Craftsman 934.205592 Operator's Manual
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Craftsman 934.205592 Operator's Manual

Craftsman 934.205592 Operator's Manual

Wire feed mig welder
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SEARS
CRRFTSMRN
Operator's Guide
WIRE FEED
MIG WELDER
Model No.
934.205592
CAUTION:
Read and follow
all Safety
Rules and
Operating
Instructions
before
First Use of this Product.
•
WARRANTY
•
INTRODUCTION
•
SAFETY
SUMMARY
•
SPECIFICATIONS
•
INSTALLATION
•
OPERATION
•
MAINTENANCE
•
SCHEMATIC
•
WIRING
DIAGRAM
•
REPLACEMENT
PARTS
Sears, Roebuck
and Co., Hoffman
Estates,
IL 60179 USA
811-642-000
September
2001

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Summary of Contents for Craftsman 934.205592

  • Page 1 MAINTENANCE • SCHEMATIC • WIRING DIAGRAM WIRE FEED • REPLACEMENT PARTS MIG WELDER Model No. 934.205592 CAUTION: Read and follow all Safety Rules and Operating Instructions before First Use of this Product. Sears, Roebuck and Co., Hoffman Estates, IL 60179 USA...
  • Page 2 On Welding Gun or Cables, Welder, and Welder's Transformer WARRANTY SERVICE IS AVAILABLE Full One Year Warranty for Craftsman BY SIMPLY CONTACTING THE Welding Gun or Cables. For one year NEAREST SEARS SERVICE CENTER. from the date of purchase, when the welding gun or cables are operated and This warranty applies only while this maintained according to the owner's...

  • Page 3: Table Of Contents

    CRAFTSMAN FULL WARRANTY ............TABLE OF CONTENTS ................. INTRODUCTION ..................SAFETY SUMMARY ................SAFETY INFORMATION ..............SHOCK HAZARDS ................FIRE HAZARDS .................. FLASH HAZARDS ................FUME HAZARDS ................COMPRESSED GASSES AND EQUIPMENT HAZARDS ....6 BURN HAZARDS ................ADDITIONAL SAFETY INFORMATION ..........
  • Page 4 Where information is shown that does This Welder User's Guide provides not necessarily apply to all models or specific information about your wire brands of welder, it will be marked as feed welder. It is to be used together either optional on some welder models with the Welding Instruction Guide to or does not apply to all models.
  • Page 5 Every craftsman respects the tools with symbols identify important which they work. They know that the safety messages in this manual. tools represent years of constantly When you see one of the symbols improved designs and developments. shown here, be alert to the possibility of The true craftsman also knows that tools personal injury and carefully read the are dangerous if misused or abused.

  • Page 6: Safety Summary

    information before proceeding withany FLASH HAZARDS oftheinstructions contained inthis user's g uide. Published standards onsafety a re available. They arelisted in WARNING ADDITIONAL SAFETY I NFORMATION attheendofthisSAFETY SUMMARY. ARC RAYS CAN INJURE EYES TheNational Electrical Code, AND BURN SKIN! To reduce risk of Occupational Safety a ndHealth A ct injury from arc rays, read,...

  • Page 7: Burn Hazards

    equipment ora bystander inthe • ANSI Standard Z87.1 i SAFE welding a reaunderstands PRACTICE FOR OCCUPATION AND follows t hese safety i nstructions EDUCATIONAL EYE AND FACE well. PROTECTION i obtainable from the American National Standards Institute, Donotuse flammable gasses w ith 11 West 42 ndSt., New York, NY 10036 MIG welders.

  • Page 8: Welder Specifications

    allowed. The balance of the 10-minute DESCRIPTION cycle is required for cooling. Your new wire feed welder is designed Your new welder has a duty cycle rating for maintenance and sheet metal of 20% at the rated output. This means fabrication.

  • Page 9: Power Source Connection

    POWER SOURCE EXTENSION CORDS CONNECTION For optimum welder performance, an extension cord should not be used POWER REQUIREMENTS unless absolutely necessary. necessary, care must be taken in This welder is designed to operate on a selecting an extension cord appropriate properly grounded 120 Volt, 60 Hz, for use with your specific welder.

  • Page 10: Install The Shielding Gas

    IMPORTANT - GAS CYLINDER SIZE Remove the protective cap from the RESTRICTION! The tank tray you have cylinder and inspect the regulator just installed on the back of the welder connecting threads for dust, dirt oil, will handle gas cylinders no larger than and grease.

  • Page 11: Check The Gas Flow

    CHECK THE GAS FLOW Release the trigger. Note: If welding outside or in a draft, it may become necessary to set up a windbreak to keep the WARNING shielding gas from being blown from the weld area. IMPROPER HANDLING AND •...

  • Page 12: Install The Welding Wire

    The drive roller has two wire Note: 6. Tighten the setscrew, while holding size grooves built into it. When the drive roller in place. installing the drive roller the INSTALL THE WELDING number stamped on the drive WIRE roller for the wire size you are using should be facing away from you.
  • Page 13 RightWay WrongWay 4" Spool Figure 4. Right and Wrong Way To 8" Spool Feed Wire From Spool Figure 5. Drive Brake Assemblies 5. If you are installing a four-inch with Four Inch and Eight Inch Wire spool of wire, install the drive brake Spools hardware on the top of the spool of If TOO MUCH tension is...

  • Page 14: Set The Wire Drive Tension

    CAUTION 18. Select a contact tip stamped with the same diameter as the wire Make certain that the welding wire is being used. If stamped in metric, actually going into the gun liner. Be see DESCRIPTION. very sure it has not somehow been 19.

  • Page 15: Preparation

    When the drive tension is set CAUTION correctly, there should be no Do not use a ratchet, crescent or other slippage between the wire and the lever type wrench to tighten the nuts drive roller. However, if an on the polarity bus. The nuts must be obstruction occurs along the wire hand tightened with a 7/16 inch nut feed path, the wire should then slip...

  • Page 16: Controls And Indicators

    Operation of this welder consists of VOLTAGE SELECTOR - The voltage selecting and adjusting operating selector controls the welding heat. The controls for optimum voltage (welding voltage selector provides continuous heat) and wire speed settings. voltage (heat) adjustment but has reference number settings 1-8.

  • Page 17: Maintenance

    GENERAL This welder has been engineered to give WARNING many years of trouble-free service providing that a few very simple steps are taken to properly maintain it. ELECTRIC SHOCK CAN KILL! To reduce the risk of electric shock, always 1. Keep the wire drive compartment closed at all times unless the wire unplug the welder from its ac power source before removing side panels.
  • Page 18 Drive Drive Tension Tension Liner Adjustment 1/4" Hex Head Screws Inlet Guide Tube End Rehef Assembly Head Screw Clamp Inlet (Tail End) Drive Guide Roller Tube Phillips Pan Str#in Drive Assembly Figure Drive Assembly Live Wire Terminal Plastic Conductor Cable Tie Valve Tube Insulation Cable...
  • Page 19 Tools Required: 10. Cut the plastic cable tie away from the cable covering (tubing). ° 5/16 inch open end wrench Note: In the following procedure step, ° Crescent Wrench (6 or 8 inch) it may be necessary to remove the gas fitting from the gas °...

  • Page 20: Maintaining The Contact Tip

    Over time, the hole in the contact 16. Insert a new plastic cable tie in tip will become worn by the wire place around the cable and tighten passing through it. The more worn it in approximately the same this hole becomes, the less efficient location as the plastic cable tie that is the transfer of welding current to was cut in step 8.

  • Page 21: Testing For A Shorted Nozzle

    A SHORTED nozzle results when With the welder unplugged from the ac spatter buildup bridges the insulation in power source, touch the probes of an the nozzle allowing welding current to ohmmeter or continuity tester to the end flow through it as well as the contact tip. of the contact tip and the outside of the When shorted, a nozzle will steal nozzle.
  • Page 22 Table 3. Troubleshooting TROUBLE POSSIBLE CAUSE POSSIBLE REMEDY Dirty, porous brittle 1. Plugged welding nozzle 1. Clean or replace nozzle weld 2. No shielding gas 2. Tank empty, flow restricted, or regulator set too low 3. See SELECTING SHIELDING 3. Wrong Type of Gas GAS in the WELDING INSTRUCTION GUIDE for proper selection...
  • Page 23 © © > © © © .___,__ © >> MODEL 205592...
  • Page 24 MODEL 205592...
  • Page 25 ITEM DESCRIPTION PART 117-084-902 ¥ 202082 Sears 105 amp MIG Welder Potentiometer 246-120-000 216-100-000 Front Panel 410-900-010 Strain Relief 541-057-000 238-223-666 Cable Assembly Knob 246-107-666 Switch 246-423-000 238-593-000 10' MIG gun Control Panel 410-869-011 Transformer 880-455-888 Left Side Panel 410-865-020 312-295-666 Slide Latch W/Clip...
  • Page 26 zo-_z_ --o d_ -%--= L. --_-- _ J MODEL 205592...
  • Page 27 Forthe repairor replacement partsyou need delivered directlyto yourhome Call 7 am - 7 pm, 7 days a week 1-800-366-PART (1-800-366-7278) For in-home major brand repair service Call 24 hours a day, 7 days a week 1-800-4-REPAIR (1-800-473-7247) The model number of your product is located on the welder nameplate.

  • Page 28: Introduction

    MAINTENANCE • SCHEMATIC • WIRING DIAGRAM WIRE FEED • REPLACEMENT PARTS MIG WELDER Model No. 934.205592 CAUTION: Read and follow all Safety Rules and Operating Instructions before First Use of this Product. Sears, Roebuck and Co., Hoffman Estates, IL 60179 USA...
  • Page 29 On Welding Gun or Cables, Welder, and Welder's Transformer WARRANTY SERVICE IS AVAILABLE Full One Year Warranty for Craftsman BY SIMPLY CONTACTING THE Welding Gun or Cables. For one year NEAREST SEARS SERVICE CENTER. from the date of purchase, when the welding gun or cables are operated and This warranty applies only while this maintained according to the owner's...

  • Page 30: Welder Installation

    CRAFTSMAN FULL WARRANTY ............TABLE OF CONTENTS ................. INTRODUCTION ..................SAFETY SUMMARY ................SAFETY INFORMATION ..............SHOCK HAZARDS ................FIRE HAZARDS .................. FLASH HAZARDS ................FUME HAZARDS ................COMPRESSED GASSES AND EQUIPMENT HAZARDS ....6 BURN HAZARDS ................ADDITIONAL SAFETY INFORMATION ..........
  • Page 31 Where information is shown that does This Welder User's Guide provides not necessarily apply to all models or specific information about your wire brands of welder, it will be marked as feed welder. It is to be used together either optional on some welder models with the Welding Instruction Guide to or does not apply to all models.

  • Page 32: Safety Information

    Every craftsman respects the tools with symbols identify important which they work. They know that the safety messages in this manual. tools represent years of constantly When you see one of the symbols improved designs and developments. shown here, be alert to the possibility of The true craftsman also knows that tools personal injury and carefully read the are dangerous if misused or abused.

  • Page 33: Shockhazards

    information before proceeding withany FLASH HAZARDS oftheinstructions contained inthis user's g uide. Published standards onsafety a re available. They arelisted in WARNING ADDITIONAL SAFETY I NFORMATION attheendofthisSAFETY SUMMARY. ARC RAYS CAN INJURE EYES TheNational Electrical Code, AND BURN SKIN! To reduce risk of Occupational Safety a ndHealth A ct injury from arc rays, read,...
  • Page 34 equipment ora bystander inthe • ANSI Standard Z87.1 i SAFE welding a reaunderstands PRACTICE FOR OCCUPATION AND follows t hese safety i nstructions EDUCATIONAL EYE AND FACE well. PROTECTION i obtainable from the American National Standards Institute, Donotuse flammable gasses w ith 11 West 42 ndSt., New York, NY 10036 MIG welders.

  • Page 35: Description

    allowed. The balance of the 10-minute DESCRIPTION cycle is required for cooling. Your new wire feed welder is designed Your new welder has a duty cycle rating for maintenance and sheet metal of 20% at the rated output. This means fabrication.

  • Page 36: Power Source Connection

    POWER SOURCE EXTENSION CORDS CONNECTION For optimum welder performance, an extension cord should not be used POWER REQUIREMENTS unless absolutely necessary. necessary, care must be taken in This welder is designed to operate on a selecting an extension cord appropriate properly grounded 120 Volt, 60 Hz, for use with your specific welder.

  • Page 37: Install The Shielding Gas

    IMPORTANT - GAS CYLINDER SIZE Remove the protective cap from the RESTRICTION! The tank tray you have cylinder and inspect the regulator just installed on the back of the welder connecting threads for dust, dirt oil, will handle gas cylinders no larger than and grease.

  • Page 38: Check The Gas Flow

    CHECK THE GAS FLOW Release the trigger. Note: If welding outside or in a draft, it may become necessary to set up a windbreak to keep the WARNING shielding gas from being blown from the weld area. IMPROPER HANDLING AND •...

  • Page 39: Install The Welding Wire

    The drive roller has two wire Note: 6. Tighten the setscrew, while holding size grooves built into it. When the drive roller in place. installing the drive roller the INSTALL THE WELDING number stamped on the drive WIRE roller for the wire size you are using should be facing away from you.
  • Page 40 RightWay WrongWay 4" Spool Figure 4. Right and Wrong Way To 8" Spool Feed Wire From Spool Figure 5. Drive Brake Assemblies 5. If you are installing a four-inch with Four Inch and Eight Inch Wire spool of wire, install the drive brake Spools hardware on the top of the spool of If TOO MUCH tension is...

  • Page 41: Set The Wire Drive Tension

    CAUTION 18. Select a contact tip stamped with the same diameter as the wire Make certain that the welding wire is being used. If stamped in metric, actually going into the gun liner. Be see DESCRIPTION. very sure it has not somehow been 19.

  • Page 42: Preparation

    When the drive tension is set CAUTION correctly, there should be no Do not use a ratchet, crescent or other slippage between the wire and the lever type wrench to tighten the nuts drive roller. However, if an on the polarity bus. The nuts must be obstruction occurs along the wire hand tightened with a 7/16 inch nut feed path, the wire should then slip...

  • Page 43: Controls And Indicators

    Operation of this welder consists of VOLTAGE SELECTOR - The voltage selecting and adjusting operating selector controls the welding heat. The controls for optimum voltage (welding voltage selector provides continuous heat) and wire speed settings. voltage (heat) adjustment but has reference number settings 1-8.

  • Page 44: General

    GENERAL This welder has been engineered to give WARNING many years of trouble-free service providing that a few very simple steps are taken to properly maintain it. ELECTRIC SHOCK CAN KILL! To reduce the risk of electric shock, always 1. Keep the wire drive compartment closed at all times unless the wire unplug the welder from its ac power source before removing side panels.
  • Page 45 Drive Drive Tension Tension Liner Adjustment 1/4" Hex Head Screws Inlet Guide Tube End Rehef Assembly Head Screw Clamp Inlet (Tail End) Drive Guide Roller Tube Phillips Pan Str#in Drive Assembly Figure Drive Assembly Live Wire Terminal Plastic Conductor Cable Tie Valve Tube Insulation Cable...
  • Page 46 Tools Required: 10. Cut the plastic cable tie away from the cable covering (tubing). ° 5/16 inch open end wrench Note: In the following procedure step, ° Crescent Wrench (6 or 8 inch) it may be necessary to remove the gas fitting from the gas °...

  • Page 47: Maintaining The Contact Tip

    Over time, the hole in the contact 16. Insert a new plastic cable tie in tip will become worn by the wire place around the cable and tighten passing through it. The more worn it in approximately the same this hole becomes, the less efficient location as the plastic cable tie that is the transfer of welding current to was cut in step 8.

  • Page 48: Testing For A Shorted Nozzle

    A SHORTED nozzle results when With the welder unplugged from the ac spatter buildup bridges the insulation in power source, touch the probes of an the nozzle allowing welding current to ohmmeter or continuity tester to the end flow through it as well as the contact tip. of the contact tip and the outside of the When shorted, a nozzle will steal nozzle.
  • Page 49 Table 3. Troubleshooting TROUBLE POSSIBLE CAUSE POSSIBLE REMEDY Dirty, porous brittle 1. Plugged welding nozzle 1. Clean or replace nozzle weld 2. No shielding gas 2. Tank empty, flow restricted, or regulator set too low 3. See SELECTING SHIELDING 3. Wrong Type of Gas GAS in the WELDING INSTRUCTION GUIDE for proper selection...
  • Page 50 © © > © © © .___,__ © >> MODEL 205592...
  • Page 51 MODEL 205592...
  • Page 52 ITEM DESCRIPTION PART 117-084-902 ¥ 202082 Sears 105 amp MIG Welder Potentiometer 246-120-000 216-100-000 Front Panel 410-900-010 Strain Relief 541-057-000 238-223-666 Cable Assembly Knob 246-107-666 Switch 246-423-000 238-593-000 10' MIG gun Control Panel 410-869-011 Transformer 880-455-888 Left Side Panel 410-865-020 312-295-666 Slide Latch W/Clip...
  • Page 53 zo-_z_ --o d_ -%--= L. --_-- _ J MODEL 205592...
  • Page 54 Forthe repairor replacement partsyou need delivered directlyto yourhome Call 7 am - 7 pm, 7 days a week 1-800-366-PART (1-800-366-7278) For in-home major brand repair service Call 24 hours a day, 7 days a week 1-800-4-REPAIR (1-800-473-7247) The model number of your product is located on the welder nameplate.

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