Craftsman 113201372 User Manual 230 AMP WELDER Manuals And Guides L0807090

CRAFTSMAN Welder Manual L0807090 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

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User Manual: Craftsman 113201372 113201372 CRAFTSMAN CRAFTSMAN 230 AMP WELDER - Manuals and Guides View the owners manual for your CRAFTSMAN CRAFTSMAN 230 AMP WELDER #113201372. Home:Tool Parts:Craftsman Parts:Craftsman CRAFTSMAN 230 AMP WELDER Manual

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MODEL N_ °
113.201372 _
Serial
Number
Model and serial
number may be found
at the rear
of the cabinet.
You should record both
model and serial number
in a safe place for
future use,

230 AMP
DUAL RANGE
ARC WELDER

CAUTION:
Read

® assembly

SAFETY
UNSTRUCTIONS

e operating

carefully

® repair parts
Sold by SEARS,
Part No. 61337

ROEBUCK

AND

CO., Chicago,

IL 60684

U.S.A.
Printed in U S A

SAFETY gNSTRUCTIONS

TO OPERATOR

For your own protection, read and observe all instructions
included in this manual as well as the following specific
safety precautions:

1, PROTECTION

FROM

ELECTRICAL

hydrocarbon
vapors
coming
from
degreasing,
cleaning, or spraying operations
The heat of the rays
of the arc can react with
solvent
vapors to form
phosgene,
a highly
toxic
gas, and other
irritating
products

SHOCK

a_ Do not let bare skin or wet clothing come between
the following combinations:

Electrode

Unprotected
spectators
must be kept clear of the
welding area due to the harmful
nature of ultra÷violet
and infra-red
arc rays, welding sparks, and welding
fumes and gases

3. FLAMMABLE
Work Clamp

Work Piece

Metal Work 'Table

80 volts exist between these parts
when welder is onH!
Wear dry hole-free, clothing,_ gloves and shoes to
protect and insulate the body.
b. Take special care to insulate" yourself from ground
using dry insulation (suchas dry wood) of-ad.equate
size when welding] in dam'p locations on metal floors
or grat ngs, and m poslt_ons (such as s=ttmg or lying ! "
where parts-or"large"areas of your body can be ir
contact with phssible ground_. ; ".;_
r o "_
C. Maintain the_.#l_ctr_de h_tder work clamp, w_ldin'g
cable and welding_:rnach_ne'._n _Qd, safe operating._
condition,
: _ _;
" " ,:'
-'
•
"
Do not use weldm_ electrode as-a claarette hg_ter, .

e. Connect the welder only to a source of electncal'.power
meeting
the
requirements,
irrcluding
grounding, of the National Electrical Code (ANSI Cl)
and local codes.
f.

Electrode coating may be electrically conductiveuse welding gloves when changing electrodes.

Remove flammable and explosive material at least 35
feet from the welding arc to prevent welding sparks
or molten metal from starting a fire Keep a type
ABC fire extinguisher within easy reach.

iild Never-c_nnect the_work cablelor clamp to any obJect
b_ _'he 'worl<:p e_e o_ me.to _ork tab e Conr]ecting
to other objects such as bu_l_mg ground can create a
fire hazard.

4. PREVENTATIVE

MAINTENANCE

Never apply power to the welder with any part of the
"cabinet" removed_ Position on-off switch in "Off"
position
and disconnect welder from the power
supply before doing maintenance work inside the
machine. Removal of the welder cabinet should be
done only by a qualified service technician,
Before connecting the welder
receptacle, check the following:

power

cord

the

c. Wear oil free protective garments, such as leather
gloves, heavy shirt, cuffless trousers and high shoes.

1 Inspect the power cord and welding cables for cuts
or burns and make sure blades and ground pin on
the plug are straighL

Protect
other
near-by
non-flammable
screening_

Inspect
parts.

Welding
can produce
fumes
and gases which
are
dangerous
to health,
Keep your
head out of the
fumes, Use enough ventilation,
exhaust at the arc, or
both, to keep fumes and gases from your breathing
zone and the general
area, Take even greater care
when welding on galvanized
or cadmium
plated steel
and
other
metals
which
produce
toxic
fumes
Ab-supplied
helmets may be necessary

Inspect electrode
or broken parts.

MATERIALS

c. When not welding, place the electrode holder where it
"" i_ ihs'61ated from the work clamp, work piece, or'
wc_rk 'table_._ Ac_'idental
grounding can cause
,_ overheating of the_ables'and_welder,
creating a fire
haz_rd_ _ ::_"
_
"

Use helmet, filter, and cover plate complying with
ANSI Z87 1 to protect your eyes and face from
sparks and the rays of the arc when welding or
observing open arc welding,
Always
wear
safety goggles with side shields
complying with ANSI Z871 when in a welding area,
or when near slag chipping operation

EXPLOSIVE

b, Welding on or near containers which hold combustibles
can cause ar_ explosion, even when they have been
cleaned= For information purchase "Safe Practices for
Welding one Cutting Containers that Have Hel d
Combustibles" (A6.0-65_ from the American Welding
:.Society 2501 Northwest Seventh St Miami, Florida

2. EYE AND BODY PROTECTION

AND

personnel

with

When working
above
floor
level, protect
from a fall should you get a shock Never
electrode

cable

weld

not

around
in

arty part of your

locations

suitable

yourself
wrap the

body
chlorinated

"On-Off"

switch

lever for cracks or broken

holder jaw insulators for cracks

Never weld anything on or to the welder cabinet, as a
burn through may cause transformer failure.

d_ For additional safety information, purchase copies of
"Practice for Occupational and Educational Eye and
Face Protection"
(ANSI Z87.1), "Safety in Welding
and Cutting" (ANSI Z49.1), and "Fire Protection in
Use of Welding and Cutting Processes" (ANSI/NFPA
No. 518) from the American National Standards
institute, 1430 Sroadway, New York, N.Y 10018_

READANDOBSERVE
THEINSTRUCTIONS
APPEARING
ONTHEWARNING
LABELSFOUNDONTHEINSIDE
OF
THEWELDING
HELMET,
ANDONTHESELECTOR
PLATE,
CABINET
ANDELECTRODE
HOLDER.
_MERIEAN

WARNII_G:

N,_ 71ON,_L ST,INI,),_RDS
PttEC,_UTION_RY
I Af]EL
prolel:I
VotJt_ell
_t_d
unders14_mt lh_ I_bel

F UJ%_ES AND
GASES
ARC
RAYS call inlllle
SHOCK
cml kill
• Be,_d and understand
and yo_Jt amployef's

hV_TITUTE

WARNING

{_thefs

_e;l(I

;_f_{I

c;lll he (i,ln{J_ f al_s tn ymJl he_hh
eyel and hum stroll ELECTRIC
_l_e incm_Hanh_fef
_alely

_ =nslnJ_io_t_

pr acllce_

_ar _nd body

salely spectacles)
shou+d be worn
wheII U_l_ 0 this device It_cl fesislanl plal_
ale DOT un_le.lkable
elted ¢_ s_la_h_d _Je_ t_u_ VISI_I
al_{_ 5_liO_$1 le_uc8
pI01eGIJ0r_-{epia_eintricately

ltlo_ectlon

• Do I_O_ _ouch llve elec_ rical I)aFt_
• See American
National
Si,_nIt,_f(I
Z49.1
S_lety
in
Wl!h_hlg
mid Cliilin=j ¸' i)_JIilillle(I
I}7 lhe Ait/eficalt
Wohthlg
Sociel¥
2501
N W 71h SI,, _,tbm_
Florida
33125;
OSIIA
Saf_W _1_{I He_hh
SI,_ndatds
29 CFR
1910,
availal)_J_
hont
U S
Dep_tmenl
o_ Labor
Washinglon
, DC 20210
DO NOT R E_,_OV E THIS LABEL

WARNING

ELeCTR,C

SHOCK

CAN

BE FATALt

FOR YOUR SAFET'_
B0 VOLT POTENTIAL
AT ELECT}IOD_

USe _lJ
101 IE,_ _n0 _y_ pi01egi0n
a_ins$ =nj_io_ rays Itom _c _ding
_nd culling
US_ propel shade li!I_
plale _P¢_.I {ssi_IO _12 plo[_ction
(Iil_ pble b_ck_up plale• s_p_lale

• Keep your head aut of _1_ h_nles
• U_a enmJ_h Vel_il_iOl_,
_xha_Jst al Ihe ;_,c, ot boUI
lo kee I) _ume_ and _ase_ from
7o_f
I_re;_lhi_ I z_)m_
and the {Jene[al area
• Wear cot _ecl eye,

R_GAR_ING
SHOC;{

CllRI0_

REGARDING

POTENTIAL

SHOCK

COW,FORMING TO 1H_ _ATIONAL
REGAROING

Inspecl
{(equ_Ily an_ immedi31_ly
I_p_u_ _om ot d_m_ged p_tls
t,it4_ ir_ t¢=¢.¢_
=f JJ.I.L
zr/1
DO NOT REMOVE "fills [/_3,E L

£yE

REGARDING

LI_

CABINET

_L_CTnlCAL

COD_

INJURY

FIRE

O_AW

_*nC eT_muY't

LENS
SHADENO

BEFORE

TURNING
WELDER
ON
CHECK
THE ELECTRODE
HOLDER
TO
BE SURE THAT
THERE
ARE NO PROTRUDING
SCREW
HEADS
AND
THAT
ALL INSULATION
IS SECURE
_ _ll!!
2

FULL ONE YEAR WARRANTY
If this Craftsman
within

ON CRAFTSMAN

Electric Welder fails to perform

one year from

the date of purchase,

Sears will

ELECTRIC

WELDER

properly, due to a defect in material or workmanship,
repair it free of charge,

WARRANTY
SERVICE IS AVAILABLE
BY SIMPLY RETURNING
THE WELDER
SEARS STORE OR SERVICE CENTER THROUGHOUT
THE UNITED STATES.
This warranty

TO THE NEAREST

gives you specific legal rights, and you may also have other rights which vary from state to

state,
SEARS,

MATERIAL

THICKNESS

ON-OFF

ROEBUCK

AND

CO.

Sears Tower_

BSC 41-3,

Chicago,

IL 60684

LOCKING

KNOB

'IAMETER

GAUGE

GAUGE.

SWITCH.-.

GETTING TO
KNOW YOUR
ARC WELDER

DUTLETJACKS

HELMET

AND
ELECTRODE

WORK

TABLE
OPERATING

AND

WORK

CLAMP

OF CONTENTS

INSTRUCTIONS

Safety I nstructions to Operator ..............................
Warranty ............................................
Getting to Know Your Welder .............................
Unpacking and Checking Contents ..........................
Assembly
...................................

CABLE

HOLDER

2
3
3
3
4

Operating Controls ................................
Operating Instructions
...........................
Trouble Shooting
...............................
ARC WELD IT YOURSELF MANUAL
..............
WELDING ROD SPECIFICATIONS
...............
REPAIR PARTS .....................................

6
7
8
1-1
2-1
2-6

SPECIFICATIONS
Input Volts (AC):
...........
Hertz (Cycles):
................
Output Amperage:
........
Rated
Short

Input Amps:
Circuit
Input

...............
Amps:
.........

UNPACKING
SET-UP

Fuse or Circuit
Breaker Required: .........
Arc Voltage:
...............
KVA:
....................
KW: ...........................

230
60
30 to 140
40 to 230
50
66

AND

50 Amps
25
108
7 1

CHECKUNG

INSTRUCTIONS

This Craftsman welder is shipped complete in one carton
In order to facilitate packaging, certain items have been
removed at the factory and must be assembled when

Max
Open Circuit
Output
Volts
..........
Power Factor
...........
Duty Cycle:
........
Electrode

Capacity:

80
66%
20 to 100%
1/16"

to 3/16"

CONTENTS

received by the purchaser
Remove all items from the
carton and identify item as shown in the exploded view
illustration
These "Loose Parts" should be accounted for
before discarding any packaging material.

LOOSE PARTS LIST
Key
No.

Part Name

O.ty.
i

1
2
3
4

WeldingHelmet (Partially assembled) ..........
Helmet band assembly (Not Assembled) ........
Electrodecable assembly .........................
LooseParts Bag- Containing the following items:
Electrode Holder .....................................
Work Clamp ...........................................
Screw, Hex.-Hd., 1/4-20 x 3/4 in...............
Nut, Hex., 1/4-20 ...........................
Washer,Flat 17/64 in...............................
Loci{washer,1/4 in

ASSEMBLY
TOOLS

NEEDED

,,lOinch
wrenchScrewdriver
(medium)
ATTACHING

ELECTRODE

TO ELECTRODE
I. Grasp the electrode
handle locking screw
handle Loosen this
until the handle can

HOLDER

CABLE

holder and locate the slotted head,
near the mid-point of the insulating
screw approximately
two turns, or
be slipped off the electrode bolder..

2 Do not remove this screw completely. Slide tile handle
off electrode holder and insert end of electrode cable
assembly through the handle.
The electrode cable is the one with insulation stripped
from

one end

3 Using a screwdriver, back out the slotted-head set screw,
located near the end of electrode holder until the end of
screw does not protrude into the wire socket in the end
of holder
4. Make sure the wire strands on stripped end of electrode
cable have not been "frayed"
Twist together with
fingers if necessary.
5 Insert stripped end of electrode cable into electrode
holder and tighten the slotted-head set screw very
firmly

.............

....

t
1
1
I
1
1
1
1
1
1

_i_i

ii _'

_ i

6 Slide the handle back into place on electrode holder and
position it until the hole in handle is directly over the
head of handle locking screw
Tighten
the screw
clockwise
@
just enough to secure the Inandle on
electrode holder

ATTACHING
THE WORK CLAMP
TO THE WORK CABLE

SCREW

1. Attach the terminal on end of work cable to the work
clamp, at the hole near the nose of the clamp with the
1/4-20 x 3/4-inch screw, 1/4-20 nut, 17/64-inch flat
washer and I/4-inch Iockwasher furnished in the loose
parts bag
2_ Do not use either of the holes in handle ends of work
clamp

LOCKWASHNUTE_

HWORKCABLE

3_ Tighten the screw firmly enough to insure good contact
and prevent the cable terminal from slipping on the
clamp

CONNECTING

WELDER

TO POWER

SOURCE

CAUTION:
Do not attempt to connect this welder to a
regular household outlet. Make sure the power-line voltage
and frequency agree with the ratings shown on the selector
plate attached to front of eabinet.
Electrical connections between the welder and grounded
230-volt, single-phase, 60-cycle a-c power source should be
made by a qualified electrician. All wiring must comply
with the National Electrical Code (ANSI C1) and local
codes
1. Install an individual (separate) line for the welder with
delayed action type circuit breaker or fuses in the line
For best results, this circuit should be as short as
possible The size of the supply conductors will depend
upon their length as shown in the table below
Supply Conductor (Incl. Extension Cords)
Up to 30 feet ............................
No_ 10 AWG Copper
30 to 50 feet .............................
No 8 AWG Copper
Over 50 feet ...................................
No 6 AWG Copper
NOTE - These conductor sizes are for use with a welder
having a rated input not more than 60 amps at 20% duty
cycle in accordance with Article 630 of the National

RECEPTACLE
k

GREENWIRE_.

Connect to

ground

bussin

Connect to hot wires o[ Q
powerponet
single phase system only

FUSES OR CIRCUIT BREAKERS

Electrical Code (ANSI C1) and may not be adequate for
other loads Consult a qualified electrician before using for
other loads
2

Install

Connect

50 ampere
230wolt

circuit
power

breakers
lines

or fuses

and

ground

as shown

figure

Use Sears Cat #20691
Power Receptacle available
through most Sears Retail or Catalog outlets or any
certified 50 amp, 250 volt, 2 pole, 3 wire, grounding
type receptacle.

OPERATnNG

CONTROLS
_TAL

The name "dual range" arc welder is derived from the fact
that your new arc welder is equipped with two separate
welding ranges,
The beginner or less-experienced welder will find the
30-140 amp range easier to use because it provides extra arc
stability when welding with some of the "more difficult to
weld with specialty rods" which are prone to pop-outs
The 40-230 amp range requires less line (input current)
draw for any given amp setting and permits the use of the
maximum
amp settings with minimum
effect on other'
electrical appliances, motors, and lights, on your electrical
system,
Either
range
may
be used,
depending
on
preferences
when the electrode
diameter
permits

TABLE

REGARDING
1

1
2
3

POTENTIAL

AT THE

SHOCK

SAME TIM
CABINET

CONNECT
ONLY TO A GROUNDING
POWER SOURCE
CONFORMING
TO THE NATIONAL
ELECTRICAL
CODE
(A N S I C1) AND LOCAL CODES
REGARDING
EYE
INJURY
WEAR WELDING
HELMET WITH NO 12 OR DARKER FILTER LENS
MEETING
REQUIREMENTS
OF A NSI.
Z87,1.
WEAR GOGGLES
OR FACE SHIELD WHILE CHIPPING
OR
BRUSHING
SLAG.
KEEP OTHER PERSONS AND PETS OUT OF WORK AREA

REGARDING
KEEP COMBUSTIBLES
uSE

OUT

FOR MINIMUM
LINE DRAW

FIRE

OF RANGE
UsE

OF WELDING

SPARKS

FOR MAXIMUM
ARC STABILITY

operator

AMP
RANGE/

CONNECTING
ELECTRODE
AND WORK CABLES
insert the tapered plug on the end of the electrode cable
into the proper outlet jack depending on amperage required
or operator preference.
To insure a good electrical connection always twist the
electrode plug slightly while inserting_ To remove the plug
twist in the opposite direction while removing
NOTE: If you extend the welding cables beyond those
already supplied, they must be No= 4 AWG or larger to
avoid an undue drop in welding current
Do not extend
cables over 50 feet,

Connect the work clamp to the piece to be welded, (to
complete the electrical circuit) or to the welding table itself
provided it is metallic or will conduct electricity!

AMP

OPERATING

RNSTRUCTIONS

We feel that welding with your new Craftsman dual range
arc welder is as simple as A B C
A Determine what diameter electrode should be used by
gauging the piece to be welded on the material thickness
gauge The fractional number directly beneath the bar
chart dictates what the proper electrode diameter is for
given thicknesses of metals You will note that a specific
diameter
of electrodes
can be used on varying
thicknesses
of material. This is accomplished
by
adjusting the heat selector for more or less amperage•

B Next verify the electrode diameter, by placing the bare
portion of the electrode into the electrode diameter
gauge on the right side of the cabinet
Because electrodes are mass produced, there may be
small burrs on the bare ends of the electrode Make sure
the bare end of the rod is as clean as possible for
accurate sizing,

C, Finally,
determine
the type of electrode
by the
identification
on the package or by the American
Welding Society number stencilled on the coated portion
of the electrode, bearing in mind the type of electrode
you have chosen - E6013 or E7014, and also its'
diameter (as previously determined)_
Locate that band on the amp scale There are two E6013
bands and two E7014 bands, use the band which
coordinates with the amp range you have selected•

Now loosen the heat selector knob and move the pointer
until the fractional
number matching your electrode
diameter appears in the pointer window
Tighten the heat selector knob
Insert
the electrode
cable into the proper jack
(depending on the range selected), Connect the work
clamp to the work.
Wear Welding Helmet,
Turn the On-Off switch to the "ON"
are ready to weld

position

and you

Because metals vary in their make up and the technique
of each operator is different, you may find it necessary
to increase or decrease the amperage output accordingly,
CAUTION:
Do not loosen and move heat selector while
welding
The duty cycle ratings bracketing the amperage scales are
provided for your convenience and protection of your new
welder_ Duty cycle is the performance level of the welder
based on a 10 minute time span. For example welding for 6

minutes out of 10 minutes is a 60% duty cycle To avoid
possible overheating of the welding transformer,
which
could shorten the life of your welder, Do Not exceed the
duty cycles listed on the nameplate
7

TROUBLE

SHOOTING

WARNING:

Removal of the welder cabinet top for any reason must be done by
a qualified service technician.

TROUBLE

TROUBLE
Fan and welder do not
operate, or continually
blow fuses.

Welding current low
or weak,

Can't hold an arc.

PROBABLE

SHOOTING

CAUSE

CHART

SUGGESTED

REMEDY

1. Improperly fused or
protected_

1. Use 50 ampere fuses of the delayed
action type such as "'Fusetron" or
"Fustat" or 50 ampere 240 volt
circuit breaker.

2 Blown fuse, or open
circuit breaker_

2 Replace fuse, or reset the circuit
breaker.

3_ "On-Off"

3 Turn switch "On".

switch not "On".

1. Low line voltage,

1_ Have a voltage check performed
the local power company_

2_ Welding current
setting too Iow_

2. Check current recommended for
the electrode being used.

3, Poor connections.

3, Check electrode holder, work and
electrode cable connections

1 Using a D.C. welding
rod.

1_ Use AC or AC-DC rods

2. Low hydrogen rod

2, Use rod of 1/8-inch maximum
dian'leter, or' smaller on 30-140
amp range.

SERVICE

TIPS

FAN MOTOR
No provision has been made for lubricating the fan motor,
as extra large oil reservoirs provide lubrication for the life
of the motor.
SELECTOR

PLUGS OR CONTACTS

WARNING:

Be positive you have disconnected the power
supply to the welder_

If for any reason the selector plugs or mating contacts
become burned or pitted, tiley should be cleaned-up with a
fine grade of emery cloth or dressed very lightly with a fine
file,

A COMPREHENSIVE
GUIDE FOR YOUR
NEW CRAFTSMAN
ARC WELDER AND
WHAT iT W_LL DO
CONTAINS:
INFORMATION
o VARIOUS
o USEFUL

ABOUT
TYPES OF RODS

ACCESSORIES

TIPS ON CUTTING,
AND BRAZING

WELDING
,,,J

Form No SP574-4

1-]

IJELD

gT Y©U SELF

TABLE

CONTENTS

Page

Your WelderandWhat It Will Oo .............
1-3
How the CraftsmanContactRodSimplifiesWelding 1-3
What HappensWhenYou Weld? ..............
1-3
ReadBeforaWelding .......................
14
LearnBy Doing ..........................
1-5
PositionWelding .........................
1-11
Cast-IronWelding ........................
1-14
HardSurfacingWornCutting Edges ..........
1-15
TheTwin CarbonArc Torch ...............
1-16
CuttingandOther Miscellaneous
Operations ..o
1-17
Inert-GasMetal-ArcWelding ................
1-19

Read this Manual

carefully

for additional

SEARS, ROEBUCK AND COMPANY
AND SIMPSONS-SEARS LIMITED
1o2

welding

information.

YOUR

WELDER

and what it will do = °.

Your CRAFTSMAN Arc Welderis a sturdilyconstructedend thoroughlytestedmachineengineeredto
give many years of efficient trouble-free service. It is listed by Underwriters' Laboratories,
incorporated,which meansthat it passesall requirementsof safety,fire hazardand temperaturerise
limits asspecifiedin theirStandard for Transfer-TypeArc-WeldingEquipment,

HOW THE CRAFTSMAN ELECTRODE
SIMPLIFIES WELDING
Craftsman
Contact Electrode is self-starting-plus
restarting , The electrode startson contacL

automatic

Craftsman Contact Electrode is serf-cleaning..... Under normal
conditionsthe slagremovesitselfasthe weld cools, Spatter is almost
nen-existenL Craftsman Contact Electrode has an exceptionally
good appearance _
With fine ripple, unusually clean, smooth
appearance,andreduced slaginclusions
Craftsman Contact Electrode depositsmore metal faster
the powdered iron in the flux goesinto tile weld_

. Because

Arc Welding is the process of fusing two or more pieces of
metal together to form one piece. It is accomplished by
heating adjacent metal surfaces to the melting point with an
electric arc, then adding a sufficient amount of molten
metal to provide reinforcement and fill any vacant space
between the parts being joined, as shown in the accompanying illustrations
The arc is created when an electric current, regulated by
a welding transformer, flows across an air gap between an
electrode and the work being welded, The intense heat
generated by the arc is ideally suited for welding, as it
can be directed to affect only the part of the metal to be
welded, Uniform heat from the arc, is acquired by keeping
its length the same for a given rod size and current setting,
At the instant an arc is "struck", a portion of the base
metal directly beneath it, is melted, resulting in a small
pool of molten metal, some of which is forced out by the
blast of the arc and deposited along the weld path, The
depth of the crater thus formed, is the distance the weld
will extend into the base metal and is referred to as the
penetration of the weld

Beth edges of the metal
are heated by the arc,
until --

mere molten metal and
flux is added from the
rod, which5

they melt and flow to
gether forming one piece,
instantly --

fills the crater andcovers
the top of the weld with
slag,

This process continues the entire length of the weld

Some of the electrode (which consists of o metal rod surrounded by a flux coating) is melted simultaneously with
the base metal and is carried by the arc to the liquid pool
This added metal combines with the base metal to form
the deposited weld,
During th_s operation a part of the flux coating burns off
and forms a gaseous smoke screen that completely envelops the arc, protecting the molten metal from harmful
effects of oxygen and nitrogen in the surrounding atmosphere, The remainder of the flux coating that melts is
carried to the molten pool where it mixes with the metal
to combine with various impurities It then floats to the
surfaces to form a coating of slag which covers the deposited weld metal, protecting it from the atmosphere and
retarding its cooilng
I-3

READ

5EFORE

WELDI NG

When operating a welder, certain precautions must
be taken to prevent minor injuries to yourself and
others, Although injuries may not be serious or permanent, knowing
how to use the protective equipment to safeguard against them is the first step in
learning to weld_

The effects of heat and light given off by the arc, while
electric welding, may be compared to that of the sun's rays_
Even greater precautions are necessary for electric arc
welding. Before starting a weld, caution anyone in the
immediate vicinity against looking at the arc_ in case of
occidental eye injury, contact a physician immediately.
To protect the face and eyes a heat-resisting, fibreglass
helmet is used. The special tens, which allows the user
to view the arc safely, is inserted into the framed opening
of the helmet The clear glass, which should be replaced
from time to time, protects the expensive special lens
from breakage and weld spatter. The helmet is held firmly
in place on the head with an adjustable head band, thereby
leaving both hands free° A close-flttlng skull cap should
be worn with the helmet° As the helmet is used only when
actually welding, a tilting arrangement permits it to be
swung up clear of the face. When the welding is resumed
a slight nod of the head tips the helmet down over the face.
To protect the eyes further while cleaning the weld, goggles
should be worn by the welder and others working around
him_ Animals are also affected by the rays and should be
kept at a safe distance_
To safeguard the hands against heat and weld spatter,
gauntlet-type
leather gloves should be worn. A leather
jacket will give better protection against the shower of
1-4

sparks than ordinary clothing. High top shoes (not oxfords)
should be worn. If a great deal of welding is to be done,
foundrymen's shoes are best.
Precautions must also be taken to protect property and
equipment against flre_ A large fire extinguisher should be
within easy reach. The welding area should have a concrete
or cinder floor, kept dry and clear of inflammable rubbish.
Sometimes, it is necessary to weld close to a fuel tank. If
practical, remove the part to be welded. If not, drain the
tank and completely fill it with water.
Few tools, in addition to those supplied with the welding
machine, are needed and most of them can be found in
the average shop Two sawhorses supporting a 1/4-inch
steel plate makes an excellent welding table A permanent
bench, using the same steel plate, can be made of angle
iron or pipe. A chipping hammer is used to clean slag off
a weld and pliers will be useful for handling hot metak A
wire brush is used to clean the work before welding and
remove small pieces of slag after chipping_
Small pieces of mild-steel scrap iron, reasonably free of
rust and paint, should be used for practice welding_ Angle
iron, bar stock or plate steel are good examples. Do not
use scrap cast iron, high carbon or hardened steel as these
metals require special electrodes and welding techniques.
These should be set aside for future practice after completing elementary practice lessons°

LEARN

BY DOBNG

I
90
OFWELG
OIRECTiON

Experience has proven that short periods of practice at
regular intervals are the best way to teach yourself how
to weld. As learning to weld is simply a process of trial
and error, all practice work should be done on scrap metal
that can be discarded. Do not attempt to make repairs on
valuable equipment until you have satisfied yourself that
your practice welds are of good appearance and free of
slag or gas inclusions. Remember, what you fail to learn
while practicing, must be learned through a series of
mistakes and rewelds later am
A comfortable body position is important when learning,
as tensed muscles will result in fatigue and lack of control.
Sit on a low stool and grasp the electrode holder in one
hand with the cable drawn across the lap. Allow enough
slack to move the holder freely and yet keep the weight
and drag of a long length of cable from becoming tiring,
The ground connection is as much a part of the welding
circuit as the cable and electrode holder_ A poor ground
connection can render the best welding equipment inefficient. When using a table with a steel top, fasten the lug of
the ground cable to it securely with a bolt or C
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Craftsman 113201372 User Manual 230 AMP WELDER Manuals And Guides L0807090

CRAFTSMAN Welder Manual L0807090 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

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