canadian Standards Association, 178

Rexdale Blvd. Etobicoke, Ontario M9W 1R3 i www.csa.ca

• American Welding Society Standard

A6.0. WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES. i obtainable from

the American Welding Society, 550

NW Le Jeune Road, Miami, FL 33126

Telephone (800) 443-9353, Fax (305) 443-7559 i www.amweld.org or www.aws.org

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DESCRIPTION

Your new wire feed welder is designed

for maintenance and sheet metal fabrication. The welder consists of a

single-phase power transformer, stabilizer, rectifier, and a unique built-in

control/feeder. This MIG welder is capable of welding with 0.024 (0.6mm)

and 0.030 (0.8mm), solid steel wire on dc reverse polarity and with .030 inch self-shielding flux-core wire on dc straight polarity. Larger, 0.035 inch (0.9mm) diameter solid steel wire, on dc reverse polarity, and self shielding flux- core wire on dc straight polarity may

also be used on this welder. The use of larger diameter wire makes welding

difficult and the results cannot be guaranteed. The manufacturer does not

recommend the use of larger diameter wire.

Now you can weld sheet metal from 24 gauge up to 1/4 inch thick with a single

pass. You can weld thicker steel with beveling and multiple pass techniques.

Table 1 lists your MIG welder

specifications.

Table 1. Welder Specifications

Primary (input) volts 120 Vac Primary (inputs) Amps 25 Phase Single

Frequency 60 Hz Secondary (output) volts 19.5 Secondary (UL output) ampsl05 Open Circuit Volts (Max.) 28 Vdc

Duty Cycle Rating 20%

WELDER OPERATING

CHARACTERISTICS

DUTY CYCLE

The duty cycle rating of a welder defines

how long the operator can weld and how long the welder must be rested and cooled. Duty cycle is expressed as a percentage of 10 minutes 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 minutes 8 minutes 40% 4 minutes 6 minutes 60% 6 minutes 4 minutes 80% 8 minutes 2 minutes

100% 10 minutes 0 minutes

INTERNAL THERMAL PROTECTION

CAUTION

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

protector will open, shutting off all welder functions except the cooling fan. If this happens, DO NOT SHUT

OFF THE WELDER. Leave the welder turned on with the fan running.

After cooling, the thermal protector will

automatically reset and the welder will function normally again. However, you should wait at least 10 minutes

after the thermal protector opens

before resuming welding. You must

do this even if the thermal protector

resets itself before the 10 minutes is

up or you may experience less than specified duty cycle performance.

If you find that your welder will not weld for 2 minutes without stopping, reduce the wire speed slightly and tune the welder in at the lowest wire speed setting that still produces a smooth arc. Welding with the wire speed set too high

causes excessive current draw and shortens the duty cycle.

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POWER SOURCE CONNECTION

POWER REQUIREMENTS

This welder is designed to operate on a

properly grounded 120 Volt, 60 Hz, single-phase alternating current (ac) power source fused with a 20 amp time- delayed fuse or circuit breaker. It is recommended that a qualified electrician

verify the ACTUAL VOLTAGE at the

receptacle into which the welder will be plugged and confirm that the receptacle

is properly fused and grounded. The use of the proper circuit size can

eliminate nuisance circuit breaker

tripping when welding.

DO HOT OPERATE THIS WELDER if

the ACTUAL power source voltage is

less than 105 Volts ac or greater than 132 Volts ac. Contact a qualified electrician if this problem exists. Improper performance and/or damage to

the welder will result if operated on

inadequate or excessive power.

CONNECT TO POWER SOURCE

WARNING

High voltage danger from power source! Consult a qualified electrician

for proper installation of receptacle at the power source.

This welder must be grounded while in

use to protect the operator from electrical shock. If you are not sure if

your outlet is properly grounded, have it

checked by a qualified electrician. Do not cut off the grounding prong or alter

the plug in any way and do not use any

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 to a properly grounded 120 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 a properly grounded extension

cord that will mate directly with the ac

power source receptacle and the welder

power cord without the use of adapters.

Make certain that the extension is properly

wired and in good electrical condition.

Extension cords must be at the smallest

a #12 gauge cord. Do not use an

extension cord over 25 ft. in length.

ASSEMBLING THE

WELDER

The following procedures describe the

process required to assemble, install,

maintain, and prepare to weld with your

new wire feed welder.

UNPACKING THE WELDER

1. Remove any cartons or bags containing parts/accessories.

2. Open the cartons or bags packed with your welder and inspect their

contents for damage. Report any missing or damaged items

immediately.

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

INSTALL THE GROUND CLAMP

Connect the ground clamp to the ground cable (coming out the front of the welder) according to the instructions packaged with the ground clamp.

INSTALL THE TANK TRAY AND BRACKET

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

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IMPORTANT - GAS CYLINDER SIZE RESTRICTION! The tank tray you have

just installed on the back of the welder will handle gas cylinders no larger than 20 cubic feet. If you select a cylinder larger than 20 cubic feet, it must be chained to a wall or other fixed support.

j 1

Figure 1. Mount Tank Tray Bracket

ToWelder

Align the four tank tray bracket (1) mounting holes (as shown in Figure

1) with the four staked nuts on the

rear of the welder. Start one 1_inch split lock washer

(2) and a 1_-20 x _/2inch hex bolt (3) in one of the top tank tray bracket (1) mounting holes, then start each of the other three split lock nuts (2) and _-20 x 1/2inch hex bolts (3) through the remaining mounting

holes.

3. Tighten all four hex bolts.

INSTALL THE SHIELDING GAS

WARNING

IMPROPER HANDLING AND

MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS

CAN RESULT IN SERIOUS INJURY OR DEATH! Always secure gas

cylinders to the tank bracket kit, a wall, or other fixed support to prevent the cylinder from falling over and rupturing.

Read, understand, and follow all the COMPRESSED GASSES AND

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.

Remove the protective cap from the cylinder and inspect the regulator connecting threads for dust, dirt oil, and grease. Remove any dust or

dirt with a clean cloth. DO NOT ATTACH THE REGULATOR IF OIL,

GREASE, OR DAMAGE ARE PRESENT.

2. Open the cylinder valve FOR JUST AN INSTANT to blow out any foreign matter inside the valve port to reduce the risk of plugging or damaging the regulator. Never aim the open cylinder valve port at yourself or bystanders.

3. Screw the regulator supplied with this welder (see Figure 2) into the

cylinder valve and tighten with a wrench.

Adjustable Regulator Preset Regulator

Figure 2. Gas Regulators

4. Insert the gas hose into the outlet port of the gas regulator. The hose locks in place in the fitting when pressed into the port.

5. To remove the gas hose, press down on the ring at the rear of the gas fitting, and pull the hose out of the fitting.

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CHECK THE GAS FLOW

WARNING

IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERIOUS INJURY

OR DEATH! To reduce the risk of injury

or death, always stand to the side of the cylinder opposite the regulator when opening the cylinder valve, keeping the cylinder valve between you and the regulator. Never aim the open cylinder

valve port at yourself or bystanders.

Failure to comply with this warning could result in serious personal injury.

Note: If the cylinder you have is

equipped with male regulator connecting threads instead of

female, you will need to obtain a special compressed gas

cylinder adapter from your gas supplier to install between your

gas cylinder and regulator.

• The gas control function does not require the welder to be

turned on or plugged in.

1. 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 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 gas flow

should be set at 15-20 cubic feet per hour. If no gas is heard or felt,

verify all steps involved in

connecting the gas.

3. Release the trigger. Note: If welding outside or in a draft, it

may become necessary to set up a windbreak to keep the

shielding gas from being blown from the weld area.

• MAKE SURE TO TURN OFF THE GAS CYLINDER VALVE WHEN DONE WELDING.

ALIGN AND SET THE DRIVE

ROLLER

Before installing any welding wire into the unit, the proper sized groove must be placed into position on the wire drive mechanism. Change to a neoprene drive roller when welding with

aluminum wire.

STANDARD DRIVE ROLLER

Change the standard drive roller according to the following steps:

1. Remove the drive tension by unscrewing the tension adjusting screw (ALL THE WAY in a counter- clockwise direction). The drive tension screw will come loose, allowing you to pull the drive tension arm up away from the drive roller. Make sure to keep the screw and the spring in place with the

drive tension arm.

If there is wire already installed in the welder, roll it back onto the wire

spool by hand-turning the spool counter-clockwise. Be careful not

to allow the wire to come out of the rear end of the gun without holding

onto it or it will unspool itself. Put the end of the wire into the hole on

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.

Loosen the drive roller setscrew and pull the drive roller off the drive

shaft.

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Note: 6. Tighten the setscrew, while holding

the drive roller in place.

The drive roller has two wire size grooves built into it. When

installing the drive roller the number stamped on the drive roller for the wire size you are using should be facing away from you. If you can read the wire size you are using on the

drive roller, it is installed backwards. Use only the

proper size drive roller when using your welder.

Find the side of the drive roller that is stamped with the same wire

diameter as that of the wire being installed (see Figure 3, and if in

metric, see DESCRIPTION in the WELDER SPECIFICATIONS

section). Make certain the spacing washer is still on the motor shaft

and push the drive roller onto the motor shaft, aligning the setscrew

with the flat side of the drive shaft.

Make sure the side stamped with the desired wire diameter is away from you.

Drive Roller

Shaft

Washer

Figure 3. Drive Roller

Slide the roller onto the shaft so that 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.

INSTALL THE WELDING WIRE

WARNING

Electric shock can kill! Always turn

the POWER switch OFF and unplug the power cord from the ac power source before installing wire.

Be very careful when removing the welding nozzle. The contact tip on this welder is electrically hot as long as

POWER is turned ON. Make certain POWER is turned OFF.

Remove the nozzle and contact tip from the end of the gun assembly.

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.

Unwrap the spool of wire then find the leading end of the wire (it goes through a hole in the outer edge of the spool and is bent over the spool edge to prevent the wire from unspooling) BUT DO NOT

UNHOOK IT YET.

Place the spool on the spindle in such a manner that when the wire

comes off the spool, it will look like the top illustration in Figure 4. The

welding wire should always come off the top of the spool into the drive

mechanism.

Page 13

RightWay

WrongWay

Figure 4. Right and Wrong Way To

Feed Wire From Spool

5. If you are installing a four-inch spool of wire, install the drive brake hardware on the top of the spool of

wire according to Figure 5A. If you Note: are installing an eight-inch spool,

install the spindle adapter and drive brake hardware as shown in Figure 5B. The purpose of the drive brake is to cause the spool of wire to stop

turning at nearly the same moment that wire feeding stops.

6. Once the drive brake hardware is installed, set the spool tension.

With one hand, turn the wire spool 7. and continue turning it while adjusting the tension on the spool. With your free hand, tighten (turn clockwise) the wing nut that holds

the spool in place. Stop tightening

when drag is felt on the wire spool

that you are turning, then stop hand 8. turning the wire spool.

4" Spool

8" Spool

Figure 5. Drive Brake Assemblies with Four Inch and Eight Inch Wire

Spools

10.

If TOO MUCH tension is applied to the wire spool, the

wire will slip on the drive roller

or will not be able to feed at all. If TOO LITTLE tension is

applied, the spool of wire will

want to unspool itself. Readjust the drive brake tension as

necessary to correct for either problem.

After checking to make sure that your welder is disconnected from

the ac power source, free the leading end of the wire from the

spool, but do not let go of it until told to do so, or the wire will unspool

itself. Using a wire cutter, cut the bent end

off the leading end of the wire so that only a straight leading end

remains. Loosen the tension adjusting screw

holding the drive tension arm in place and lift the tension arm up off

the drive roller. Insert the leading end of the wire

into the inlet guide tube. Then push it across the drive roller and into the

gun assembly about six inches.

Page 14

CAUTION

Make certain that the welding wire is actually going into the gun liner. Be very sure it has not somehow been accidentally been routed alongside

the liner or even in some other direction. If this should happen, the

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

tension adjusting screw until the tension roller is applying enough

force on the wire to prevent it from

slipping out of the drive assembly.

13. Let go of the wire.

14. Connect the welder power cord to

the ac power source. Turn the

welder POWER switch ON. Set the VOLTAGE switch to the voltage

(heat) setting recommended for the gauge metal that is to be welded. Refer to the label mounted on the

cover, inside the drive compartment, for recommended

voltage (heat) settings for your

welding job. The VOLTAGE selector controls the weld heat.

There are eight voltage (heat)

selections (numbered 1 through 8) available on this welder.

Numbered position 1 provides the lowest voltage (heat) and position 8 the highest voltage (heat).

15. Set the WIRE SPEED control to the middle of the wire speed range.

16. Pull the trigger on the welding gun

to feed the wire through the gun

assembly.

17. When at least an inch of wire sticks out past the end of the gun, release

the trigger.

18. Select a contact tip stamped with the 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 the

gun). Thread the contact tip into the end of the gun and hand-tighten

securely.

20. Install the nozzle on the gun assembly. For best results, coat the

inside of the nozzle with anti-stick spray or gel (part #4312, not

supplied).

21. Cut off the excess wire that extends past the end of the nozzle.

SET THE WIRE DRIVE TENSION

WARNING

To reduce the risk of arc flash, make certain that the wire coming out of the end of the gun does not come in contact with the workpiece clamp or any grounded material during the drive tension setting process or arcing will occur.

Pull the trigger on the gun. Turn the drive tension adjustment

knob clockwise, increasing the drive tension until the wire seems

to feed smoothly without slipping. Block the end of the nozzle by

holding it up against something that doesn't conduct electricity,

such as a block of wood or a concrete floor, then trigger the gun

again. The wire should slip at the drive roller. However, if the wire bird-nests at the drive roller,

rethread the drive system using less drive tension and try again.

Page 15

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.

PREPARATION

CHANGE POLARITY

This welder allows you the capability to

change 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, stainless steel, flux cored hardfacing of steel, and silicon bronze welding of steel, select dc Reverse Polarity (dc + MIG). When using self-shielding, flux- core steel wire, use dc Straight Polarity (dc - Flux Cored).

Change the polarity of your welder according to the following procedure steps. Figure 8 shows what the polarity block should look like for each polarity setting.

WARNING

Electric shock can kill! Always turn the POWER switch OFF and unplug the power cord from the ac power source before changing polarity.

CAUTION

Do not use a ratchet, crescent or other lever type wrench to tighten the nuts

on the polarity bus. The nuts must be

hand tightened with a 7/16 inch nut

driver only. Too much torque applied to the one of the nuts could cause the

threaded post to break off.

Tools Required:

• 7/16 inch nut driver

With a 7/16 inch nut driver, remove all four nuts and pull out the

vertically mounted copper straps. Replace the copper straps

horizontally in the dc Straight Polarity (dc - Flux Cored) configuration shown in Figure 6.

DC+ DC MIG FLUX CORED

Figure 6. Welder Polarity Selections

3. Start the four nuts on the four connecting posts and hand snug

each nut with the 7/16 nut driver. Do not use a ratchet, crescent or

other lever type wrench.

Page 16

Operation of this welder consists of selecting and adjusting operating controls for optimum voltage (welding heat) and wire speed settings.

CONTROLS AND INDICATORS

WARNING

Electric shock can kill! To remove

the risk of electric shock, be aware that the VOLTAGE selector, when

OFF, does not remove power from all internal circuitry in the welder.

POWER - This welder has a POWER switch mounted on the front panel. The

POWER switch is used to initiate (turn

the welder ON) or extinguish (turn the

welder OFF) ac power to the welder.

VOLTAGE SELECTOR - The voltage selector controls the welding heat. The voltage selector provides continuous voltage (heat) adjustment but has reference number settings 1-8. Number 1 is the lowest voltage (heat) setting and number 8 the highest. Refer

to the label under the welder hood for recommended voltage (heat) settings

for your welding job. WIRE SPEED CONTROL - The WIRE

SPEED CONTROL adjusts the speed at which the wire is fed out of the welding gun. The wire speed needs to be closely matched (tuned-in) to the rate at which it is being melted off (see TUNING IN THE WIRE SPEED, (in the Welding Instruction Guide). Some things that affect wire speed selection are the type and diameter of the wire being used, the heat setting selected, and the welding position to be used.

Page 17

GENERAL

This welder has been engineered to give

many years of trouble-free service providing that a few very simple steps are taken to properly maintain it.

1. Keep the wire drive compartment lid closed at all times unless the wire

needs to be changed or the drive

tension needs adjusting.

2. Keep all consumables (contact tips, nozzles, and gun liner) clean and replace when necessary. See

CONSUMABLE MAINTENANCE AND TROUBLESHOOTING later in

this section for detailed information.

Replace power cord, ground cable, ground clamp, or gun assembly

when damaged or worn. Periodically clean dust, dirt, grease,

etc. from your welder. Every six months or as necessary, remove

the side panels from the welder and

air-blow any dust and dirt that may have accumulated inside the

welder.

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 assembly. Over time it will accumulate dust, dirt, and other debris. Replacement is necessary when these accumulations begin to restrict the free flow of wire through the gun 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 or replacement will be necessary. See Figure 7 for the drive assembly and Figure 8 for the gun assembly.

Page 18

Drive Drive Gun

Tension Tension Liner

Adjustment Arm

1/4" Hex

Head Screws

Inlet Guide

Tube End

Inlet

Guide

Tube

l Phillips Pan Str#in

Rehef

Head Screw Clamp

Drive Roller

Drive

Assembly

Gun

Assembly

(Tail End)

Figure 7. Drive Assembly

Gun

Cable

Plastic

Cable Tie

Cable

Coverin(

Handle Wire

Case

Live Wire Terminal

Contact

Gas Conductor

Gas Valve Tube Insulation

Lockwasher

Head End Gun Liner

Tube

Gas

Diffuser Contact

(has lefthand Tip

Nozzle

Figure 8. Gun Assembly

Page 19

Tools Required: ° 5/16 inch open end wrench

° Crescent Wrench (6 or 8 inch) ° 9 mm open end wrench (or 3 inch

crescent)

° Phillips Screwdriver ° Straight Blade Screwdriver or 1_inch

hex driver

Turn OFF welder POWER SWITCH.

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 the

wire itself while turning the spool or

the wire will unspool itself when it

becomes free of the gun liner), removing wire from gun assembly.

5. Remove two 1_ inch hex head screws (may also be removed with

a straight blade screwdriver) and one pan head Phillips screw (inlet guide tube end) from the drive roller and lift away the strain relief clamp that holds the tail end of the gun in the drive assembly.

6. Leave the gun assembly (consists of nozzle, gas diffuser, conductor

tube, handle and cable containing

gas tubing electrical cable and liner) attached to the welder but

move the welder to a place where

the 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 together) from the

conductor tube on the end of the gun. Remove the four Phillips head

screws that hold the handle case

together. With the exception of the trigger, completely remove the

contents of the handle case.

10. Cut the plastic cable tie away from the cable covering (tubing).

Note: In the following procedure step,

it may be necessary to remove

the gas fitting from the gas valve in order to make room to

turn out the head end of the

gun liner.

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

from the gas valve. Save the internal star lock-washer and note

the orientation of the live wire terminal. If you find it necessary to

remove the gas hose connector, press down on the ring at the rear

of the gas fitting to release the gas hose and pull out the gas hose.

Remove the gas fitting with a 9 mm open end wrench or three inch

crescent.

12. Pull the liner out of the cable covering (tubing) from the handle

end and push the small piece of liner out of the conductor tube.

13. Carefully insert the new liner into the cable taking particular care to

keep the liner straight (especially at the terminal end) to ease its

passage through cable covering. It may be desirable, perhaps even

necessary, to apply some silicon grease to the outside of the new

liner so that it will slide easily through the cable.

14. Insert the new piece of liner in the conductor tube.

Note: If you found it necessary to

remove the gas and hose connector at step 9, remember to reconnect it after completing step 12. The gas hose can be

reconnected by simply pushing

it into the back of the connector.

15. Insert the head of the gun liner through the internal star lock

washer and the live wire terminal (repeat the orientation noted in

step 9). With a 5/16 inch open end wrench, screw the head end of the

new liner into the gas valve.

Page 20

16. Insert a new plastic cable tie in place around the cable and tighten

it in approximately the same location as the plastic cable tie that

was cut in step 8.

17. Return all components to the handle casing and realign them as

they were originally.

18. With both halves of the handle case in place, tighten the four

Philips pan head screws making sure the trigger remains seated in

place.

19. Push the cable into the welder far enough so that the end of the gun

liner protrudes through the inlet guide tube end of 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_inch 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

place.

22. Re-install the welding wire according to INSTALL THE

WELDING WIRE.

MAINTAINING THE CONTACT TIP

The purpose of the CONTACT TIP is to transfer welding current to the welding

wire while allowing the wire to pass

through it smoothly.

Always use a contact tip stamped with

the same diameter as the wire it will be

used with.

If the wire burns back into the tip, remove the tip from the gun and

clean the hole running through it with an oxygen-acetylene torch tip

cleaner or tip drill.

2, Over time, the hole in the contact

tip will become worn by the wire passing through it. The more worn

this hole becomes, the less efficient is the transfer of welding current to

the wire and eventually arc breakage and difficult arc starting will result. Replace contact tips when signs of wear become apparent.

MAINTAINING THE NOZZLE

The nozzle directs the shielding gas to the weld puddle, determines the size of the shielding area, and prevents the electrically hot contact tip from contacting the work piece.

CAUTION

KEEP THE NOZZLE CLEAN! During

the welding process, spatter and slag will build up inside the nozzle and

must be cleaned out periodically. Failure to clean and/or replace the nozzle in a timely fashion WILL

CAUSE DAMAGE TO THE FRONT-

END OF THE GUN ASSEMBLY.

For best results, coat the inside of a new or freshly cleaned nozzle with anti-stick spray or gel.

1. Stop welding and clean any accumulated slag or spatter from the nozzle every 5 to 10 minutes of welding time.

2. When welding overhead, if any molten metal drips from the weld

puddle and falls into the nozzle, STOP WELDING IMMEDIATELY

and clean the nozzle.

If the slag cannot be thoroughly cleaned from the nozzle,

REPLACE THE NOZZLE!

Failure to keep the nozzle adequately cleaned can result in the following problems:

Page 21

A SHORTED nozzle results when

spatter buildup bridges the insulation in the nozzle allowing welding current to flow through it as well as the contact tip.

When shorted, a nozzle will steal

welding current from the wire whenever

it contacts the grounded work piece. This causes erratic welds and reduced

penetration.

In addition, a shorted nozzle overheats the end of the gun, which can DAMAGE the front-end of the gun.

A RESTRICTED nozzle is created when

enough slag builds up in the nozzle to

affect the direction, concentration, and

or rate of the shielding gas flow. 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 ohmmeter or continuity tester to the end of the contact tip and the outside of the nozzle. If there is any continuity at all, the nozzle IS shorted. Clean or replace

as needed.

PREVENTIVE MAINTENANCE

Except for internal and external cleaning, cleaning the nozzle, and occasionally retightening screws, there is no periodic maintenance recommended for your welder.

TROUBLESHOOTING

The following TROUBLESHOOTING information is provided as a guide to

help resolve some of the more common problems that could be encountered.

Table 3 is a troubleshooting table provided to help you determine a possible remedy when you are having a problem with your welder. This table does not provide all possible solutions, only those possibilities considered to likely be common faults. The table consists of a TROUBLE or symptom, a POSSIBLE CAUSE for that symptom,

and a POSSIBLE REMEDY for that symptom.

Page 22

Table 3. Troubleshooting

TROUBLE

Dirty, porous brittle weld

Wire feed works but no arc

Arc works but not feeding wire.

Nothing works except fan

Low output or non-penetrating weld.

Wire is birdnesting at the drive roller

Wire burns back to contact tip

POSSIBLE CAUSE

1. Plugged welding nozzle

2. No shielding gas

3. Wrong Type of Gas

4. Dirty or rusty welding wire

1. Bad ground or loose connection

2. Bad connection to gun or faulty gun

1. Faulty wire speed control assembly

2. No tension on the drive roller

3. Faulty drive motor (very rare)

1. Faulty trigger on gun

2. Faulty transformer (rare)

3. Exceeded duty cycle; thermal protector opened

1. Loose connection inside machine

2. Too long or improper extension cord

3. Wrong type or size wire

4. Poor ground connection

5. Wrong size contact tip

6. Loose gun connection or faulty gun assembly

7. Wrong welding polarity set

8. Dirty or rusty welding wire

1. Too much tension on drive roller

2. Gun liner worn or damaged

3. Contact tip is clogged or damaged

4. Liner is stretched or is too long

1. Gun liner is worn or damaged

2. Liner stretched or is too long

3. Wrong size contact tip

4. contact tip clogged or damaged

POSSIBLE REMEDY

1. Clean or replace nozzle

2. Tank empty, flow restricted, or regulator set too low

3. See SELECTING SHIELDING GAS in the WELDING

INSTRUCTION GUIDE for proper selection

4. Replace spool of wire

1. Check ground and connections tighten as necessary

2. Check connection to gun or replace gun

1. Replace wire speed control assembly

2. Adjust the drive tension

3. Replace drive motor

1. Replace trigger

2. Replace transformer

3. Allow welder to cool at least 10 minutes (observe and maintain

proper duty cycle

1. Blow inside of machine out with 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

6. Tighten gun or replace gun

7. Change polarity to proper for wire being used

8. Replace spool of wire

1. Adjust the drive tension (see INSTALLING THE WELDING

WIRE)

2. Replace gun liner

3. Replace contact tip

4. Trim liner to proper length

1. Replace gun liner

2. Trim liner for proper length

3. Use correct size contact tip

4. Replace contact tip

Ground clamp and!or Bad connection from cable to Tighten connection or replace cable cable gets hot clamp

Gun nozzle arcs Slag buildup inside nozzle or Clean or replace nozzle as needed to work surface nozzle is shorted

Page 23

v v © ©

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MODEL 205592

Page 24

MODEL 205592

Page 25

PART NO.

117-084-902 246-120-000 216-100-000 410-900-010 541-057-000 238-223-666 246-107-666 246-423-000

238-593-000

410-869-011 880-455-888

410-865-020 312-295-666 246-414-000 880-406-000 310-187-666

131-419-000 312-076-666 410-960-010

880-456-666 880-425-000 253-333-000 248-351-000 239-074-000 880-454-666 312-296-666 410-864-020 216-055-666 412-723-000 880-431-000

880-435-000 412-635-010 238-593-000

43090 43100

43480 334-440-000 334-465-000 334-495-666 059-217-040 334-468-666

334-467-000

ITEM DESCRIPTION

¥ 202082 Sears 105 amp MIG Welder

1 Potentiometer 2 Fan 3 Front Panel 4 Strain Relief

5 Cable Assembly 6 Knob

7 Switch 8 10' MIG gun 9 Control Panel

10 Transformer

11 Left Side Panel

12 Slide Latch W/Clip 13 Terminal Block

14 Wire Feed Motor 15 Steel Drive Roller 16 Tension Hardware

17 Spindle 18 Center Panel 19 Circuit Board

20 Wire Harness

21 Fitting

22 Power Cord 23 Strain Relief 24 Rectifier 25 Handle W/Hardware

26 Right Side Panel 27 Relay

28 Heatsink 29 Base

30 Thermo Breaker 31 Tank Bracket

¥ Trafimet MIG Gun (10 foot cable)

32 Contact Tip 0.024" (0,6 mm)

Contact Tip 0.030" (0,8 ram)

33 Nozzle 34 Trigger (MIG Gun)

35 Gun Cable, Complete 36 Handle (With Trigger)

37 Gas Hose 38 Liner

39 Gas Hose Quick Connector

¥ Gun Head: Gas Valve, Conductor Tube,

Conductor Tube Insulation, Gas Diffuser

40 Gas Valve

41 Conductor Tube Insulation

42 Conductor Tube 43 Gas Diffuser (MIG Gun)

1- Regulator 1- Tube Fitting for Regulator 1- Wire Spool Adapter (for 8") 1- Ground Clamp 1- Welding Face Shield 1- Not Shown In Drawing ¥ Complete Assembly

334-490-666

334-491-666 334-493-666

334-492-666 334-494-666 334-460-000 253-406-666 312-110-666 239-010-102 332-239-666

Page 26

L.)

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MODEL 205592

Page 27

Fortherepairorreplacementpartsyouneed

delivereddirectlytoyourhome

Call 7 am - 7 pm, 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

S ARS

America's Repair Specialists

Page 28

SEARS

CRRFTSMRN

Operator's Guide

WIRE FEED

MIG WELDER

Model No.

934.205592

CAUTION: Read and follow all Safety Rules and

Operating Instructions before First Use of this Product.

• WARRANTY

• INTRODUCTION

• SAFETY SUMMARY

• SPECIFICATIONS

• INSTALLATION

• OPERATION

• MAINTENANCE

• SCHEMATIC

• WIRING DIAGRAM

• REPLACEMENT PARTS

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

811-642-000 September 2001

Page 29

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

Full One Year Warranty for Craftsman Welding Gun or Cables. For one year

from the date of purchase, when the

welding gun or cables are operated and maintained according to the owner's manual instructions, if the welding gun

or cables fail due to a defect in material or workmanship, Sears will repair or

replace the welding gun or cables free of charge. This warranty does not cover parts consumed in normal operation, such as contact tips, nozzles, gun liners,

and drive rollers. Full Three Year 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 SERVICE IS AVAILABLE BY SIMPLY CONTACTING THE NEAREST SEARS SERVICE CENTER.

This warranty applies only while this product is in use in the United States.

This warranty gives you specific legal rights, and you may also have other

rights which vary from state to state. Sears Roebuck and Co., Dept. 817WA,

Hoffman Estates, IL 60179.

Page 30