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Owner's Manual
JCRAFTSMAN"I
WIRE FEED MIG WELDER
Model No.
196.205690
CAUTION: Before using this
product, read this manual and
EspaSol p.31
follow all its Safety Rules and
Operating Instructions.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
www.sears.com/craftsman
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Check the Gas Flow ........................ 12 Craftsman Limited Warranty .............. 2 Introduction ........................................ 2 Align and Set the Drive Roller .......... 13 Safety Summary .................................. 3 Install the Welding Wire .................. 13 Set the Wire Drive Tension .............. 15 Safety Information .............................. 3 Shock Hazards .................................. 4 Change Polarity ................................ 15 Flash Haz
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Note: • The following safety alert symbols identify Every craftsman respects the tools with important safety messages in this manual. which they work. They know that the tools • When you see one of the symbols shown represent years of constantly improved here, be alert to the possibility of personal designs and developments. The true injury and carefully read the message that craftsman also knows that tools are follows. dangerous if misused or abused. This symbol indicates that the Reading this
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SHOCK HAZARD into the power source if the ground prong on power cord plug is bent over, broken off, or missing. • Do not allow the welder to be connected WARNING to the power source or attempt to weld if the welder, welding cables, welding site, or welder power cord are exposed to any ELECTRIC SHOCK CAN KILLI To reduce form of atmospheric precipitation, or salt the risk of death or serious injury from shock, water spray. read, understand, and follow the following • Do not carry coiled welding ca
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helmet and replace any cracked or • Do not wear gloves or other clothing that broken filter lenses IMMEDIATELY. contains oil, grease, or other Do not allow the uninsulated portion flammable substances. • Do not wear flammable hair of the wire feed gun to touch the ground clamp or grounded work to prevent an preparations. arc flash from being Do not weld in an area until it is checked created on contact. and cleared of combustible and/or Provide bystanders with shields or flammable materials. BE
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to prevent spatter or slag from falling chlorinated hydrocarbons, such as into ear. trichloroethylene and perchloroethylene, Make sure welding area has a good, can be decomposed by the heat of an electric arc or its ultraviolet radiation. solid, safe floor, preferably concrete or masonry, not tiled, carpeted, or made of These actions can cause PHOSGENE, a any other flammable material. HIGHLY TOXIC gas to form, along with Protect flammable walls, ceilings, other lung and eye-irritating gasses. Do
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temperatures above 130°F will require ADDITIONAL SAFETY water spray cooling. INFORMATION • Do not expose cylinders to electricity of For additional information concerning any kind. welding safety, refer to the following Do not use a cylinder or its contents for standards and comply with them as anything other than its intended use. Do applicable. not use as a support or roller. • Do not locate cylinders in passageways • ANSI Standard Z49.1 - SAFETY IN or work area where they may WELDING AND CUTT
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DESCRIPTION can weld for four (4) minutes out of 10 with Your new MIG (Metal Inert Gas) wire feed the remaining six (6) minutes required for cooling. (See Table 2). welder is designed for maintenance and sheet metal fabrication. The welder consists Table 2. Duty Cycle Ratings of a single-phase power transformer, stabilizer, rectifier, and a unique built-in control/feeder. Duty Maximum Required Cycle Welding Resting Now you can weld sheet metal from 24 Rating Time Time gauge up to 3/16 inch thick
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Power Switch - This switch turns the welder ON and OFF. (Make sure the power switch is Handle in the OFF position before performing any maintenance on the welder.) Wire Speed Gun Cable Power Cord - This is a standard, grounded Voltage 120 volt power cord. (Make sure you are Selector using a properly grounded 120 Vac, 60Hz, single phase, 20 amp power source.) Power Ground Clamp -Attaching the ground clamp to your work piece "completes" the welding current circuit. You must attach the ground clami
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Select a properly grounded extension cord that will mate directly with the power source POWER SOURCE CONNECTION receptacle and the welder power cord without the use of adapters. Make certain that the POWER REQUIREMENTS extension is properly wired and in good electrical condition. This welder is designed to operate on a properly grounded 120 volt, 60Hz, single- Extension cords must be a #12 gauge cord at the smallest. Do not use an extension cord phase alternating current (ac) power source fused
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shield handle. (DO NoT DISCARDT) tighten both screws. 2. Place the shaded lens into the space 5. Align the holes of the back foot with the provided on the inside of the face shield. rear screw holes on the bottom of the welder. The curved face of the back foot 3. Screw the lens retaining nuts into the holes to either side of the lens until they should face the rear of the welder. are tight against lens. 6. Insert the two Phillips head screws 4. Insert threaded peg on shield handle into (included
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Gas Selection For Stainless Steel Welding CHECK THE GAS FLOW The best shielding gas for stainless steel welding is a mixture of 90% Helium, 7.5% WARNING Argon, and 2.5% Carbon Dioxide. However, 100% Argon can also be used, but an increase in the area being heated by the arc IMPROPER HANDLING AND MAINTENANCE will be experienced causing slightly greater distortion of the base metal. OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERIOUS Gas Selection For Steel Welding With INJURY OR DEAT
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-MAKE SURE TO TURN OFF THE GAS , Drive CYLINDER VALVE WHEN DONE Roller WELDING. ALIGN AND SET THE DRIVE ROLLER Before installing any welding wire into the unit, the proper sized groove must be placed into position on the wire drive mechanism. Change the drive roller according to the fol- lowing steps: _Motor Shaft 1. Remove the drive tension by unscrewing tl_e tension adjusting screw (ALL THE Rgure 5. Drive Roller V_AY in a counterclockwise direction). 5. Slide the roller onto the shaft so that
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Note: If TOO MUCH tension is applied to the wire spool, the wire will slip on the drive roller or will not be able to feed at all. If TOO LITTLE tension is applied, the spool of wire will want to unspool itself. Readjust the drive Right Way brake tension as necessary to correct for either problem. 7. After checking to make sure that your welder is disconnected from the ac power source, free the leading end of the wire from the spool, but do not let go of it until told to do so, or the wire will
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CHANGE POLARITY job. The VOLTAGE selector controls the weld heat. There are four voltage heat This welder allows you the capability to selections (lettered A through D) available change the welding current polarity. You may on this welder. Position A provides the select either dc Straight (dc - Flux Cored) or lowest voltage (heat) and position D the dc Reverse Polarity (dc + MIG). For welding highest voltage (heat). steel with solid wire, stainless steel, flux cored 15. Set the WIRE SPEED contro
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allowing the metals to flow together through the use of an electrical arc. The electrical arc is created between a continuous consumable Operation of this welder consists of selecting and adjusting operating controls for optimum wire electrode (the welding wire) and the voltage (welding heat) and wire speed settings. work piece. An inert shielding gas is used to protect the weld puddle from contamination CONTROLS ANDINDICATORS and enhance the welding capabilities of the electrical arc. WARNING W
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degrees. The point at which the gun Distance from the Work Piece handle is parallel to the work piece. If The end of the welding gun is designed with angle A is increased, penetration will the contact tip recessed from the end of the increase. If angle A is decreased, pene- nozzle and the nozzle electrically insulated tration will decrease also. from the rest of the gun. This permits the operator to actually rest the nozzle on the work piece and drag it along while welding. This can be very help
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relation to the weld puddle. The gun is either centered over the weld joint. This is the easi- est type of bead to make. PUSHED (see Figure 11) into the weld pud- dle or PULLED away from the weld puddle. PUSH Puddle PULL Figure 11. Travel Direction Figure 12. Stringer Bead For most welding jobs you will pull the gun along the weld joint to take advan- - 2. The WEAVE BEAD (Figure 13) is used tage of the greater weld puddle visibility. when you want to deposit metal over a wider space than would b
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angle B (see HOLDING THE GUN - p.16) is such that the wire, and therefore the arc force, is directed more toward the metal above the ]WARNING weld joint. This is to help prevent the weld puddle from running downward while still allowing slow enough travel speed to achieve Hot slag can cause fires and serious injury good penetration. A good starting point for from burns! Be sure to wear protective cloth- angle B is about 30 degrees DOWN from ing and eye gear when using the Overhead Position. bei
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NOTE: WHEN USING SELF-SHIELDING of a continuous weld bead. There are three FLUX-CORE WIRE it is very important to methods of spot welding: Burn-Through, thoroughly chip and brush the slag off each Punch and Fill, and Lap (see Figure 20). completed weld bead before making another Each has advantages and disadvantages pass or the next pass will be of poor quality. depending on the specific application as well as personal preference. PUNCH AND FILL _ LAP SPOT BURN THROUGH Figure 20. Spot Welding .
