Craftsman 196.20569 owner manual Maintaining the Nozzle, GUN Assembly, Replace a GUN Liner

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Always use a contact tip stamped with the same diameter as the wire it will be used with.

Note: Due to inherent variances in flux-cored welding wire, it may be necessary to use a contact tip one size larger than your flux core wire if wire jams occur.

. If the wire burns back into the tip, remove

the tip from the gun and clean the hole running through it with an oxygen-acety- lene torch tip cleaner or tip drill.

. Over time, the hole in the contact tip will become worn by the wire passing through it. The more worn this hole becomes, the less efficient is the transfer of welding current to the wire and eventu- ally arc breakage and difficult arc starting will result. Replace contact tips when signs of wear become apparent.

MAINTAINING THE NOZZLE

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

CAUTION\.

KEEP THE NOZZLE CLEAN! During the welding process, spatter and slag will build up inside the nozzle and must be cleaned out periodically. Failure to clean and/or

replace the nozzle in a timely fashion WILL CAUSE DAMAGE TO THE FRONT-END OF

THE GUN ASSEMBLY.

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

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

2.When welding overhead, if any molten metal drips from the weld puddle and falls into the nozzle, STOP WELDING IMMEDIATELY and clean the nozzle.

3.If the slag cannot be thoroughly cleaned from the nozzle, REPLACE THE NOZZLE!

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

A SHORTED nozzle results when spatter buildup bridges the insulation in the nozzle,

allowing welding current to flow through it as well as the contact tip. When shorted, a nozzle will steal welding current from the wire whenever it contacts the grounded work piece. This causes erratic welds and reduced penetration. In addition, a shorted nozzle overheats the end of the gun, which can DAMAGE the front-end of the gun.

A RESTRICTED nozzle is created when enough slag builds up in the nozzle to affect the direction, concentration, and/or rate of the shielding gas flow. This problem can cause porous, brittle welds and reduce penetration.

TESTING FOR A SHORTED NOZZLE Arcing between the nozzle and the work piece ALWAYS means the nozzle is shorted, but this can be hard to detect through the lens of a welding helmet. The following

testing method is another way to tell if a nozzle is shorted.

With the welder unplugged from the ac power source, touch the probes of an ohmmeter or continuity tester to the end of the contact tip and the outside of the nozzle. If there is any continuity at all, the nozzle IS shorted. Clean or replace as needed.

REPLACE A GUN LINER

When installing a new gun liner, care must be taken not to kink or otherwise damage the gun liner. See Figure 21 for the drive assembly and Figure 22 for the gun assembly.

1.Turn OFF welder POWER SWITCH and unplug welder from power supply.

2.Open the welder side panel.

3.Loosen the tension arm and lift it up off the drive roller.

4.Turn the wire spool counter-clockwise (be sure to hold onto the wire itself while

turning the spool or the wire will unspool itself when it becomes free of the gun liner), and remove wire from gun assembly.

5.Lay gun cable and gun handle straight out in front of unit.

6.Remove gun liner holding clamp by removing two self tapping screws and two bolts with nuts.

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Contents Jcraftsmani Maintenance Shield Installing Handle Feet Selecting Shielding GasAssemble Important Safety Information Retain These Instructions for Future ReferenceFlash Hazards Shock HazardElectric Shock can Killi To reduce Fire or Explosion can Cause DEATH, INJURY, and Property DAM Fire HazardsAGE! To reduce the risk of death, injury, or Fume Hazards Improper Handling Maintenance of Compressed GASCompressed Gasses and Equipment Hazards Temperatures above 130F will require Additional Safety InformationDescription Welder OperatingInternal Thermal Protection Duty CycleHandle Power Source Connection Packing ListInstalling the Feet Installing the HandleSelecting Shielding GAS Pressed Gasses and Equipment Check the GAS FlowTOR if OIL, GREASE, or Damage are Present Drive Roller Install the Welding WireCord from the ac power source before installing wire Electric shock can kill! Always turnRight Way SET the Wire Drive Tension Change PolarityLearning to Weld Controls AndindicatorsHolding the GUN Angle B Welding TechniquesAngle a Distance from the Work PieceTypes of Weld Beads Welding PositionsOverhead Position Multiple Pass WeldingSpecial Welding Methods Three Passes TJont n Li, Three PassesSpot Welding Instructions Consumable MaintenanceElectric shock can kill! To reduce the risk Maintaining the Nozzle GUN AssemblyReplace a GUN Liner Cleaning the nozzle, and occasionally Preventive MaintenanceTroubleshooting Trouble Possible Cause Possible Remedy Low output or non- enetrating weld£.J Description Qty 66J Page Wire Feed Welder Model 196.205690 GUN Description QtySuggested Settings for Welder Riesgos De Vapores RiesgosRiesgos Destello Informaci6n Adicional de SeguridadConservar Estas Instrucciones Para Referencia Futura Informacion Importante DE SeguridadNota Riesgos DE Choque Electrico Destellos PeligrososAdvertencia Riegos DE IncendioRiesgos DE Gases Comprimidos Y DE SUS Equipos Riesgos DE VaporesILA Manipulacion O EL Mantenimiento Informacion Adicional DE Seguridad Proteccion Tirmica Interna DescripcinCaracteristicas DE Operacion DE LA Soldadora Ciclo DE FuncionamientoCordbn de Suministro Elctrico Cordbn de Soldadura La acumulaci6nElectrico Lista DE ContenidoInstalaciin DE LAS Patas Ensamblaje DE LA Careta Para SoldarInstalacicn DEL ASA Seleccibn del gas para soldar con alambre de aceroINSTALACI6N DEL GAS Protector Verificacin DEL Flujo DE GASSeleccion del Gas para Soldar Acero Inoxidable No Instalar EL Regulador SI Tiene ACEITE, Grasa O DanosAlineamiento Y Regulacin DEL Rodillo DE Avance Instalacion DEL Alambre SoldadorDesengancharlo AUN Figura PrecaucinCambio DE Polaridad Regulacion DE LA Tensin DEL Mecanismo DE AvancePrecaucin Aprenda a Soldar Controles E IndicadoresIlas Descargas Elictricas Pueden Como Sostener LA PistolaAngulo B Tecnicas Para SoldarAngulo a ILAS Descargas ElectricasCord6n de refuerzo Posici6n Vertical Mitodosespeciales Para Soldar Soldadura DE Puntos Figura 15. Junta a tope en V de tres pasadasILAS Descargas Electricas Pueden Instrucciones Para Soldadura DE PuntosMantenimiento General Mantenimiento DE InsumosPrueba DE Cortocircuito EN LA Boquilla Mantenimiento DE LA BoquillaPrecaucion Reemplazo DEL Forro DE LA PistolaInstalacin DEL Alambresoldador Diagnstico DE ProblemasMantenimiento Preventivo Problema Causa POSlBLE SOLUCl6N POSlBLE12ov!sl Transformador115V40x60AL 6257 ILl Soldadora CON Alimentador DE Alambre Modelo DescripcibnGraduaciones Sugeridas Para LA Soldadora 0308EAR8
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