Craftsman 934.205592, Operator'S Manual

Page 1: ... 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 2: ...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 SERVI...

Page 3: ... 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 MAI...

Page 4: ...o 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 ...

Page 5: ...hat 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 ...

Page 6: ...derstands 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 6 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 a...

Page 7: ...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 ...

Page 8: ...percentage of 10 minutes and represents the maximum welding time 8 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 Rati...

Page 9: ...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 Selec...

Page 10: ...port 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 1 Remove the protective cap from the cylinder and inspect the regulator connecting threads for dust dirt oil and grease Remove any dust...

Page 11: ...lding 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 B...

Page 12: ...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...

Page 13: ...p hand 8 turning the wire spool 4 Spool 8 Spool Figure 5 Drive Brake Assemblies with Four Inch and Eight Inch Wire Spools 9 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 pro...

Page 14: ... 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 ...

Page 15: ... 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...

Page 16: ...oltage 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 o...

Page 17: ...els 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 unres...

Page 18: ... 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 18 ...

Page 19: ...ts 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 orientatio...

Page 20: ...he 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 ...

Page 21: ...wing 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 an...

Page 22: ...gged 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 ...

Page 23: ...w_ L v v J _j n _ r n C3 cD o I ___ __ _E _ MODEL 205592 23 ...

Page 24: ... MODEL 205592 24 ...

Page 25: ...nal 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 ...

Page 26: ...28 L _ _ 0 0 i_ n rn g _ cy 2 O3 L _ _ J CJ_ YY rn cY _ o d_ 5 0 c _o z z _o 2 zo _z_ MODEL 205592 ...

Page 27: ...AIR 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 Rep...

Page 28: ... 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: ...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 SERVI...

Page 30: ... 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 MAI...

Page 31: ...o 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 ...

Page 32: ...hat 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 ...

Page 33: ...derstands 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 6 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 a...

Page 34: ...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 ...

Page 35: ...percentage of 10 minutes and represents the maximum welding time 8 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 Rati...

Page 36: ...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 Selec...

Page 37: ...port 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 1 Remove the protective cap from the cylinder and inspect the regulator connecting threads for dust dirt oil and grease Remove any dust...

Page 38: ...lding 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 B...

Page 39: ...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...

Page 40: ...p hand 8 turning the wire spool 4 Spool 8 Spool Figure 5 Drive Brake Assemblies with Four Inch and Eight Inch Wire Spools 9 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 pro...

Page 41: ... 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 ...

Page 42: ... 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...

Page 43: ...oltage 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 o...

Page 44: ...els 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 unres...

Page 45: ... 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 18 ...

Page 46: ...ts 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 orientatio...

Page 47: ...he 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 ...

Page 48: ...wing 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 an...

Page 49: ...gged 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 ...

Page 50: ...w_ L v v J _j n _ r n C3 cD o I ___ __ _E _ MODEL 205592 23 ...

Page 51: ... MODEL 205592 24 ...

Page 52: ...nal 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 ...

Page 53: ...28 L _ _ 0 0 i_ n rn g _ cy 2 O3 L _ _ J CJ_ YY rn cY _ o d_ 5 0 c _o z z _o 2 zo _z_ MODEL 205592 ...

Page 54: ...AIR 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 Rep...