SEARS

CRRFTSMRNOperator's Guide

WIRE FEEDMIG WELDERModel No.

934.205592

CAUTION: Read and follow

all Safety Rules andOperating Instructions beforeFirst 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

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

Full One Year Warranty for CraftsmanWelding Gun or Cables. For one yearfrom the date of purchase, when thewelding gun or cables are operated andmaintained according to the owner'smanual instructions, if the welding gunor cables fail due to a defect in material

or workmanship, Sears will repair orreplace the welding gun or cables free ofcharge. This warranty does not coverparts consumed in normal operation,such as contact tips, nozzles, gun liners,and drive rollers.

Full Three Year Warranty on CraftsmanWelder For three years from the date ofpurchase, when the welder is operatedand maintained according to the owner'smanual instructions, if the welder failsdue to a defect in material or

workmanship, Sears will repair orreplace the welder free of charge. Thiswarranty does not cover the weldinggun, cables, or normal consumableparts.

WARRANTY SERVICE IS AVAILABLEBY SIMPLY CONTACTING THENEAREST SEARS SERVICE CENTER.

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

This warranty gives you specific legalrights, and you may also have otherrights which vary from state to state.

Sears Roebuck and Co., Dept. 817WA,Hoffman Estates, IL 60179.

CRAFTSMAN FULL WARRANTY ......................................................... 2TABLE OF CONTENTS ......................................................................... 3INTRODUCTION .................................................................................... 4SAFETY SUMMARY ............................................................................... 5

SAFETY INFORMATION ...................................................................... 5SHOCK HAZARDS ............................................................................. 6FIRE HAZARDS .................................................................................. 6FLASH HAZARDS .............................................................................. 6FUME HAZARDS ................................................................................ 6COMPRESSED GASSES AND EQUIPMENT HAZARDS .................. 6BURN HAZARDS ................................................................................ 7

ADDITIONAL SAFETY INFORMATION ............................................... 7WELDER SPECIFICATIONS .................................................................. 8

DESCRIPTION ...................................................................................... 8WELDER OPERATING CHARACTERISTICS ...................................... 8

DUTY CYCLE ..................................................................................... 8INTERNAL THERMAL PROTECTION .................................................. 8

WELDER INSTALLATION ..................................................................... 9POWER SOURCE CONNECTION ....................................................... 9

POWER REQUIREMENTS ................................................................. 9CONNECT TO POWER SOURCE ...................................................... 9EXTENSION CORDS .......................................................................... 9

ASSEMBLING THE WELDER ............................................................... 9UNPACKING THE WELDER ............................................................... 9INSTALL THE GROUND CLAMP ....................................................... 9INSTALL THE TANK TRAY AND BRACKET ........................................ 9INSTALL THE SHIELDING GAS ....................................................... 10

CHECK THE GAS FLOW .................................................................... 11ALIGN AND SET THE DRIVE ROLLER ............................................. 11

STANDARD DRIVE ROLLER ............................................................ 11INSTALL THE WELDING WIRE .......................................................... 12SET THE WIRE DRIVE TENSION ...................................................... 14PREPARATION .................................................................................... 15CHANGE POLARITY ........................................................................ 15

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

MAINTENANCE .................................................................................... 17GENERAL ........................................................................................... 17

REPLACE A GUN LINER .................................................................. 17MAINTAINING THE CONTACT TIP .................................................. 20MAINTAINING THE NOZZLE ........................................................... 20TESTING FOR A SHORTED NOZZLE ............................................ 21PREVENTIVE MAINTENANCE ......................................................... 21

TROUBLESHOOTING ........................................................................ 21WIRING DIAGRAM ............................................................................... 23REPLACEMENT PARTS LIST ............................................................. 24SCHEMATIC ......................................................................................... 26

This Welder User's Guide providesspecific information about your wirefeed welder. It is to be used togetherwith the Welding Instruction Guide toprovide all of the information needed tosafely and effectively use your wirefeed welder. The information in thisbook applies to your specific model ofwire feed welder and gives instructionon set-up, installation, and actual useof the welder.

Where information is shown that does

not necessarily apply to all models orbrands of welder, it will be marked aseither optional on some welder modelsor does not apply to all models.

Every craftsman respects the tools withwhich they work. They know that thetools represent years of constantlyimproved designs and developments.The true craftsman also knows that toolsare dangerous if misused or abused.

Reading this Operator's Guide and theWelding Instruction Guide before usingthe welder will enable you to do a better,safer job. Learn the welder'sapplications and limitations as well asthe specific potential hazards peculiar towelding.

SAFETY INFORMATION

The following safety information isprovided as guidelines to help youoperate your new welder under thesafest possible conditions. Anyequipment that uses electrical powercan be potentially dangerous to usewhen safety or safe handling instructionsare not known or not followed. Thefollowing safety information is providedto give you the information necessary forsafe use and operation.

When a procedure step is preceded bya WARNING, it is an indication that thestep contains a procedure that might beinjurious to a person if proper safetyprecautions are not heeded.

When a procedure step is preceded bya CAUTION, it is an indication that thestep contains a procedure that mightdamage the equipment being used.

A NOTE may be used before or after aprocedure step to highlight or explainsomething in that step.

READ ALL SAFETY INSTRUCTIONS

CAREFULLY before attempting toinstall, operate, or service this welder.Failure to comply with these instructionscould result In personal injury and/orproperty damage.

RETAIN THESE INSTRUCTIONSFOR FUTURE REFERENCE.

Note: The followingsafety alert

symbols identify importantsafety messages in this manual.

When you see one of the symbolsshown here, be alert to the possibility ofpersonal injury and carefully read themessage that follows.

This symbol indicates that thepossibility of electric shockhazard exists during theoperation of the step(s) thatfollow.

This symbol indicates that thepossibility of fire hazard existsduring the operation of thestep(s) that follow.

This symbol indicates that thehelmet must be worn duringthe step(s) that follow toprotect against eye damageand burns due to flashhazard.

This symbol indicates that thepossibility of toxic gas hazardexists during operation of thestep(s) that follow.

This symbol indicates that thepossibility of being burned byhot slag exists duringoperation of the step(s) thatfollow.

This symbol indicates that theeye protection should be wornto protect against flying debrisin the following step(s).

This symbol indicates that thepossibility of injury or deathexists due to improperhandling and maintenance ofcompressed gas cylinders orregulators

Full explanations of the specific hazardsare shown in the WELDINGINSTRUCTION GUIDE. Make sure youhave read and understand all of the

informationbeforeproceedingwithanyoftheinstructionscontainedinthisuser'sguide.Publishedstandardsonsafetyareavailable.TheyarelistedinADDITIONALSAFETYINFORMATIONattheendofthisSAFETYSUMMARY.TheNationalElectricalCode,OccupationalSafetyandHealthActregulations,localindustrialcodesandlocalinspectionrequirementsalsoprovideabasisforequipmentinstallation,use,andservice.SHOCKHAZARDS

WARNING

ELECTRIC SHOCK CAN KILL! Toreduce the risk of death or serious

injury from shock, read, understand,and follow the following safetyinstructions. In addition, makecertain that anyone else who usesthis welding equipment, or who is abystander in the welding areaunderstands and follows these safetyinstructions as well.

FIRE HAZARDS

WARNING

FIRE OR EXPLOSION CAN CAUSEDEATH, INJURY, AND PROPERTYDAMAGE! To reduce risk of death,injury, or property damage from fireor explosion, read, understand, andfollow the following safetyinstructions. In addition, makecertain that anyone else that usesthis welding equipment, or is abystander in the welding area,understands and follows these safetyinstructions as well. REMEMBER!Welding by nature produces sparks,hot spatter, molten metal drops, hotslag, and hot metal parts that canstart fires, burn skin, and damageeyes.6

FLASH HAZARDS

WARNING

ARC RAYS CAN INJURE EYESAND BURN SKIN! To reduce risk ofinjury from arc rays, read,understand, and follow the followingsafety instructions. In addition, makecertain that anyone else that usesthis welding equipment, or is abystander in the welding area,understands and follows these safetyinstructions as well.

FUME HAZARDS

WARNING

FUMES, GASSES, AND VAPORSCAN CAUSE DISCOMFORT,ILLNESS, AND DEATH! To reducerisk of discomfort, illness, or death,read, understand, and follow thefollowing safety instructions. Inaddition, make certain that anyoneelse that uses this welding equipmentor is a bystander in the welding area,understands and follows these safetyinstructions as well.

COMPRESSED GASSES ANDEQUIPMENT HAZARDS

WARNING

IMPROPER HANDLING ANDMAINTENANCE OF COMPRESSEDGAS CYLINDERS ANDREGULATORS CAN RESULT INSERIOUS INJURY OR DEATH! To

reduce risk of injury or death fromcompressed gasses and equipmenthazards, read understand and followthe following safety instructions. Inaddition, make certain that anyoneelse who uses this welding

equipmentorabystanderintheweldingareaunderstandsandfollowsthesesafetyinstructionsaswell.

DonotuseflammablegasseswithMIGwelders.OnlyinertornonflammablegassesaresuitableforMIGwelding.ExamplesareCarbonDioxide,Argon,Helium,etc.ormixturesofmorethanoneofthesegasses.BURN HAZARDS

WARNING

Hot slag can cause fires andserious injury from burns. Toreduce the risk of discomfort or

serious injury due to burns alwayswear heavy protective clothing, eyeand face protection, and glovesdesigned for welding. To prevent therisk of fires starting, use a metal plateor some other material with a highflash point to catch and shieldcombustibles from the hot slag.

ADDITIONAL SAFETYINFORMATION

For additional information concerningwelding safety, refer to the followingstandards and comply with them asapplicable.

• ANSI Standard Z49.1 i SAFETY INWELDING AND CUTTING i

obtainable from the American WeldingSociety, 550 NW Le Jeune Road,Miami, FL 33126 Telephone (800)443-9353, Fax (305) 443-7559 iwww.amweld.org or www.aws.org

• ANSI Standard Z87.1 i SAFEPRACTICE FOR OCCUPATION ANDEDUCATIONAL EYE AND FACEPROTECTION i obtainable from theAmerican National Standards Institute,11 West 42ndSt., New York, NY 10036Telephone (212) 642-4900, Fax (212)398-0023 i www.ansi.org

• NFPA Standard 51B i CUTTINGAND WELDING PROCESS iobtainable from the National FireProtection Association, 1Batterymarch Park, P.O. Box 9101,Quincy, MA 02269-9101 Telephone(617) 770-3000, Fax (617) 770-0700i www.nfpa.org

• CGA Pamphlet P-I i SAFEHANDLING OF COMPRESSEDGASSES IN CYLINDERS iobtainable from the Compressed GasAssociation, 1725 Jefferson DavisHighway, Suite 1004, Arlington, VA22202-4102 Telephone (703) 412-0900 Fax (703) 412-0128 iwww.cagnet.com

• OSHA Standard 29 CFR, Part 1910,Subpart Q., WELDING, CUTTINGAND BRAZING i obtainable fromyour state OSHA office or U. S. Dept.of Labor OSHA, Office of PublicAffairs, Room N3647, 200 ConstitutionAve. Washington, DC 20210 iwww.osha.gov

• CSA Standard W117.2 i Code forSAFETY IN WELDING ANDCUTTING. i obtainable fromCanadian Standards Association, 178Rexdale Blvd. Etobicoke, OntarioM9W 1R3 i www.csa.ca

• American Welding Society StandardA6.0. WELDING AND CUTTINGCONTAINERS WHICH HAVE HELDCOMBUSTIBLES. i obtainable from

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

DESCRIPTION

Your new wire feed welder is designedfor maintenance and sheet metalfabrication. The welder consists of a

single-phase power transformer,stabilizer, rectifier, and a unique built-incontrol/feeder. This MIG welder is

capable of welding with 0.024 (0.6mm)and 0.030 (0.8mm), solid steel wire ondc reverse polarity and with .030 inchself-shielding flux-core wire on dcstraight polarity. Larger, 0.035 inch(0.9mm) diameter solid steel wire, on dcreverse polarity, and self shielding flux-core wire on dc straight polarity mayalso be used on this welder. The use of

larger diameter wire makes weldingdifficult and the results cannot be

guaranteed. The manufacturer does notrecommend the use of larger diameterwire.

Now you can weld sheet metal from 24gauge up to 1/4 inch thick with a singlepass. You can weld thicker steel withbeveling and multiple pass techniques.Table 1 lists your MIG welderspecifications.

Table 1. Welder Specifications

Primary (input) volts 120 VacPrimary (inputs) Amps 25Phase SingleFrequency 60 HzSecondary (output) volts 19.5Secondary (UL output) ampsl05Open Circuit Volts (Max.) 28 VdcDuty Cycle Rating 20%

WELDER OPERATINGCHARACTERISTICS

DUTY CYCLE

The duty cycle rating of a welder defineshow long the operator can weld andhow long the welder must be rested andcooled. Duty cycle is expressed as apercentage of 10 minutes andrepresents the maximum welding time

8

allowed. The balance of the 10-minute

cycle is required for cooling.

Your new welder has a duty cycle ratingof 20% at the rated output. This meansthat you can weld for two (2) minutes outof 10 with the remaining eight (8) minutesrequired for cooling. (See Table 2).

Table 2. Duty Cycle Ratings

Duty Maximum RequiredCycle Welding RestingRating Time Time

20% 2 minutes 8 minutes40% 4 minutes 6 minutes60% 6 minutes 4 minutes80% 8 minutes 2 minutes100% 10 minutes 0 minutes

INTERNAL THERMALPROTECTION

CAUTION

Do not constantly exceed the dutycycle or damage to this welder canresult. If you exceed the duty cycle ofyour welder, an internal thermalprotector will open, shutting off allwelder functions except the coolingfan. If this happens, DO NOT SHUTOFF THE WELDER. Leave the

welder turned on with the fan running.After cooling, the thermal protector willautomatically reset and the welder willfunction normally again. However,you should wait at least 10 minutesafter the thermal protector opensbefore resuming welding. You mustdo this even if the thermal protectorresets itself before the 10 minutes is

up or you may experience less thanspecified duty cycle performance.

If you find that your welder will not weldfor 2 minutes without stopping, reducethe wire speed slightly and tune thewelder in at the lowest wire speedsetting that still produces a smooth arc.Welding with the wire speed set too highcauses excessive current draw andshortens the duty cycle.

POWER SOURCECONNECTION

POWER REQUIREMENTS

This welder is designed to operate on aproperly grounded 120 Volt, 60 Hz,single-phase alternating current (ac)power source fused with a 20 amp time-delayed fuse or circuit breaker. It isrecommended that a qualified electricianverify the ACTUAL VOLTAGE at thereceptacle into which the welder will beplugged and confirm that the receptacleis properly fused and grounded. Theuse of the proper circuit size caneliminate nuisance circuit breaker

tripping when welding.

DO HOT OPERATE THIS WELDER if

the ACTUAL power source voltage isless than 105 Volts ac or greater than132 Volts ac. Contact a qualifiedelectrician if this problem exists.Improper performance and/or damage tothe welder will result if operated oninadequate or excessive power.

CONNECT TO POWER SOURCE

WARNING

High voltage danger from powersource! Consult a qualified electricianfor proper installation of receptacle atthe power source.

This welder must be grounded while inuse to protect the operator fromelectrical shock. If you are not sure ifyour outlet is properly grounded, have itchecked by a qualified electrician. Donot cut off the grounding prong or alterthe plug in any way and do not use anyadapters between the welder's powercord and the power source receptacle.

Make sure the POWER switch is OFFthen connect your welder's power cordto a properly grounded 120 Vac, 60 Hz,single phase, 20 amp power source.

EXTENSION CORDS

For optimum welder performance, anextension cord should not be used

unless absolutely necessary. Ifnecessary, care must be taken inselecting an extension cord appropriatefor use with your specific welder.

Select a properly grounded extensioncord that will mate directly with the acpower source receptacle and the welderpower cord without the use of adapters.Make certain that the extension is properlywired and in good electrical condition.

Extension cords must be at the smallesta #12 gauge cord. Do not use anextension cord over 25 ft. in length.

ASSEMBLING THEWELDER

The following procedures describe theprocess required to assemble, install,maintain, and prepare to weld with yournew wire feed welder.

UNPACKING THE WELDER

1. Remove any cartons or bagscontaining parts/accessories.

2. Open the cartons or bags packedwith your welder and inspect theircontents for damage. Report anymissing or damaged itemsimmediately.

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

INSTALL THE GROUND CLAMP

Connect the ground clamp to the groundcable (coming out the front of thewelder) according to the instructionspackaged with the ground clamp.

INSTALL THE TANK TRAYAND BRACKET

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

IMPORTANT - GAS CYLINDER SIZE

RESTRICTION! The tank tray you havejust installed on the back of the welderwill handle gas cylinders no larger than20 cubic feet. If you select a cylinderlarger than 20 cubic feet, it must bechained to a wall or other fixed support.

j 1

Figure 1. Mount Tank Tray BracketTo Welder

2.

Align the four tank tray bracket (1)mounting holes (as shown in Figure1) with the four staked nuts on therear 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 eachof the other three split lock nuts (2)and _-20 x 1/2inch hex bolts (3)through the remaining mountingholes.

3. Tighten all four hex bolts.

INSTALL THE SHIELDING GAS

WARNING

IMPROPER HANDLING ANDMAINTENANCE OF COMPRESSEDGAS CYLINDERS AND REGULATORSCAN RESULT IN SERIOUS INJURY

OR DEATH! Always secure gascylinders to the tank bracket kit, a wall,or other fixed support to prevent thecylinder from falling over and rupturing.Read, understand, and follow all theCOMPRESSED GASSES ANDEQUIPMENT HAZARDS in the SAFETYSUMMARY at the front of this manual.

Secure your gas cylinder to the tankbracket kit, a wall, or other fixed support.

1. Remove the protective cap from thecylinder and inspect the regulatorconnecting threads for dust, dirt oil,and grease. Remove any dust ordirt with a clean cloth. DO NOTATTACH THE REGULATOR IF OIL,GREASE, OR DAMAGE AREPRESENT.

2. Open the cylinder valve FOR JUSTAN INSTANT to blow out anyforeign matter inside the valve portto reduce the risk of plugging ordamaging the regulator. Never aimthe open cylinder valve port atyourself or bystanders.

3. Screw the regulator supplied withthis welder (see Figure 2) into thecylinder valve and tighten with awrench.

Adjustable Regulator Preset Regulator

Figure 2. Gas Regulators

4. Insert the gas hose into the outletport of the gas regulator. The hoselocks in place in the fitting whenpressed into the port.

5. To remove the gas hose, pressdown on the ring at the rear of thegas fitting, and pull the hose out ofthe fitting.

10

CHECK THE GAS FLOW

WARNING

IMPROPER HANDLING ANDMAINTENANCE OF COMPRESSEDGAS CYLINDERS AND REGULATORSCAN RESULT IN SERIOUS INJURY

OR DEATH! To reduce the risk of injuryor death, always stand to the side of thecylinder opposite the regulator whenopening the cylinder valve, keeping thecylinder valve between you and theregulator. Never aim the open cylindervalve port at yourself or bystanders.Failure to comply with this warning couldresult in serious personal injury.

Note: If the cylinder you have isequipped with male regulatorconnecting threads instead offemale, you will need to obtaina special compressed gascylinder adapter from your gassupplier to install between yourgas cylinder and regulator.

• The gas control function doesnot require the welder to beturned on or plugged in.

1. Slowly crack open the cylindervalve, then turn open ALL THEWAY.

2. Pull the trigger on the gun to allowthe gas to flow. KEEP THETRIGGER PULLED. Listen and feelfor gas flowing from the end of thewelding gun. If your regulator hasno adjustment, it has been pre-setat the factory for a flow of 20 cubicfeet per hour. If your gas regulatorhas an adjustment to control thegas flow rate, turn the adjustmentkey clockwise to increase gas flow;counterclockwise to reduce flow.For most welding, the gas flowshould be set at 15-20 cubic feetper hour. If no gas is heard or felt,verify all steps involved inconnecting the gas.

3. Release the trigger.

Note: If welding outside or in a draft, itmay become necessary to setup a windbreak to keep theshielding gas from being blownfrom the weld area.

• MAKE SURE TO TURN OFFTHE GAS CYLINDER VALVEWHEN DONE WELDING.

ALIGN AND SET THE DRIVEROLLER

Before installing any welding wire intothe unit, the proper sized groove mustbe placed into position on the wire drivemechanism. Change to a neoprenedrive roller when welding withaluminum wire.

STANDARD DRIVE ROLLER

Change the standard drive rolleraccording to the following steps:

1. Remove the drive tension byunscrewing the tension adjustingscrew (ALL THE WAY in a counter-clockwise direction). The drivetension screw will come loose,allowing you to pull the drivetension arm up away from the driveroller. Make sure to keep the screwand the spring in place with thedrive tension arm.

2.

3.

If there is wire already installed inthe welder, roll it back onto the wirespool by hand-turning the spoolcounter-clockwise. Be careful notto allow the wire to come out of the

rear end of the gun without holdingonto it or it will unspool itself. Putthe end of the wire into the hole on

the outside edge of the wire spooland bend it over to hold the wire in

place. Remove the spool of wirefrom the welder.

Loosen the drive roller setscrewand pull the drive roller off the driveshaft.

11

Note: 6. Tighten the setscrew, while holdingthe drive roller in place.

4,

5,

The drive roller has two wire

size grooves built into it. Wheninstalling the drive roller thenumber stamped on the driveroller for the wire size you areusing should be facing awayfrom you. If you can read thewire size you are using on thedrive roller, it is installedbackwards. Use only theproper size drive roller whenusing your welder.

Find the side of the drive roller that

is stamped with the same wirediameter as that of the wire beinginstalled (see Figure 3, and if inmetric, see DESCRIPTION in theWELDER SPECIFICATIONS

section). Make certain the spacingwasher is still on the motor shaft

and push the drive roller onto themotor shaft, aligning the setscrewwith the flat side of the drive shaft.

Make sure the side stamped withthe desired wire diameter is awayfrom you.

Drive Roller

Shaft

Washer

Figure 3. Drive Roller

Slide the roller onto the shaft sothat the groove in the roller lines upwith the inlet tube and the weldinggun liner. You can look at thealignment from the top of thewelder.

INSTALL THE WELDINGWIRE

WARNING

Electric shock can kill! Always turnthe POWER switch OFF and unplug thepower cord from the ac power sourcebefore installing wire.

Be very careful when removing thewelding nozzle. The contact tip on thiswelder is electrically hot as long asPOWER is turned ON. Make certainPOWER is turned OFF.

1,

2.

Remove the nozzle and contact tipfrom the end of the gun assembly.

Make sure the proper groove onthe drive roller is in place for thewire being installed. If the propergroove is not in place, change thedrive roller as described above.

3, Unwrap the spool of wire then findthe leading end of the wire (it goesthrough a hole in the outer edge ofthe spool and is bent over the spooledge to prevent the wire fromunspooling) BUT DO NOTUNHOOK IT YET.

4, Place the spool on the spindle insuch a manner that when the wire

comes off the spool, it will look likethe top illustration in Figure 4. Thewelding wire should always comeoff the top of the spool into the drivemechanism.

12

RightWay

WrongWay

Figure 4. Right and Wrong Way ToFeed Wire From Spool

5. If you are installing a four-inchspool of wire, install the drive brakehardware on the top of the spool ofwire according to Figure 5A. If you Note:are installing an eight-inch spool,install the spindle adapter and drivebrake hardware as shown in Figure5B. The purpose of the drive brakeis to cause the spool of wire to stopturning at nearly the same momentthat wire feeding stops.

6. Once the drive brake hardware isinstalled, set the spool tension.With one hand, turn the wire spool 7.and continue turning it whileadjusting the tension on the spool.With your free hand, tighten (turnclockwise) the wing nut that holdsthe spool in place. Stop tighteningwhen 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 Assemblieswith Four Inch and Eight Inch Wire

Spools

9,

10.

If TOO MUCH tension isapplied to the wire spool, thewire will slip on the drive rolleror will not be able to feed at all.If TOO LITTLE tension isapplied, the spool of wire willwant to unspool itself. Readjustthe drive brake tension asnecessary to correct for eitherproblem.

After checking to make sure thatyour welder is disconnected fromthe ac power source, free theleading end of the wire from thespool, but do not let go of it until toldto do so, or the wire will unspoolitself.

Using a wire cutter, cut the bent endoff the leading end of the wire sothat only a straight leading endremains.

Loosen the tension adjusting screwholding the drive tension arm inplace and lift the tension arm up offthe drive roller.

Insert the leading end of the wireinto the inlet guide tube. Then pushit across the drive roller and into the

gun assembly about six inches.

13

CAUTION

Make certain that the welding wire isactually going into the gun liner. Bevery sure it has not somehow beenaccidentally been routed alongsidethe liner or even in some other

direction. If this should happen, thewire could feed inside the cable

casing or take a right angle and followthe wires and gas hose inside thewelder. It could also feed back on

itself jamming up the mechanism.

11. Line the wire up in the inside grooveof the drive roller, then allow thedrive tension arm to drop onto thedrive roller.

12. Tighten (turn clockwise)the drivetension adjusting screw until thetension roller is applying enoughforce on the wire to prevent it fromslipping out of the drive assembly.

13. Let go of the wire.

14. Connect the welder power cord tothe ac power source. Turn thewelder POWER switch ON. Set the

VOLTAGE switch to the voltage(heat) setting recommended for thegauge metal that is to be welded.Refer to the label mounted on thecover, inside the drivecompartment, for recommendedvoltage (heat) settings for yourwelding job. The VOLTAGEselector controls the weld heat.

There are eight voltage (heat)selections (numbered 1 through 8)available on this welder.

Numbered position 1 provides thelowest voltage (heat) and position8 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 gunto feed the wire through the gunassembly.

17. When at least an inch of wire sticks

out past the end of the gun, releasethe trigger.

18. Select a contact tip stamped withthe 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 thegun). Thread the contact tip intothe end of the gun and hand-tightensecurely.

20. Install the nozzle on the gunassembly. For best results, coat theinside of the nozzle with anti-stick

spray or gel (part #4312, notsupplied).

21. Cut off the excess wire that extends

past the end of the nozzle.

SET THE WIRE DRIVETENSION

WARNING

To reduce the risk of arc flash, makecertain that the wire coming out ofthe end of the gun does not come incontact with the workpiece clamp orany grounded material during thedrive tension setting process orarcing will occur.

1,

2.

3,

Pull the trigger on the gun.

Turn the drive tension adjustmentknob clockwise, increasing thedrive tension until the wire seems

to feed smoothly without slipping.

Block the end of the nozzle byholding it up against somethingthat doesn't conduct electricity,such as a block of wood or a

concrete floor, then trigger the gunagain. The wire should slip at thedrive roller. However, if the wirebird-nests at the drive roller,rethread the drive system usingless drive tension and try again.

14

4, When the drive tension is setcorrectly, there should be noslippage between the wire and thedrive roller. However, if anobstruction occurs along the wirefeed path, the wire should then slipon the drive roller.

PREPARATION

CHANGE POLARITY

This welder allows you the capability tochange 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 ofsteel, and silicon bronze welding ofsteel, 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 welderaccording to the following procedure steps.Figure 8 shows what the polarity blockshould look like for each polarity setting.

WARNING

Electric shock can kill! Always turn thePOWER switch OFF and unplug thepower cord from the ac power sourcebefore changing polarity.

CAUTION

Do not use a ratchet, crescent or otherlever type wrench to tighten the nutson the polarity bus. The nuts must behand tightened with a 7/16 inch nutdriver only. Too much torque appliedto the one of the nuts could cause the

threaded post to break off.

Tools Required:

• 7/16 inch nut driver

1,

2,

With a 7/16 inch nut driver, removeall four nuts and pull out thevertically mounted copper straps.

Replace the copper strapshorizontally in the dc StraightPolarity (dc - Flux Cored)configuration shown in Figure 6.

DC+ DCMIG FLUX CORED

Figure 6. Welder Polarity Selections

3. Start the four nuts on the four

connecting posts and hand snugeach nut with the 7/16 nut driver.

Do not use a ratchet, crescent orother lever type wrench.

15

Operation of this welder consists ofselecting and adjusting operatingcontrols for optimum voltage (weldingheat) and wire speed settings.

CONTROLS ANDINDICATORS

WARNING

Electric shock can kill! To removethe risk of electric shock, be awarethat the VOLTAGE selector, whenOFF, does not remove power from allinternal circuitry in the welder.

POWER - This welder has a POWERswitch mounted on the front panel. ThePOWER switch is used to initiate (turnthe welder ON) or extinguish (turn thewelder OFF) ac power to the welder.

VOLTAGE SELECTOR - The voltageselector controls the welding heat. Thevoltage selector provides continuousvoltage (heat) adjustment but hasreference number settings 1-8.Number 1 is the lowest voltage (heat)setting and number 8 the highest. Referto the label under the welder hood for

recommended voltage (heat) settingsfor your welding job.

WIRE SPEED CONTROL - The WIRESPEED CONTROL adjusts the speed atwhich the wire is fed out of the weldinggun. The wire speed needs to beclosely matched (tuned-in) to the rate atwhich it is being melted off (seeTUNING IN THE WIRE SPEED, (in theWelding Instruction Guide). Somethings that affect wire speed selectionare the type and diameter of the wirebeing used, the heat setting selected,and the welding position to be used.

16

GENERAL

This welder has been engineered to givemany years of trouble-free serviceproviding that a few very simple stepsare taken to properly maintain it.

1. Keep the wire drive compartment lidclosed at all times unless the wire

needs to be changed or the drivetension needs adjusting.

2. Keep all consumables (contact tips,nozzles, and gun liner) clean andreplace when necessary. SeeCONSUMABLE MAINTENANCEAND TROUBLESHOOTING later inthis section for detailed information.

3,

4,

Replace power cord, ground cable,ground clamp, or gun assemblywhen damaged or worn.

Periodically clean dust, dirt, grease,etc. from your welder. Every sixmonths or as necessary, removethe side panels from the welder andair-blow any dust and dirt that mayhave accumulated inside thewelder.

WARNING

ELECTRIC SHOCK CAN KILL! To

reduce the risk of electric shock, alwaysunplug the welder from its ac powersource before removing side panels.

IT IS VERY IMPORTANT TO MAINTAINTHE CONSUMABLES TO AVOID THENEED FOR PREMATUREREPLACEMENT OF THE GUNASSEMBLY.

The GUN LINER is intended to providean unrestricted path for the welding wireto flow through the gun assembly. Overtime it will accumulate dust, dirt, andother debris. Replacement is necessarywhen these accumulations begin torestrict the free flow of wire through thegun assembly.

REPLACE A GUN LINER

When removing or installing a gun liner,care must be taken not to kink orotherwise damage the gun liner orreplacement will be necessary. SeeFigure 7 for the drive assembly andFigure 8 for the gun assembly.

17

Drive Drive GunTension Tension Liner

Adjustment Arm1/4" Hex

Head Screws

Inlet GuideTube End

InletGuideTube l Phillips Pan Str#in

RehefHead Screw Clamp

DriveRoller

DriveAssembly

GunAssembly(Tail End)

Figure 7. Drive Assembly

GunCable

PlasticCable Tie

CableCoverin(

Handle WireCase

Live WireTerminal

Contact

Gas ConductorGas Valve Tube Insulation

Lockwasher

Head EndGun Liner

Tube

GasDiffuser Contact

(has lefthand Tip

Nozzle

Figure 8. Gun Assembly

18

Tools Required:

° 5/16 inch open end wrench

° Crescent Wrench (6 or 8 inch)

° 9 mm open end wrench (or 3 inchcrescent)

° Phillips Screwdriver

° Straight Blade Screwdriver or 1_ inchhex driver

1,

2.

3.

Turn OFF welder POWER SWITCH.

Open the welder side panel.Loosen the tension arm and lift itup off the drive roller.

4. Turn the wire spool counter-clockwise (be sure to hold onto thewire itself while turning the spool orthe wire will unspool itself when itbecomes free of the gun liner),removing wire from gun assembly.

5. Remove two 1_ inch hex headscrews (may also be removed witha straight blade screwdriver) andone pan head Phillips screw (inletguide tube end) from the driveroller and lift away the strain reliefclamp that holds the tail end of thegun in the drive assembly.

6. Leave the gun assembly (consistsof nozzle, gas diffuser, conductortube, handle and cable containinggas tubing electrical cable andliner) attached to the welder butmove the welder to a place wherethe gun assembly can be laid outstraight on a table or workbench orsimilar flat surface.

7,

8.

9,

Unscrew and remove the nozzle.

With a crescent wrench (six or eightinch), turn the gas diffuserclockwise (has left hand threads)and remove the gas diffuser (andcontact tip together) from theconductor tube on the end of the

gun.

Remove the four Phillips headscrews that hold the handle casetogether. With the exception of thetrigger, completely remove thecontents of the handle case.

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

Note: In the following procedure step,it may be necessary to removethe gas fitting from the gasvalve in order to make room toturn out the head end of thegun liner.

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

from the gas valve. Save theinternal star lock-washer and notethe orientation of the live wire

terminal. If you find it necessary toremove the gas hose connector,press down on the ring at the rearof the gas fitting to release the gashose and pull out the gas hose.Remove the gas fitting with a 9 mmopen end wrench or three inchcrescent.

12. Pull the liner out of the cable

covering (tubing) from the handleend and push the small piece ofliner out of the conductor tube.

13. Carefully insert the new liner intothe cable taking particular care tokeep the liner straight (especially atthe terminal end) to ease itspassage through cable covering. Itmay be desirable, perhaps evennecessary, to apply some silicongrease to the outside of the newliner so that it will slide easilythrough the cable.

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

Note: If you found it necessary toremove the gas and hoseconnector at step 9, rememberto reconnect it after completingstep 12. The gas hose can bereconnected by simply pushingit into the back of the connector.

15. Insert the head of the gun linerthrough the internal star lockwasher and the live wire terminal

(repeat the orientation noted instep 9). With a 5/16 inch open endwrench, screw the head end of thenew liner into the gas valve.

19

16. Insert a new plastic cable tie inplace around the cable and tightenit in approximately the samelocation as the plastic cable tie thatwas cut in step 8.

17. Return all components to thehandle casing and realign them asthey were originally.

18. With both halves of the handle

case in place, tighten the fourPhilips pan head screws makingsure the trigger remains seated inplace.

19. Push the cable into the welder far

enough so that the end of the gunliner protrudes through the inletguide tube end of the wire-feedtorch clamp far enough so that it iswithin approximately 1/16 inch oftouching the drive roller.

20. Make sure the cable covering(tubing) is far enough in themachine so that it is covered by thewire-feed torch clamp.

21. Tighten the two 1_ inch hex headscrews (may also be tightened by astraight blade screwdriver) and onepan head Phillips screw to thedrive roller securing the gun inplace.

22. Re-install the welding wireaccording to INSTALL THEWELDING WIRE.

MAINTAINING THE CONTACT TIP

The purpose of the CONTACT TIP is totransfer welding current to the weldingwire while allowing the wire to passthrough it smoothly.

Always use a contact tip stamped withthe same diameter as the wire it will beused with.

If the wire burns back into the tip,remove the tip from the gun andclean the hole running through itwith an oxygen-acetylene torch tipcleaner or tip drill.

2, Over time, the hole in the contacttip will become worn by the wirepassing through it. The more wornthis hole becomes, the less efficientis the transfer of welding current tothe wire and eventually arcbreakage and difficult arc startingwill result. Replace contact tipswhen signs of wear becomeapparent.

MAINTAINING THE NOZZLE

The nozzle directs the shielding gas tothe weld puddle, determines the size ofthe shielding area, and prevents theelectrically hot contact tip fromcontacting the work piece.

CAUTION

KEEP THE NOZZLE CLEAN! Duringthe welding process, spatter and slagwill build up inside the nozzle andmust be cleaned out periodically.Failure to clean and/or replace thenozzle in a timely fashion WILLCAUSE DAMAGE TO THE FRONT-END OF THE GUN ASSEMBLY.

For best results, coat the inside of a newor freshly cleaned nozzle with anti-stickspray or gel.

1. Stop welding and clean anyaccumulated slag or spatter fromthe nozzle every 5 to 10 minutes ofwelding time.

2. When welding overhead, if anymolten metal drips from the weldpuddle and falls into the nozzle,STOP WELDING IMMEDIATELYand clean the nozzle.

3, If the slag cannot be thoroughlycleaned from the nozzle,REPLACE THE NOZZLE!

Failure to keep the nozzle adequatelycleaned can result in the followingproblems:

20

A SHORTED nozzle results when

spatter buildup bridges the insulation inthe nozzle allowing welding current toflow through it as well as the contact tip.When shorted, a nozzle will stealwelding current from the wire wheneverit contacts the grounded work piece.This causes erratic welds and reduced

penetration.

In addition, a shorted nozzle overheatsthe end of the gun, which can DAMAGEthe front-end of the gun.

A RESTRICTED nozzle is created whenenough slag builds up in the nozzle toaffect the direction, concentration, andor rate of the shielding gas flow. Thisproblem can cause porous, brittle weldsand reduce penetration.

TESTING FOR A SHORTEDNOZZLE

Arcing between the nozzle and the workpiece ALWAYS means the nozzle isshorted, but this can be hard to detectthrough the lens of a welding helmet.The following testing method is anotherway to tell if a nozzle is shorted.

With the welder unplugged from the acpower source, touch the probes of anohmmeter or continuity tester to the endof the contact tip and the outside of thenozzle. If there is any continuity at all,the nozzle IS shorted. Clean or replaceas needed.

PREVENTIVE MAINTENANCE

Except for internal and externalcleaning, cleaning the nozzle, andoccasionally retightening screws, thereis no periodic maintenancerecommended for your welder.

TROUBLESHOOTING

The following TROUBLESHOOTINGinformation is provided as a guide tohelp resolve some of the more commonproblems that could be encountered.

Table 3 is a troubleshooting tableprovided to help you determine apossible remedy when you are having aproblem with your welder. This tabledoes not provide all possible solutions,only those possibilities considered tolikely be common faults. The tableconsists of a TROUBLE or symptom, aPOSSIBLE CAUSE for that symptom,and a POSSIBLE REMEDY for thatsymptom.

21

Table 3. Troubleshooting

TROUBLE

Dirty, porous brittleweld

Wire feed works butno arc

Arc works but not

feeding wire.

Nothing worksexcept fan

Low output ornon-penetrating weld.

Wire is birdnestingat the drive roller

Wire burns back

to contact tip

POSSIBLE CAUSE

1. Plugged welding nozzle2. No shielding gas

3. Wrong Type of Gas

4. Dirty or rusty welding wire

1. Bad ground or looseconnection

2. Bad connection to gun orfaulty gun1. Faulty wire speed controlassembly2. No tension on the drive roller

3. Faulty drive motor (very rare)1. Faulty trigger on gun2. Faulty transformer (rare)3. Exceeded duty cycle; thermalprotector opened

1. Loose connection insidemachine

2. Too long or improperextension cord

3. Wrong type or size wire4. Poor ground connection

5. Wrong size contact tip6. Loose gun connection orfaulty gun assembly7. Wrong welding polarity set8. Dirty or rusty welding wire1. Too much tension on driveroller

2. Gun liner worn or damaged3. Contact tip is clogged ordamaged4. Liner is stretched or is too

long

1. Gun liner is worn or damaged2. Liner stretched or is too long3. Wrong size contact tip4. contact tip clogged ordamaged

POSSIBLE REMEDY

1. Clean or replace nozzle2. Tank empty, flow restricted, orregulator set too low3. See SELECTING SHIELDINGGAS in the WELDING

INSTRUCTION GUIDE for properselection

4. Replace spool of wire

1. Check ground and connectionstighten as necessary2. Check connection to gun orreplace gun1. Replace wire speed controlassembly2. Adjust the drive tension3. Replace drive motor1. Replace trigger2. Replace transformer3. Allow welder to cool at least 10

minutes (observe and maintainproper duty cycle1. Blow inside of machine out with

compressed air, clean and tightenall connections2. See EXTENSION CORD USE inthis manual

3. Use correct size welding wire4. Reposition clamp and checkcable to clamp connection5. Use correct size contact tip6. Tighten gun or replace gun7. Change polarity to proper forwire being used8. Replace spool of wire

1. Adjust the drive tension(see INSTALLING THE WELDINGWIRE)2. Replace gun liner3. Replace contact tip

4. Trim liner to proper length

1. Replace gun liner

2. Trim liner for proper length3. Use correct size contact tip4. Replace contact tip

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

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

22

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MODEL 205592

23

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MODEL 205592

24

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

25

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MODEL 205592

Fortherepairor replacementpartsyouneeddelivereddirectlyto yourhomeCall 7 am - 7 pm, 7 days a week

1-800-366-PART(1-800-366-7278)

For in-home major brand repair serviceCall 24 hours a day, 7 days a week

1-800-4-REPAIR

(1-800-473-7247)

The model number of your product is locatedon the welder nameplate.If the parts you need are not stocked locally,your order will be electronically transmitted toa Sears Repair Parts Distribution Center forexpedited handling.When requesting service or ordering parts,always give the following information:

• Product Name* Model Number• Part Number

. Part Description

S ARSAmerica's Repair Specialists

SEARS

CRRFTSMRNOperator's Guide

WIRE FEEDMIG WELDERModel No.

934.205592

CAUTION: Read and follow

all Safety Rules andOperating Instructions beforeFirst 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

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

Full One Year Warranty for CraftsmanWelding Gun or Cables. For one yearfrom the date of purchase, when thewelding gun or cables are operated andmaintained according to the owner'smanual instructions, if the welding gunor cables fail due to a defect in material

or workmanship, Sears will repair orreplace the welding gun or cables free ofcharge. This warranty does not coverparts consumed in normal operation,such as contact tips, nozzles, gun liners,and drive rollers.

Full Three Year Warranty on CraftsmanWelder For three years from the date ofpurchase, when the welder is operatedand maintained according to the owner'smanual instructions, if the welder failsdue to a defect in material or

workmanship, Sears will repair orreplace the welder free of charge. Thiswarranty does not cover the weldinggun, cables, or normal consumableparts.

WARRANTY SERVICE IS AVAILABLEBY SIMPLY CONTACTING THENEAREST SEARS SERVICE CENTER.

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

This warranty gives you specific legalrights, and you may also have otherrights which vary from state to state.

Sears Roebuck and Co., Dept. 817WA,Hoffman Estates, IL 60179.

CRAFTSMAN FULL WARRANTY ......................................................... 2TABLE OF CONTENTS ......................................................................... 3INTRODUCTION .................................................................................... 4SAFETY SUMMARY ............................................................................... 5

SAFETY INFORMATION ...................................................................... 5SHOCK HAZARDS ............................................................................. 6FIRE HAZARDS .................................................................................. 6FLASH HAZARDS .............................................................................. 6FUME HAZARDS ................................................................................ 6COMPRESSED GASSES AND EQUIPMENT HAZARDS .................. 6BURN HAZARDS ................................................................................ 7

ADDITIONAL SAFETY INFORMATION ............................................... 7WELDER SPECIFICATIONS .................................................................. 8

DESCRIPTION ...................................................................................... 8WELDER OPERATING CHARACTERISTICS ...................................... 8

DUTY CYCLE ..................................................................................... 8INTERNAL THERMAL PROTECTION .................................................. 8

WELDER INSTALLATION ..................................................................... 9POWER SOURCE CONNECTION ....................................................... 9

POWER REQUIREMENTS ................................................................. 9CONNECT TO POWER SOURCE ...................................................... 9EXTENSION CORDS .......................................................................... 9

ASSEMBLING THE WELDER ............................................................... 9UNPACKING THE WELDER ............................................................... 9INSTALL THE GROUND CLAMP ....................................................... 9INSTALL THE TANK TRAY AND BRACKET ........................................ 9INSTALL THE SHIELDING GAS ....................................................... 10

CHECK THE GAS FLOW .................................................................... 11ALIGN AND SET THE DRIVE ROLLER ............................................. 11

STANDARD DRIVE ROLLER ............................................................ 11INSTALL THE WELDING WIRE .......................................................... 12SET THE WIRE DRIVE TENSION ...................................................... 14PREPARATION .................................................................................... 15CHANGE POLARITY ........................................................................ 15

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

MAINTENANCE .................................................................................... 17GENERAL ........................................................................................... 17

REPLACE A GUN LINER .................................................................. 17MAINTAINING THE CONTACT TIP .................................................. 20MAINTAINING THE NOZZLE ........................................................... 20TESTING FOR A SHORTED NOZZLE ............................................ 21PREVENTIVE MAINTENANCE ......................................................... 21

TROUBLESHOOTING ........................................................................ 21WIRING DIAGRAM ............................................................................... 23REPLACEMENT PARTS LIST ............................................................. 24SCHEMATIC ......................................................................................... 26

This Welder User's Guide providesspecific information about your wirefeed welder. It is to be used togetherwith the Welding Instruction Guide toprovide all of the information needed tosafely and effectively use your wirefeed welder. The information in thisbook applies to your specific model ofwire feed welder and gives instructionon set-up, installation, and actual useof the welder.

Where information is shown that does

not necessarily apply to all models orbrands of welder, it will be marked aseither optional on some welder modelsor does not apply to all models.

Every craftsman respects the tools withwhich they work. They know that thetools represent years of constantlyimproved designs and developments.The true craftsman also knows that toolsare dangerous if misused or abused.

Reading this Operator's Guide and theWelding Instruction Guide before usingthe welder will enable you to do a better,safer job. Learn the welder'sapplications and limitations as well asthe specific potential hazards peculiar towelding.

SAFETY INFORMATION

The following safety information isprovided as guidelines to help youoperate your new welder under thesafest possible conditions. Anyequipment that uses electrical powercan be potentially dangerous to usewhen safety or safe handling instructionsare not known or not followed. Thefollowing safety information is providedto give you the information necessary forsafe use and operation.

When a procedure step is preceded bya WARNING, it is an indication that thestep contains a procedure that might beinjurious to a person if proper safetyprecautions are not heeded.

When a procedure step is preceded bya CAUTION, it is an indication that thestep contains a procedure that mightdamage the equipment being used.

A NOTE may be used before or after aprocedure step to highlight or explainsomething in that step.

READ ALL SAFETY INSTRUCTIONS

CAREFULLY before attempting toinstall, operate, or service this welder.Failure to comply with these instructionscould result In personal injury and/orproperty damage.

RETAIN THESE INSTRUCTIONSFOR FUTURE REFERENCE.

Note: The followingsafety alert

symbols identify importantsafety messages in this manual.

When you see one of the symbolsshown here, be alert to the possibility ofpersonal injury and carefully read themessage that follows.

This symbol indicates that thepossibility of electric shockhazard exists during theoperation of the step(s) thatfollow.

This symbol indicates that thepossibility of fire hazard existsduring the operation of thestep(s) that follow.

This symbol indicates that thehelmet must be worn duringthe step(s) that follow toprotect against eye damageand burns due to flashhazard.

This symbol indicates that thepossibility of toxic gas hazardexists during operation of thestep(s) that follow.

This symbol indicates that thepossibility of being burned byhot slag exists duringoperation of the step(s) thatfollow.

This symbol indicates that theeye protection should be wornto protect against flying debrisin the following step(s).

This symbol indicates that thepossibility of injury or deathexists due to improperhandling and maintenance ofcompressed gas cylinders orregulators

Full explanations of the specific hazardsare shown in the WELDINGINSTRUCTION GUIDE. Make sure youhave read and understand all of the

informationbeforeproceedingwithanyoftheinstructionscontainedinthisuser'sguide.Publishedstandardsonsafetyareavailable.TheyarelistedinADDITIONALSAFETYINFORMATIONattheendofthisSAFETYSUMMARY.TheNationalElectricalCode,OccupationalSafetyandHealthActregulations,localindustrialcodesandlocalinspectionrequirementsalsoprovideabasisforequipmentinstallation,use,andservice.SHOCKHAZARDS

WARNING

ELECTRIC SHOCK CAN KILL! Toreduce the risk of death or serious

injury from shock, read, understand,and follow the following safetyinstructions. In addition, makecertain that anyone else who usesthis welding equipment, or who is abystander in the welding areaunderstands and follows these safetyinstructions as well.

FIRE HAZARDS

WARNING

FIRE OR EXPLOSION CAN CAUSEDEATH, INJURY, AND PROPERTYDAMAGE! To reduce risk of death,injury, or property damage from fireor explosion, read, understand, andfollow the following safetyinstructions. In addition, makecertain that anyone else that usesthis welding equipment, or is abystander in the welding area,understands and follows these safetyinstructions as well. REMEMBER!Welding by nature produces sparks,hot spatter, molten metal drops, hotslag, and hot metal parts that canstart fires, burn skin, and damageeyes.6

FLASH HAZARDS

WARNING

ARC RAYS CAN INJURE EYESAND BURN SKIN! To reduce risk ofinjury from arc rays, read,understand, and follow the followingsafety instructions. In addition, makecertain that anyone else that usesthis welding equipment, or is abystander in the welding area,understands and follows these safetyinstructions as well.

FUME HAZARDS

WARNING

FUMES, GASSES, AND VAPORSCAN CAUSE DISCOMFORT,ILLNESS, AND DEATH! To reducerisk of discomfort, illness, or death,read, understand, and follow thefollowing safety instructions. Inaddition, make certain that anyoneelse that uses this welding equipmentor is a bystander in the welding area,understands and follows these safetyinstructions as well.

COMPRESSED GASSES ANDEQUIPMENT HAZARDS

WARNING

IMPROPER HANDLING ANDMAINTENANCE OF COMPRESSEDGAS CYLINDERS ANDREGULATORS CAN RESULT INSERIOUS INJURY OR DEATH! To

reduce risk of injury or death fromcompressed gasses and equipmenthazards, read understand and followthe following safety instructions. Inaddition, make certain that anyoneelse who uses this welding

equipmentorabystanderintheweldingareaunderstandsandfollowsthesesafetyinstructionsaswell.

DonotuseflammablegasseswithMIGwelders.OnlyinertornonflammablegassesaresuitableforMIGwelding.ExamplesareCarbonDioxide,Argon,Helium,etc.ormixturesofmorethanoneofthesegasses.BURN HAZARDS

WARNING

Hot slag can cause fires andserious injury from burns. Toreduce the risk of discomfort or

serious injury due to burns alwayswear heavy protective clothing, eyeand face protection, and glovesdesigned for welding. To prevent therisk of fires starting, use a metal plateor some other material with a highflash point to catch and shieldcombustibles from the hot slag.

ADDITIONAL SAFETYINFORMATION

For additional information concerningwelding safety, refer to the followingstandards and comply with them asapplicable.

• ANSI Standard Z49.1 i SAFETY INWELDING AND CUTTING i

obtainable from the American WeldingSociety, 550 NW Le Jeune Road,Miami, FL 33126 Telephone (800)443-9353, Fax (305) 443-7559 iwww.amweld.org or www.aws.org

• ANSI Standard Z87.1 i SAFEPRACTICE FOR OCCUPATION ANDEDUCATIONAL EYE AND FACEPROTECTION i obtainable from theAmerican National Standards Institute,11 West 42ndSt., New York, NY 10036Telephone (212) 642-4900, Fax (212)398-0023 i www.ansi.org

• NFPA Standard 51B i CUTTINGAND WELDING PROCESS iobtainable from the National FireProtection Association, 1Batterymarch Park, P.O. Box 9101,Quincy, MA 02269-9101 Telephone(617) 770-3000, Fax (617) 770-0700i www.nfpa.org

• CGA Pamphlet P-I i SAFEHANDLING OF COMPRESSEDGASSES IN CYLINDERS iobtainable from the Compressed GasAssociation, 1725 Jefferson DavisHighway, Suite 1004, Arlington, VA22202-4102 Telephone (703) 412-0900 Fax (703) 412-0128 iwww.cagnet.com

• OSHA Standard 29 CFR, Part 1910,Subpart Q., WELDING, CUTTINGAND BRAZING i obtainable fromyour state OSHA office or U. S. Dept.of Labor OSHA, Office of PublicAffairs, Room N3647, 200 ConstitutionAve. Washington, DC 20210 iwww.osha.gov

• CSA Standard W117.2 i Code forSAFETY IN WELDING ANDCUTTING. i obtainable fromCanadian Standards Association, 178Rexdale Blvd. Etobicoke, OntarioM9W 1R3 i www.csa.ca

• American Welding Society StandardA6.0. WELDING AND CUTTINGCONTAINERS WHICH HAVE HELDCOMBUSTIBLES. i obtainable from

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

DESCRIPTION

Your new wire feed welder is designedfor maintenance and sheet metalfabrication. The welder consists of a

single-phase power transformer,stabilizer, rectifier, and a unique built-incontrol/feeder. This MIG welder is

capable of welding with 0.024 (0.6mm)and 0.030 (0.8mm), solid steel wire ondc reverse polarity and with .030 inchself-shielding flux-core wire on dcstraight polarity. Larger, 0.035 inch(0.9mm) diameter solid steel wire, on dcreverse polarity, and self shielding flux-core wire on dc straight polarity mayalso be used on this welder. The use of

larger diameter wire makes weldingdifficult and the results cannot be

guaranteed. The manufacturer does notrecommend the use of larger diameterwire.

Now you can weld sheet metal from 24gauge up to 1/4 inch thick with a singlepass. You can weld thicker steel withbeveling and multiple pass techniques.Table 1 lists your MIG welderspecifications.

Table 1. Welder Specifications

Primary (input) volts 120 VacPrimary (inputs) Amps 25Phase SingleFrequency 60 HzSecondary (output) volts 19.5Secondary (UL output) ampsl05Open Circuit Volts (Max.) 28 VdcDuty Cycle Rating 20%

WELDER OPERATINGCHARACTERISTICS

DUTY CYCLE

The duty cycle rating of a welder defineshow long the operator can weld andhow long the welder must be rested andcooled. Duty cycle is expressed as apercentage of 10 minutes andrepresents the maximum welding time

8

allowed. The balance of the 10-minute

cycle is required for cooling.

Your new welder has a duty cycle ratingof 20% at the rated output. This meansthat you can weld for two (2) minutes outof 10 with the remaining eight (8) minutesrequired for cooling. (See Table 2).

Table 2. Duty Cycle Ratings

Duty Maximum RequiredCycle Welding RestingRating Time Time

20% 2 minutes 8 minutes40% 4 minutes 6 minutes60% 6 minutes 4 minutes80% 8 minutes 2 minutes100% 10 minutes 0 minutes

INTERNAL THERMALPROTECTION

CAUTION

Do not constantly exceed the dutycycle or damage to this welder canresult. If you exceed the duty cycle ofyour welder, an internal thermalprotector will open, shutting off allwelder functions except the coolingfan. If this happens, DO NOT SHUTOFF THE WELDER. Leave the

welder turned on with the fan running.After cooling, the thermal protector willautomatically reset and the welder willfunction normally again. However,you should wait at least 10 minutesafter the thermal protector opensbefore resuming welding. You mustdo this even if the thermal protectorresets itself before the 10 minutes is

up or you may experience less thanspecified duty cycle performance.

If you find that your welder will not weldfor 2 minutes without stopping, reducethe wire speed slightly and tune thewelder in at the lowest wire speedsetting that still produces a smooth arc.Welding with the wire speed set too highcauses excessive current draw andshortens the duty cycle.

POWER SOURCECONNECTION

POWER REQUIREMENTS

This welder is designed to operate on aproperly grounded 120 Volt, 60 Hz,single-phase alternating current (ac)power source fused with a 20 amp time-delayed fuse or circuit breaker. It isrecommended that a qualified electricianverify the ACTUAL VOLTAGE at thereceptacle into which the welder will beplugged and confirm that the receptacleis properly fused and grounded. Theuse of the proper circuit size caneliminate nuisance circuit breaker

tripping when welding.

DO HOT OPERATE THIS WELDER if

the ACTUAL power source voltage isless than 105 Volts ac or greater than132 Volts ac. Contact a qualifiedelectrician if this problem exists.Improper performance and/or damage tothe welder will result if operated oninadequate or excessive power.

CONNECT TO POWER SOURCE

WARNING

High voltage danger from powersource! Consult a qualified electricianfor proper installation of receptacle atthe power source.

This welder must be grounded while inuse to protect the operator fromelectrical shock. If you are not sure ifyour outlet is properly grounded, have itchecked by a qualified electrician. Donot cut off the grounding prong or alterthe plug in any way and do not use anyadapters between the welder's powercord and the power source receptacle.

Make sure the POWER switch is OFFthen connect your welder's power cordto a properly grounded 120 Vac, 60 Hz,single phase, 20 amp power source.

EXTENSION CORDS

For optimum welder performance, anextension cord should not be used

unless absolutely necessary. Ifnecessary, care must be taken inselecting an extension cord appropriatefor use with your specific welder.

Select a properly grounded extensioncord that will mate directly with the acpower source receptacle and the welderpower cord without the use of adapters.Make certain that the extension is properlywired and in good electrical condition.

Extension cords must be at the smallesta #12 gauge cord. Do not use anextension cord over 25 ft. in length.

ASSEMBLING THEWELDER

The following procedures describe theprocess required to assemble, install,maintain, and prepare to weld with yournew wire feed welder.

UNPACKING THE WELDER

1. Remove any cartons or bagscontaining parts/accessories.

2. Open the cartons or bags packedwith your welder and inspect theircontents for damage. Report anymissing or damaged itemsimmediately.

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

INSTALL THE GROUND CLAMP

Connect the ground clamp to the groundcable (coming out the front of thewelder) according to the instructionspackaged with the ground clamp.

INSTALL THE TANK TRAYAND BRACKET

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

IMPORTANT - GAS CYLINDER SIZE

RESTRICTION! The tank tray you havejust installed on the back of the welderwill handle gas cylinders no larger than20 cubic feet. If you select a cylinderlarger than 20 cubic feet, it must bechained to a wall or other fixed support.

j 1

Figure 1. Mount Tank Tray BracketTo Welder

2.

Align the four tank tray bracket (1)mounting holes (as shown in Figure1) with the four staked nuts on therear 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 eachof the other three split lock nuts (2)and _-20 x 1/2inch hex bolts (3)through the remaining mountingholes.

3. Tighten all four hex bolts.

INSTALL THE SHIELDING GAS

WARNING

IMPROPER HANDLING ANDMAINTENANCE OF COMPRESSEDGAS CYLINDERS AND REGULATORSCAN RESULT IN SERIOUS INJURY

OR DEATH! Always secure gascylinders to the tank bracket kit, a wall,or other fixed support to prevent thecylinder from falling over and rupturing.Read, understand, and follow all theCOMPRESSED GASSES ANDEQUIPMENT HAZARDS in the SAFETYSUMMARY at the front of this manual.

Secure your gas cylinder to the tankbracket kit, a wall, or other fixed support.

1. Remove the protective cap from thecylinder and inspect the regulatorconnecting threads for dust, dirt oil,and grease. Remove any dust ordirt with a clean cloth. DO NOTATTACH THE REGULATOR IF OIL,GREASE, OR DAMAGE AREPRESENT.

2. Open the cylinder valve FOR JUSTAN INSTANT to blow out anyforeign matter inside the valve portto reduce the risk of plugging ordamaging the regulator. Never aimthe open cylinder valve port atyourself or bystanders.

3. Screw the regulator supplied withthis welder (see Figure 2) into thecylinder valve and tighten with awrench.

Adjustable Regulator Preset Regulator

Figure 2. Gas Regulators

4. Insert the gas hose into the outletport of the gas regulator. The hoselocks in place in the fitting whenpressed into the port.

5. To remove the gas hose, pressdown on the ring at the rear of thegas fitting, and pull the hose out ofthe fitting.

10

CHECK THE GAS FLOW

WARNING

IMPROPER HANDLING ANDMAINTENANCE OF COMPRESSEDGAS CYLINDERS AND REGULATORSCAN RESULT IN SERIOUS INJURY

OR DEATH! To reduce the risk of injuryor death, always stand to the side of thecylinder opposite the regulator whenopening the cylinder valve, keeping thecylinder valve between you and theregulator. Never aim the open cylindervalve port at yourself or bystanders.Failure to comply with this warning couldresult in serious personal injury.

Note: If the cylinder you have isequipped with male regulatorconnecting threads instead offemale, you will need to obtaina special compressed gascylinder adapter from your gassupplier to install between yourgas cylinder and regulator.

• The gas control function doesnot require the welder to beturned on or plugged in.

1. Slowly crack open the cylindervalve, then turn open ALL THEWAY.

2. Pull the trigger on the gun to allowthe gas to flow. KEEP THETRIGGER PULLED. Listen and feelfor gas flowing from the end of thewelding gun. If your regulator hasno adjustment, it has been pre-setat the factory for a flow of 20 cubicfeet per hour. If your gas regulatorhas an adjustment to control thegas flow rate, turn the adjustmentkey clockwise to increase gas flow;counterclockwise to reduce flow.For most welding, the gas flowshould be set at 15-20 cubic feetper hour. If no gas is heard or felt,verify all steps involved inconnecting the gas.

3. Release the trigger.

Note: If welding outside or in a draft, itmay become necessary to setup a windbreak to keep theshielding gas from being blownfrom the weld area.

• MAKE SURE TO TURN OFFTHE GAS CYLINDER VALVEWHEN DONE WELDING.

ALIGN AND SET THE DRIVEROLLER

Before installing any welding wire intothe unit, the proper sized groove mustbe placed into position on the wire drivemechanism. Change to a neoprenedrive roller when welding withaluminum wire.

STANDARD DRIVE ROLLER

Change the standard drive rolleraccording to the following steps:

1. Remove the drive tension byunscrewing the tension adjustingscrew (ALL THE WAY in a counter-clockwise direction). The drivetension screw will come loose,allowing you to pull the drivetension arm up away from the driveroller. Make sure to keep the screwand the spring in place with thedrive tension arm.

2.

3.

If there is wire already installed inthe welder, roll it back onto the wirespool by hand-turning the spoolcounter-clockwise. Be careful notto allow the wire to come out of the

rear end of the gun without holdingonto it or it will unspool itself. Putthe end of the wire into the hole on

the outside edge of the wire spooland bend it over to hold the wire in

place. Remove the spool of wirefrom the welder.

Loosen the drive roller setscrewand pull the drive roller off the driveshaft.

11

Note: 6. Tighten the setscrew, while holdingthe drive roller in place.

4,

5,

The drive roller has two wire

size grooves built into it. Wheninstalling the drive roller thenumber stamped on the driveroller for the wire size you areusing should be facing awayfrom you. If you can read thewire size you are using on thedrive roller, it is installedbackwards. Use only theproper size drive roller whenusing your welder.

Find the side of the drive roller that

is stamped with the same wirediameter as that of the wire beinginstalled (see Figure 3, and if inmetric, see DESCRIPTION in theWELDER SPECIFICATIONS

section). Make certain the spacingwasher is still on the motor shaft

and push the drive roller onto themotor shaft, aligning the setscrewwith the flat side of the drive shaft.

Make sure the side stamped withthe desired wire diameter is awayfrom you.

Drive Roller

Shaft

Washer

Figure 3. Drive Roller

Slide the roller onto the shaft sothat the groove in the roller lines upwith the inlet tube and the weldinggun liner. You can look at thealignment from the top of thewelder.

INSTALL THE WELDINGWIRE

WARNING

Electric shock can kill! Always turnthe POWER switch OFF and unplug thepower cord from the ac power sourcebefore installing wire.

Be very careful when removing thewelding nozzle. The contact tip on thiswelder is electrically hot as long asPOWER is turned ON. Make certainPOWER is turned OFF.

1,

2.

Remove the nozzle and contact tipfrom the end of the gun assembly.

Make sure the proper groove onthe drive roller is in place for thewire being installed. If the propergroove is not in place, change thedrive roller as described above.

3, Unwrap the spool of wire then findthe leading end of the wire (it goesthrough a hole in the outer edge ofthe spool and is bent over the spooledge to prevent the wire fromunspooling) BUT DO NOTUNHOOK IT YET.

4, Place the spool on the spindle insuch a manner that when the wire

comes off the spool, it will look likethe top illustration in Figure 4. Thewelding wire should always comeoff the top of the spool into the drivemechanism.

12

RightWay

WrongWay

Figure 4. Right and Wrong Way ToFeed Wire From Spool

5. If you are installing a four-inchspool of wire, install the drive brakehardware on the top of the spool ofwire according to Figure 5A. If you Note:are installing an eight-inch spool,install the spindle adapter and drivebrake hardware as shown in Figure5B. The purpose of the drive brakeis to cause the spool of wire to stopturning at nearly the same momentthat wire feeding stops.

6. Once the drive brake hardware isinstalled, set the spool tension.With one hand, turn the wire spool 7.and continue turning it whileadjusting the tension on the spool.With your free hand, tighten (turnclockwise) the wing nut that holdsthe spool in place. Stop tighteningwhen 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 Assemblieswith Four Inch and Eight Inch Wire

Spools

9,

10.

If TOO MUCH tension isapplied to the wire spool, thewire will slip on the drive rolleror will not be able to feed at all.If TOO LITTLE tension isapplied, the spool of wire willwant to unspool itself. Readjustthe drive brake tension asnecessary to correct for eitherproblem.

After checking to make sure thatyour welder is disconnected fromthe ac power source, free theleading end of the wire from thespool, but do not let go of it until toldto do so, or the wire will unspoolitself.

Using a wire cutter, cut the bent endoff the leading end of the wire sothat only a straight leading endremains.

Loosen the tension adjusting screwholding the drive tension arm inplace and lift the tension arm up offthe drive roller.

Insert the leading end of the wireinto the inlet guide tube. Then pushit across the drive roller and into the

gun assembly about six inches.

13

CAUTION

Make certain that the welding wire isactually going into the gun liner. Bevery sure it has not somehow beenaccidentally been routed alongsidethe liner or even in some other

direction. If this should happen, thewire could feed inside the cable

casing or take a right angle and followthe wires and gas hose inside thewelder. It could also feed back on

itself jamming up the mechanism.

11. Line the wire up in the inside grooveof the drive roller, then allow thedrive tension arm to drop onto thedrive roller.

12. Tighten (turn clockwise)the drivetension adjusting screw until thetension roller is applying enoughforce on the wire to prevent it fromslipping out of the drive assembly.

13. Let go of the wire.

14. Connect the welder power cord tothe ac power source. Turn thewelder POWER switch ON. Set the

VOLTAGE switch to the voltage(heat) setting recommended for thegauge metal that is to be welded.Refer to the label mounted on thecover, inside the drivecompartment, for recommendedvoltage (heat) settings for yourwelding job. The VOLTAGEselector controls the weld heat.

There are eight voltage (heat)selections (numbered 1 through 8)available on this welder.

Numbered position 1 provides thelowest voltage (heat) and position8 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 gunto feed the wire through the gunassembly.

17. When at least an inch of wire sticks

out past the end of the gun, releasethe trigger.

18. Select a contact tip stamped withthe 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 thegun). Thread the contact tip intothe end of the gun and hand-tightensecurely.

20. Install the nozzle on the gunassembly. For best results, coat theinside of the nozzle with anti-stick

spray or gel (part #4312, notsupplied).

21. Cut off the excess wire that extends

past the end of the nozzle.

SET THE WIRE DRIVETENSION

WARNING

To reduce the risk of arc flash, makecertain that the wire coming out ofthe end of the gun does not come incontact with the workpiece clamp orany grounded material during thedrive tension setting process orarcing will occur.

1,

2.

3,

Pull the trigger on the gun.

Turn the drive tension adjustmentknob clockwise, increasing thedrive tension until the wire seems

to feed smoothly without slipping.

Block the end of the nozzle byholding it up against somethingthat doesn't conduct electricity,such as a block of wood or a

concrete floor, then trigger the gunagain. The wire should slip at thedrive roller. However, if the wirebird-nests at the drive roller,rethread the drive system usingless drive tension and try again.

14

4, When the drive tension is setcorrectly, there should be noslippage between the wire and thedrive roller. However, if anobstruction occurs along the wirefeed path, the wire should then slipon the drive roller.

PREPARATION

CHANGE POLARITY

This welder allows you the capability tochange 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 ofsteel, and silicon bronze welding ofsteel, 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 welderaccording to the following procedure steps.Figure 8 shows what the polarity blockshould look like for each polarity setting.

WARNING

Electric shock can kill! Always turn thePOWER switch OFF and unplug thepower cord from the ac power sourcebefore changing polarity.

CAUTION

Do not use a ratchet, crescent or otherlever type wrench to tighten the nutson the polarity bus. The nuts must behand tightened with a 7/16 inch nutdriver only. Too much torque appliedto the one of the nuts could cause the

threaded post to break off.

Tools Required:

• 7/16 inch nut driver

1,

2,

With a 7/16 inch nut driver, removeall four nuts and pull out thevertically mounted copper straps.

Replace the copper strapshorizontally in the dc StraightPolarity (dc - Flux Cored)configuration shown in Figure 6.

DC+ DCMIG FLUX CORED

Figure 6. Welder Polarity Selections

3. Start the four nuts on the four

connecting posts and hand snugeach nut with the 7/16 nut driver.

Do not use a ratchet, crescent orother lever type wrench.

15

Operation of this welder consists ofselecting and adjusting operatingcontrols for optimum voltage (weldingheat) and wire speed settings.

CONTROLS ANDINDICATORS

WARNING

Electric shock can kill! To removethe risk of electric shock, be awarethat the VOLTAGE selector, whenOFF, does not remove power from allinternal circuitry in the welder.

POWER - This welder has a POWERswitch mounted on the front panel. ThePOWER switch is used to initiate (turnthe welder ON) or extinguish (turn thewelder OFF) ac power to the welder.

VOLTAGE SELECTOR - The voltageselector controls the welding heat. Thevoltage selector provides continuousvoltage (heat) adjustment but hasreference number settings 1-8.Number 1 is the lowest voltage (heat)setting and number 8 the highest. Referto the label under the welder hood for

recommended voltage (heat) settingsfor your welding job.

WIRE SPEED CONTROL - The WIRESPEED CONTROL adjusts the speed atwhich the wire is fed out of the weldinggun. The wire speed needs to beclosely matched (tuned-in) to the rate atwhich it is being melted off (seeTUNING IN THE WIRE SPEED, (in theWelding Instruction Guide). Somethings that affect wire speed selectionare the type and diameter of the wirebeing used, the heat setting selected,and the welding position to be used.

16

GENERAL

This welder has been engineered to givemany years of trouble-free serviceproviding that a few very simple stepsare taken to properly maintain it.

1. Keep the wire drive compartment lidclosed at all times unless the wire

needs to be changed or the drivetension needs adjusting.

2. Keep all consumables (contact tips,nozzles, and gun liner) clean andreplace when necessary. SeeCONSUMABLE MAINTENANCEAND TROUBLESHOOTING later inthis section for detailed information.

3,

4,

Replace power cord, ground cable,ground clamp, or gun assemblywhen damaged or worn.

Periodically clean dust, dirt, grease,etc. from your welder. Every sixmonths or as necessary, removethe side panels from the welder andair-blow any dust and dirt that mayhave accumulated inside thewelder.

WARNING

ELECTRIC SHOCK CAN KILL! To

reduce the risk of electric shock, alwaysunplug the welder from its ac powersource before removing side panels.

IT IS VERY IMPORTANT TO MAINTAINTHE CONSUMABLES TO AVOID THENEED FOR PREMATUREREPLACEMENT OF THE GUNASSEMBLY.

The GUN LINER is intended to providean unrestricted path for the welding wireto flow through the gun assembly. Overtime it will accumulate dust, dirt, andother debris. Replacement is necessarywhen these accumulations begin torestrict the free flow of wire through thegun assembly.

REPLACE A GUN LINER

When removing or installing a gun liner,care must be taken not to kink orotherwise damage the gun liner orreplacement will be necessary. SeeFigure 7 for the drive assembly andFigure 8 for the gun assembly.

17

Drive Drive GunTension Tension Liner

Adjustment Arm1/4" Hex

Head Screws

Inlet GuideTube End

InletGuideTube l Phillips Pan Str#in

RehefHead Screw Clamp

DriveRoller

DriveAssembly

GunAssembly(Tail End)

Figure 7. Drive Assembly

GunCable

PlasticCable Tie

CableCoverin(

Handle WireCase

Live WireTerminal

Contact

Gas ConductorGas Valve Tube Insulation

Lockwasher

Head EndGun Liner

Tube

GasDiffuser Contact

(has lefthand Tip

Nozzle

Figure 8. Gun Assembly

18

Tools Required:

° 5/16 inch open end wrench

° Crescent Wrench (6 or 8 inch)

° 9 mm open end wrench (or 3 inchcrescent)

° Phillips Screwdriver

° Straight Blade Screwdriver or 1_ inchhex driver

1,

2.

3.

Turn OFF welder POWER SWITCH.

Open the welder side panel.Loosen the tension arm and lift itup off the drive roller.

4. Turn the wire spool counter-clockwise (be sure to hold onto thewire itself while turning the spool orthe wire will unspool itself when itbecomes free of the gun liner),removing wire from gun assembly.

5. Remove two 1_ inch hex headscrews (may also be removed witha straight blade screwdriver) andone pan head Phillips screw (inletguide tube end) from the driveroller and lift away the strain reliefclamp that holds the tail end of thegun in the drive assembly.

6. Leave the gun assembly (consistsof nozzle, gas diffuser, conductortube, handle and cable containinggas tubing electrical cable andliner) attached to the welder butmove the welder to a place wherethe gun assembly can be laid outstraight on a table or workbench orsimilar flat surface.

7,

8.

9,

Unscrew and remove the nozzle.

With a crescent wrench (six or eightinch), turn the gas diffuserclockwise (has left hand threads)and remove the gas diffuser (andcontact tip together) from theconductor tube on the end of the

gun.

Remove the four Phillips headscrews that hold the handle casetogether. With the exception of thetrigger, completely remove thecontents of the handle case.

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

Note: In the following procedure step,it may be necessary to removethe gas fitting from the gasvalve in order to make room toturn out the head end of thegun liner.

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

from the gas valve. Save theinternal star lock-washer and notethe orientation of the live wire

terminal. If you find it necessary toremove the gas hose connector,press down on the ring at the rearof the gas fitting to release the gashose and pull out the gas hose.Remove the gas fitting with a 9 mmopen end wrench or three inchcrescent.

12. Pull the liner out of the cable

covering (tubing) from the handleend and push the small piece ofliner out of the conductor tube.

13. Carefully insert the new liner intothe cable taking particular care tokeep the liner straight (especially atthe terminal end) to ease itspassage through cable covering. Itmay be desirable, perhaps evennecessary, to apply some silicongrease to the outside of the newliner so that it will slide easilythrough the cable.

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

Note: If you found it necessary toremove the gas and hoseconnector at step 9, rememberto reconnect it after completingstep 12. The gas hose can bereconnected by simply pushingit into the back of the connector.

15. Insert the head of the gun linerthrough the internal star lockwasher and the live wire terminal

(repeat the orientation noted instep 9). With a 5/16 inch open endwrench, screw the head end of thenew liner into the gas valve.

19

16. Insert a new plastic cable tie inplace around the cable and tightenit in approximately the samelocation as the plastic cable tie thatwas cut in step 8.

17. Return all components to thehandle casing and realign them asthey were originally.

18. With both halves of the handle

case in place, tighten the fourPhilips pan head screws makingsure the trigger remains seated inplace.

19. Push the cable into the welder far

enough so that the end of the gunliner protrudes through the inletguide tube end of the wire-feedtorch clamp far enough so that it iswithin approximately 1/16 inch oftouching the drive roller.

20. Make sure the cable covering(tubing) is far enough in themachine so that it is covered by thewire-feed torch clamp.

21. Tighten the two 1_ inch hex headscrews (may also be tightened by astraight blade screwdriver) and onepan head Phillips screw to thedrive roller securing the gun inplace.

22. Re-install the welding wireaccording to INSTALL THEWELDING WIRE.

MAINTAINING THE CONTACT TIP

The purpose of the CONTACT TIP is totransfer welding current to the weldingwire while allowing the wire to passthrough it smoothly.

Always use a contact tip stamped withthe same diameter as the wire it will beused with.

If the wire burns back into the tip,remove the tip from the gun andclean the hole running through itwith an oxygen-acetylene torch tipcleaner or tip drill.

2, Over time, the hole in the contacttip will become worn by the wirepassing through it. The more wornthis hole becomes, the less efficientis the transfer of welding current tothe wire and eventually arcbreakage and difficult arc startingwill result. Replace contact tipswhen signs of wear becomeapparent.

MAINTAINING THE NOZZLE

The nozzle directs the shielding gas tothe weld puddle, determines the size ofthe shielding area, and prevents theelectrically hot contact tip fromcontacting the work piece.

CAUTION

KEEP THE NOZZLE CLEAN! Duringthe welding process, spatter and slagwill build up inside the nozzle andmust be cleaned out periodically.Failure to clean and/or replace thenozzle in a timely fashion WILLCAUSE DAMAGE TO THE FRONT-END OF THE GUN ASSEMBLY.

For best results, coat the inside of a newor freshly cleaned nozzle with anti-stickspray or gel.

1. Stop welding and clean anyaccumulated slag or spatter fromthe nozzle every 5 to 10 minutes ofwelding time.

2. When welding overhead, if anymolten metal drips from the weldpuddle and falls into the nozzle,STOP WELDING IMMEDIATELYand clean the nozzle.

3, If the slag cannot be thoroughlycleaned from the nozzle,REPLACE THE NOZZLE!

Failure to keep the nozzle adequatelycleaned can result in the followingproblems:

20

A SHORTED nozzle results when

spatter buildup bridges the insulation inthe nozzle allowing welding current toflow through it as well as the contact tip.When shorted, a nozzle will stealwelding current from the wire wheneverit contacts the grounded work piece.This causes erratic welds and reduced

penetration.

In addition, a shorted nozzle overheatsthe end of the gun, which can DAMAGEthe front-end of the gun.

A RESTRICTED nozzle is created whenenough slag builds up in the nozzle toaffect the direction, concentration, andor rate of the shielding gas flow. Thisproblem can cause porous, brittle weldsand reduce penetration.

TESTING FOR A SHORTEDNOZZLE

Arcing between the nozzle and the workpiece ALWAYS means the nozzle isshorted, but this can be hard to detectthrough the lens of a welding helmet.The following testing method is anotherway to tell if a nozzle is shorted.

With the welder unplugged from the acpower source, touch the probes of anohmmeter or continuity tester to the endof the contact tip and the outside of thenozzle. If there is any continuity at all,the nozzle IS shorted. Clean or replaceas needed.

PREVENTIVE MAINTENANCE

Except for internal and externalcleaning, cleaning the nozzle, andoccasionally retightening screws, thereis no periodic maintenancerecommended for your welder.

TROUBLESHOOTING

The following TROUBLESHOOTINGinformation is provided as a guide tohelp resolve some of the more commonproblems that could be encountered.

Table 3 is a troubleshooting tableprovided to help you determine apossible remedy when you are having aproblem with your welder. This tabledoes not provide all possible solutions,only those possibilities considered tolikely be common faults. The tableconsists of a TROUBLE or symptom, aPOSSIBLE CAUSE for that symptom,and a POSSIBLE REMEDY for thatsymptom.

21

Table 3. Troubleshooting

TROUBLE

Dirty, porous brittleweld

Wire feed works butno arc

Arc works but not

feeding wire.

Nothing worksexcept fan

Low output ornon-penetrating weld.

Wire is birdnestingat the drive roller

Wire burns back

to contact tip

POSSIBLE CAUSE

1. Plugged welding nozzle2. No shielding gas

3. Wrong Type of Gas

4. Dirty or rusty welding wire

1. Bad ground or looseconnection

2. Bad connection to gun orfaulty gun1. Faulty wire speed controlassembly2. No tension on the drive roller

3. Faulty drive motor (very rare)1. Faulty trigger on gun2. Faulty transformer (rare)3. Exceeded duty cycle; thermalprotector opened

1. Loose connection insidemachine

2. Too long or improperextension cord

3. Wrong type or size wire4. Poor ground connection

5. Wrong size contact tip6. Loose gun connection orfaulty gun assembly7. Wrong welding polarity set8. Dirty or rusty welding wire1. Too much tension on driveroller

2. Gun liner worn or damaged3. Contact tip is clogged ordamaged4. Liner is stretched or is too

long

1. Gun liner is worn or damaged2. Liner stretched or is too long3. Wrong size contact tip4. contact tip clogged ordamaged

POSSIBLE REMEDY

1. Clean or replace nozzle2. Tank empty, flow restricted, orregulator set too low3. See SELECTING SHIELDINGGAS in the WELDING

INSTRUCTION GUIDE for properselection

4. Replace spool of wire

1. Check ground and connectionstighten as necessary2. Check connection to gun orreplace gun1. Replace wire speed controlassembly2. Adjust the drive tension3. Replace drive motor1. Replace trigger2. Replace transformer3. Allow welder to cool at least 10

minutes (observe and maintainproper duty cycle1. Blow inside of machine out with

compressed air, clean and tightenall connections2. See EXTENSION CORD USE inthis manual

3. Use correct size welding wire4. Reposition clamp and checkcable to clamp connection5. Use correct size contact tip6. Tighten gun or replace gun7. Change polarity to proper forwire being used8. Replace spool of wire

1. Adjust the drive tension(see INSTALLING THE WELDINGWIRE)2. Replace gun liner3. Replace contact tip

4. Trim liner to proper length

1. Replace gun liner

2. Trim liner for proper length3. Use correct size contact tip4. Replace contact tip

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

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

22

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MODEL 205592

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MODEL 205592

24

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

25

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MODEL 205592

Fortherepairor replacementpartsyouneeddelivereddirectlyto yourhomeCall 7 am - 7 pm, 7 days a week

1-800-366-PART(1-800-366-7278)

For in-home major brand repair serviceCall 24 hours a day, 7 days a week

1-800-4-REPAIR

(1-800-473-7247)

The model number of your product is locatedon the welder nameplate.If the parts you need are not stocked locally,your order will be electronically transmitted toa Sears Repair Parts Distribution Center forexpedited handling.When requesting service or ordering parts,always give the following information:

• Product Name* Model Number• Part Number

. Part Description

S ARSAmerica's Repair Specialists