Craftsman 113201892 User Manual TRIPLE RANGE ARC WELDER Manuals And Guides L0904586

CRAFTSMAN Welder Manual L0904586 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

User Manual: Craftsman 113201892 113201892 CRAFTSMAN TRIPLE RANGE ARC WELDER - Manuals and Guides View the owners manual for your CRAFTSMAN TRIPLE RANGE ARC WELDER #113201892. Home:Tool Parts:Craftsman Parts:Craftsman TRIPLE RANGE ARC WELDER Manual

Open the PDF directly: View PDF .
Page Count: 36

Save this Manual

For Future Reference

S_ AJRS

MODEL NO.

113.201892

Serial

Number

Model and serial

number may be found

at the rear

of the cabinet.

You should record both

model and seriaI number

in a safe place for

future use.

CAUTION:

Read

SAFETY

iNSTRUCTIONS

carefully

AC 230 AMP/DC

TRIPLE RANGE

ARC WELDER

®assembly

•operating

=repair parts

140 AMP

Sold by

Part No. 61477

SEARS, ROEBUCK AND COl, Chicago, iL 60684 U.S.A.

P_nted _rl USA

.... -:%. :.

': SAFET INST.UCT

: iFail_re:i!t_:;:!f0i 0w these ::instructions may result in

sedods personat!njury_ :. :::i;i::: :

FIJME'S ND G A S ES :iMAY B El :D AN G E ROU S TO

_O'U R :NEAETH::: ::: ,' :i:'i

::iN:_iIjR E:::EYE S :A:ND :BElRN S KIN.:

SH O : ::::i::::

wEL:B:tNG SPARKS cAN: CAOSE_:E:XP_OSfON O R:

MRE:": :: ::

To pt0i_ectlyourself: and others fforn these and othei _

hazard:s; read and 0bServe all instructions included:

in tfiis rnanl_at asW_i!as!:the f01ibwing specific safety

precautionS:_ !: i :::::::!: !

1: SHOCK

ai: or live metal parts

0fi:the :electrode:holder to touch bare skin Or

any ii:lara p::0(: wet id6ve ring:of the body. The

electri6dec0atiiig Should be €0nsidered as an

electrlCat COndu(_toiL Do not:insert electrode in

electrode holder with your:bare hand wear

proper gloves on both hands:.

ELECTRODE AND ELECTRODE HOLDER

WORK CLAMP :WORK PIECE METAL TABLE

80 Volts exist between these paris

when welder is 0n!

Wear dry hole-free ctothing:,::gtoves and shoes

to protect and insulate tfie bodY.

b.-Fake special care to insuiate "yourself from

ground using dry insulation {such as dry_

wood) ol adequate size when welding on meta_

floors:or gratings, and in positions (such as

sitting 0r lying ) where parts or large areas of

y0ur:body can be in contact with possible

grounds.

c: Turn sw_tch "OFF" and remove plug from

power source before picking upor moving the

::- wefdeL

d: Maintain the:electrode holder work clamp,

wetdin9 cable and welding machine in good,

safe operating condition by practicing

periodic inSpect.ion and preventative

IONS:TO: OPERATOR

cooling louvers in the welding cabinet. If these

objects contact the internal parts of the welder

they couid damage the welder or result in an

electrically hazardous condition.

2. EYE AND BODY PROTECTION

a. 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.

b_ Always where safety goggles with side shields

complying with ANSI Z87.1 when in a welding

area or when near a slag chipping operation

c. Wear oil free flame resistant protechve

garments, such as leather gloves, heavy long

sleeved shirt cufflesstrousers and h pgh shoes

See picture of appropriate dress=n "'Arc Weld _t

YOurself" section of this manual

d. Protect other nearby personel with suitable

non-flammable screening.

e. 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.

Air-Supplied helmets may be necessary.

" f. Protect yourself against a fall should you

receive an electric shock, particularly when

working above floor level. Keep floor around

your operating position free of clutter. Never

wrap the electrode cable around any part of

your body.

g Do not weld in locations close to chlorinated

hydrocarbon vapors coming from degreasmg.

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.

h. Unprotected spectators must keep 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.

maintenance; ......... 3. FIRE AND EXPLOSION PREVENTION

This 0se under .... a Remove flammable and explosive material at

electricaiiy hazardoi]S:c0nd t_ns due to water least 35 feet from the welding arc t,o prevent

or perspiration Under these conditions

automahc control equipment _s required in

accordance with ANSI Z-491 "SAFETY IN

WELDING AND CUTTING "

f_ Connect the welder only to a source of

electrical power meeting the requirements.

including grounding, of the National Electrical

Code (ANSI C1) and local codes.

Improper!y wired extensfon cords can cause a

potentially fatal shock hazard by electrically

energ z ng the welder cabinet Use only a

proper!y wired and adequately sized extension

cord which has a grounded conductor (See

'Connecting the Welder to the Power Supply

elsewhere in this manual for more

information}

f you recewe a shock from the welder cabinetl

_mmediately disconnect the we_der from the

[_ower supply and obtain help from a qualified

electrician

g Do not drop or insert objects through the

welding sparks or molten metal from starting a

fire. Keep a type ABC fire extinguisher within

easy reach.

b: Welding on or near containers which hold or

have held combustibles can cause an

exDtos_on even when they have been cleaned.

Do not weld on such containers until you have

read "Recommended Safe Practices for

Welding and Cutting Containers and Pping

That Have Held Hazardous Substances" F4.1

available from the American Welding Society,

550 LeJeune Road Miami. FL 33135.

c. Vent hollow castings or containers before

heating, cutting, or welding. They may explode

from expansion of trapped air or boiling

liquids.

d. When not welding, place the electrode holder

where it is insulated from thework clamp work

piece, or work table. Accidental grounding can

cause overheating of the cables and welder,

creating a fire hazard.

e. Neverconnectthe workcableorclamptoany

objectbuttheworkpieceormetalworktable_

Connectingto otherobjectssuchasbuilding

ground can cause stray currentsto flow,

resultingin overheatingor fire.

4. PREVENTATIVE MAINTENANCE

'a. 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.

b. Before connecting the welder power cord to

the receptacle, check the following:

1. Inspect the power cord and welding cables

for cuts or burns and make sure blades and

ground pin on the plug are straighL

2. Inspect "ON-OFF" switch Iever for cracks or

broken parts.

3. inspect electrode holder jaw insulators for

cracks or broken parts.

c. Never weld anything on or to the welder

cabinet, as a burn through may cause

transformer failu re.

d. If any part of your welder is malfunctioning or

has been damaged or broken, such as switch,

cables, helmet, electrode holder, cease

operation immediately and disconnect welder

from the power source and turn switch "OFF"

until the particular part is properly repaired or

replaced.

5. ADDITIONAL SAFETY INFORMATION

a. For additional safety information, purchase

copies of "Practice for Occupational and

Educational Eye and Face Protection" (ANS!

Z87.I), "Safety in Welding and Cutting" (ANSI

Z49_!);_and "Fire Prevention in Use of Cutting

and Welding Processes" (ANSI/NFPA No.

51B) from the American National Standards

Institute, t430 Broadway, New York, New

York, 10018. Purchase copies of "OSHA Safety

and Health Standard" 29 CFR 1910 from the

U.S. Government Printing Office, Washington,

D.C. 20402.

SPECmFgCATIONS

INPUT

Volts AC ................................. 230

Hertz (Cycles) ............................. 60

Rated Input Amps .......................... 50

Delay Action Type Circuit Breaker or Fuse 50Amp

Short Circuit Amps ........................ 67

Power Cord Length ........................ 6'

OUTPUT

AC Low Range Amps .................. 35-140

AC High Range Amps .................. 50-230

DC Range Amps ....................... 30-140

Arc Voltage ................................ 25

AC Open Circuit Volts (max) ............... 74

DC Open Circuit Volts (max) ............... 80

Kilo-Volt-Amps ............................ t2

Kilo-Watts ................................ 7.2

Power Factor % ............................ 60

Duty Cycle % .......................... 20-100

GENERAL

E_ectrode Capacity .................. 1/!6_3/16

Low Hydrogen ....................... !/!6-1/8

Stainless Steel ....................... 1/!6-1/8

Aluminum ........................... 3/32-1/8

Electrode Cable Length .................... 8'

Work Cable Length ........................ 8'

Dimensions ...................... t5 x 12 x 2t

READ AND OBSERVE THE INSTRUCTIONS

APPEARING ON THE WARNING INFORMA-

TION FOUND ON THE CABINET,

ELECTRODE HOLDER AND ON THE INSIDE

OF THE WELDING HELMET,

I ..,_ WARNING E_ECTR,CSHOCKCANBEfATAl'BEfOREI

TURNING WELDER ON. CHECK THE ELEC]ROOE HOLDER TO I

BE SURE I'HA_ THERE ARE NO PROTRUDING ,SCREW H_:ADS

ANO THAT ALL INSULATION IS SiECURE

CAUTIg_

U_ 0rdy for!a_ a_d eye p_D_e_b0n

a,_ams_ _dun0u_ _y_ _0m ar_ we_d-

h1_erp!ale Impac_ _e_stantey_ p_9-

tect_o_!hll_ p_a_ ba_k-up p!atR o_

Separate _a!e_y _p_la_es_ should

Impact Tes_sIant plple$ _ t_0T u_'_-

br_akPbi_ P_'t$_0 rsc_'alchedpla_e_

_-r_lechon-- ;_pface_mme_a_I¥

_s_ect _ouen_v and _mmed_a_e_v

LENS @ "_

SHADEN0

MADE f# _TALY

WARNING! ARC WELDING CAN BE iNJURIOUS TO OPERATOI_ AND PERSONS

IN THE WORK AREA _CONSULT OWNERS MANUAL BEFORE OPERATING

To get the most from your welder we suggest you read the manual carefully --

even if you're an accomplished welder, and keep it available to serve as a

handy reference, or in the event that repair parts would be required.

FULL ONE YEAR WARRANTY ON CRAFTSMAN ELECTRIC WELDER

If this Craftsman Electric Welder fails to perform properly, due to a delecI in material or workmanship, within one year

from the date of purchase, Sears will repair it free o{ charge. this warranly applies only while this product is in use in the

United States

WARRANTY SERVICE IS AVAILABLE BY SIMPLY RE[URNING THE WELDER TO THE NEAREST SEARS STORE OR

SERVICE CENTER THROUGHOUT THE UNITED STATES.

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

SEARS. ROEBUCK AND CO,. Dept. 698/731A. Sears Tower. IL 60684

-TABLE OF CONTENTS

:i-....... ,,:. ::2 Operating: Coriti;o s: .,. _............... 6

Warrantv Troube:Sh0oting:i:i.:::.: : 8

..... ......... 2-1

'::i_:::::. ,...:.......... ::.i i:::i !:::. 4 REPAIR PARTS :... ::.:i:i i, ..... ..... 2-6

AND CHECKING CONTENTS

ON-OFF

ELECTRODE

DIAMETER GAUGES

OUTLET JACKS

WORK CABLE

DO OUTLET4

WELDING

HELMET

WORK CABLE AND

WORK CLAM P

SET-UP INSTRUCTIONS

This Craftsman welder.is shipped complete in one

carton: in :order:;_to facilitate packaging, certain

itemslmust:i be assembled when received by the

purchaSei;:2BemoVe afl items.from the carton and .

ident fy item :as :;shOwn in::,:the! e:,x,ptOded::!iview _

iilUSt:ration: These :: "Loose i Parts" :sho:ul:d i:_!:be _-_:

accounted for before discarding: any packag rig: ....

material.

WARNING: FOR YOUR OWN SAFETY, DO NOT

PLUG WELDER IN IF PARTS ARE MISSING OR

DAMAGED.

Key_ .

PartName Qty

,,, = ._

Welding HElmet:(Partially assembled) 1

N0.

Helmet band assembly (Not Assembled) .. .... ....... 1

Electrode cable assembly .............. . ::: ..... :.... 1

Work cable assembly , .................... .,.,:.., t

Loose Parts Bag -- Coetainingt;qefollowing items: ... 1

ElectrodeHolder ..... . .... : ...... :...:, 1

Work Clamp ........ .............. ..:..:....- .... . 1

Screw Hex Hd. 1/4-20x 3/4in..:;.....:,:,._,...:.. !

NuL Hex. !14-20 ::,..... ....... .-..::,.,,i..... .... /

Washer: Flat 17164in............ :. .... ...:..,...., _ 1

L0ckwasher, 1t4 in......................... !

ASSEMBLY

TOOLS NEEDED

7/16-inch wrench Screwdriver (medium)

ATTACHING ELECTRODE HOLDER

TO ELECTRODE CABLE

1. Locate the slotted head, handle locking screw

near the front of the insulating handle. Remove

this screw.

Z Slide the handleoff 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. Prepare=the end of the cable by splitting the

strands into two equal bundles. Bend the bundles

into a forked shape and twist together to prevent

fraying.

4. Back out the slotted-head screwtocated near the

end of the electrode holder until the cable end can

be placed under the rectangular clamp plate.

5. Insert the end of the cable under the clamp plate

so that the forked end of the cable passes on each

side of the screw.

6. Tighten the slotted head screw very firmly.

7. Slide the handle back into place on electrode

holder and position it until the hole in handle is

directly over the handle locking screw hole. Install

the handle locking screw and tighten.

ATTACHING THE WORK CLAMP

TO THE WORK CABLE

1. Attach the terminal on end of work cable to the

work clamp, at the ho_e 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 1/4-inch

tockwasher furnished in the loose: parts bag.

2. Do not use either of the holes in handle ends of

work clamp.

SCREW

3. Tighten the screw firmly enough to insure good

contact and prevent the cable terminal from

slipping on the clamp.

CONNECTING WELDER TO POWER SUPPLY

CAUTION: To avoid damage to unit, fire or electrical

hazards, 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 cabinet.

Electrical connections between the welder and

grounded 230-volt, single-phase, 60-cycfe a-c

power source should be made by a qualified

electrician. All wiring must comply with the National

Electrical Code (ANSl/NFPA70) 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 wilt depend upon their

length as shown in the table below.

Supply Conductor (Inc. Extension Cords)

Up to 30 feet .......... No. !0 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

GREEN W{RE

ECEPTACLE

FUSES OR C{F{CUtT BnEAKERS

Con_ecl Io g_ound buss in

power panel.

CoP_nect !:o hot ',vires of a

$ingte phase system only,

amps at 20% duty cycle in accordance with

Article 630 of the National Electrical Code

(ANSI Ct) and may not be adequate for other

loads. Consult a qualified electrician before

using for other loads.

Connect 230-volt power lines and ground as

shown in figure.

Install 50 ampere circuit breakers or fuses of the

delay action type such as "Fustron" or

"Fusetat",

Use Sears Cat. #20691 Power Receptacle

available through most Sears Retail or Cata}og

outlets or any certified 50 amp, 250 volt. 2 pole, 3

wire, grounding type receptacle.

!::O

::tt

one

our

JNTRO:L:S @

welder: is derived from

is equipped with P

ranges two :AC ranges and

== v j

ii:!:i::i:_:i::_i:i:

The 50-230amp AC range requi_:es less line (input

current) draw for any given amp setting and permits

SELECTING DC RANGES

Your new arc welder has a DC range which makes it

possible for youto weld aluminum using al uminum

welding rods. You will find this increasing_.y useful

as aluminum is be ngused eXtensively today,

mostly because o_ its light weight,: corrosion

resistance, and its ability to conduct heat.

The DC range is also preferred for verticat and

overhead welding, for welding thin metals, for

reducing pop-outs; with many difficult to use rods,

suitable for electrodes up to 3/!6 inch diameter.

Either range may be used, depending on operator

preferences when the electrode diameter permits.

and to reduce spatter where appearance

important.

CONNECTING ELECTRODE AND WORK

CABLES FORAC WELDING

Insert the tapered plug on the: end of the electrode

cable into theproper Outlet jack depending on

range required, insert the tapered plug on the end of

the:work cable into_the AC work jack.

:To insure agood electrical connection always twist

the: electrode plug _slightty: while inserting. To

rem0ve the plug twist in theopposite directi on while

remowng:

NOTE:: If_you extend the welding:iilCables:beyond

those already supplied, they:must be No: 4 AWG or

larger to avoid an undue drop:in:weiding:currenL

DO NOT EXTEND CABLES OVER 50 FEET.

Connect the work c amp to the: piece to be welded,

(to complete the etectdcai circuit) or to the weiding

table itself provided it is metailic orwill conductl

electricity!

CONNECTING ELECTRODE AND WORK

CABLES FOR DC WELDING

Polarity: In DC welding it is possible to change the

direction of electron flow. This is done by changing

the manner in which the electrode cable and the

workcable are plugged into the DC jacks.

ForDC Reverse Polarity: The electrode cable is

plugged into the positive DC jack and the work

cable is plugged into the negative DC jack._ In this

mode the electron flow wilt be from the wo_rk to the

electrode. This mode may be used for ahJminum

welding, weldi ng .on thi n sheet metal, cast iron and

high carbon steel. This is also the best mode for

overhead and vertical welding.

WORK

CABLE

For DC Straight Polarity: The electrode cable is:

plugged into the negative DC jack and the work

cable is plugged into the positive DC jack. In this

mode the electron flowwill be from the electrode to

the work. This mode is used for hardsurfacing, mild

steel welding, cutting and burning holes.

For more detailed information regarding the current

polarity to use with specific welding rods, refer to

the table provided on the welder and to information

provided with welding rods.

Connect the work clamp to the piece to be welded,

(to complete the electrical circuit) orto the welding

table itself provided it is metallic or will conduct

electricity.

ELECTRODE

DC _/ORK

CABLE

Welds

Aluminum

140ou,.u,

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 tess amperage.

B, Next verify the electrode diameter, by placing

the bare portion of the electrode against the

electrode diameter gauge located under the bar

chart.

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. f

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 or aluminum and also its'

diameter (as previously determined).

Locate the electrode size and type in the

recommended amperage range table below the

welding rod gauge, and read the recommended

amperage setting, Where the electrode can be

used on either AC or DC, both recommended

settings are given,

..:Now !oosen tlie heat selector knob and move the

: pointer urtti/_i_ecommehded Setting: appears_:: in

:: thep0i ::i _i:!: .:::i: ,:i i: :

i: i :' .nob: ::

selected)::_ Connect.the Work Clam p to the w6rk

Wear ! .

Turn:the 'ON" position,

• lower your:Welding: He!meL, and you are ready

to:weld,:- ....

up and the

technique of each operator fsdifferent, you may

find it necessary to increase or decrease the

amperage setting; accordingly.

CAUTION: Donot loosen and move amp selector

while welding.

The duty cycle scales: bracketing the amperage

scales are provided for :your convenience and

protection ofly0ur new welder. Duty cycle is the

performance level of the welder based on a t0

minute time span, For example welding for 6

minutes oul of 10 minutes is a 60% duty cycle. To

avoid possible overheating of the welding

transformer, which could shorten the fife of your

welder, Do Not exceed the duty cycles indicated on

the duty cycle scales.

TROUBLE SHOOTmNG

WARNING: Removal of the welder cabinet top for any reason must be done by

a qualified service technician.

TROUBLE SHOOTING CHART

:i/: :

TROUBLE : ::: iPROBABLE CAUSE !SUGGESTED REMEDY

Fan and welder do:i Improperly fused or 1 Use 50 ampere fuses of the delayed

: r " tr n" r

not operate, or :-:: ....... i _P otected, achon type such as Fuse o o Fustat

:Continually blow _:i Ior 50 ampere 240 volt circuit breaker.

:fuses: i : 112. Blown fuse, or open 2, Replace fuse, or reset the circuit

.... breaker,

: ::: i:i;;; "OmOif:" :switch 3: Turn:switch "On". :

Welding currentlow t Low line v01tage_ iti:,111 Haven voltage check performed by

or weak ! " the local power company,

2, Welding Cur:rent i:! 2. Check Current recommended for

Setting too low. : ! the electrode being used.

: 3, Poor connections: 3, Check electrode holder, work and

".:_L_ _ electrode cable connections.

Can't hold an arc. ,

Using a D.C. welding

rod on A,C, range.

Using low hydrogen

rod,

Improper polarity on

D.C. range,

1. Use AC or AC-DC rods,

2. Use rod of 1/8-inch maximum diameter,

or smaller on 30-140 amp A.C. range or

use D.C. range with reverse polarity.

3, Check that cables are plugged into the

correct jacks to give polarity per the

recommended amp range table.

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,

A COMPREHENSIVE

GUIDE FOR YOUR

NEW CRAFTSMAN

ARC WELDER AND

WHAT iT WiLL DO

CONTAINS:

INFORMATION ABOUT

= VARIOUS TYPES OF RODS

=USEFUL ACCESSORIES

°TIPS ON CUTTING, WELDING

AND BRAZING

Form No. SP574_5 14

•ii:i•I;••••

TABLE OF CONTENTS

Page

YourWelderandWhat It Will Do ............. 1-3

Howthe CraftsmanContactRod SimplifiesWelding 1-3

WhatHappensWhenYouWeld? .............. 1-3

ReadBeforeWelding ...................... 14

LearnBy Doing............................ 1-5

PositionWelding ......................... 1-11

Cast-IronWelding ........................ 1-14

HardSurfacingWoreCuttingEdges .......... 1-15

TheTwin CarbonArc Torch ............... 1-16

Cuttingand OtherMiscellaneousOperations .,. 1-17

Read this Manual carefully for additional welding information.

SEARS,' ROEBUCK AND COMPANY

AND SIMPSONS-SEARS LIMITED

1-2

YOUR WELDER and what it will do..,

Your CRAFTSMAN Arc Welder is a sturdily constructed and thoroughly tested machine engineered to

give many years of efficient trouble-free service. It is listed by Underwriters' Laboratories,

incorporated, which meansthat it passesall requirements of safety, fire hazard and temperature rise

limits asspecified in their Standard for Transfer-Type Arc-Welding Equipment.

HOWTHE CRAFTSMAN ELECTRODE

SIMPLIFIES WELDING

Craftsman Contact Electrode is self-starting-plus automatic

restarting... The electrode starts on contact.

Craftsman Contact Electrode is self-cleaning ... Under normal

conditions the slag removes itself asthe weld cools. Spatter is almost

non-existent. Craftsman Contact Electrode has an exceptionally

good appearance .., With fine ripple, unusually clean, smooth

appearance, and reduced slaginclusions,

Craftsman Contact Electrode deposits more metal faster,,. Because

the powdered iron in the flux goes into the weld.

W' H AT H A P P E N S WHEN YOU WELD?

|Seth edges of the metal

are heated by the arc,

until-

2they meft and flew to-

gether formingone piece,

instantly--

more molten metal and

flux is added from the

rod, which -

4fills the crater and covers

the top of the weld with

slag.

5This process continues the entire length of the weld.

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 ioined, as shown in the accompany-

ing 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 we_ded. The intense heat

generated by the arc is ic{eally 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

poot 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

wit[ extend into the base metal and is referred to as the

penetration of the weld.

Some of the electrode (which consists of a metal rod sur-

rounded by aflux coating) is melted simultaneously with

the base metal and is carried by the arc to the liquid pool.

This added metal combines with t_e base metal to form

the deposited weld.

During this operation a part of the flux coating burns off

and forms a gaseous smoke screen that completely en-

velops the arc, protecting the molten metal from harmful

effects of oxygen and nitrogen in the surrounding atmos-

phere. The remainder of the flux coating that melts is

carriec_ 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 de-

posited weld metal, protecting it from the atmosphere and

retarding its cooling.

When operating awelder, certain precautions must be

taken to prevent injuries to yourself and others. 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 We ding, may be corollated t0 that of the S_Jh;Sr:_ys.

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

accidental eYe injury, contact a physician immediately.

Animals are also affected by the rays and should be kept at

asafe distance.

To protect the face and eyes a heat-resisting; fiber:glass

helmet is used, The special fens, 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-fitting skull cap should be

worn with the helmet. As the helmet is used only when

actually welding, atilting 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.

To safeguard the hands against heat and weld spatter,

gauntlet-type leather gloves should be worn. Aleather

jacket or apron will give better protection against the

_hower of sparks than ordinary clothing. High top shoes

(not oXfords) should be worn. If agreat deal of welding is

tobe done, foundrymen's shoes are best.

Precautions must als0 be taken to protect property and

equipment against fire. A large fire extinguisher should be

wlthin 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 dose to €: 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. Apermanent

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 metal. 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, reasonobly 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 com-

pleting elementary practice lessons.

LEARN BY E:)O NG

DIRECTION

OFWELD

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 aprocess 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 on.

A comfortable body position is important when learning,

as tensed muscles will result in fatigue and Jack of control.

Sit on a low stool and grasp the electrode holder in one

hand with the cable drawn across the }ap. 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 work connection is as much a part of the welding

circuit as the cable and electrode holder. A poor work

connection can render the best wetding equipment

inefficient. When using a table with a steel top, fasten the

lug of the work cable to it securely with abolt or C-clamp,

so that any piece of iron placed on the table top wilt be

properly grounded, tf a steel table is not used, connect the

work cable directly to the work with a work clamp or belt.

Select a fairly large piece of steel plate approximately

1/4-inch thick and clamp it to the table top to prevent it

from tiffing, should the electrode stick or "freeze" when

,,','I ,111t

,; ;' I!11

,' ';lIill

,i4_tlr,,.

_777///////////,, _///////////2V/////.

Figure 1

To strike an arc, scratchthe

end nf the rnd en the plate

and then quickly raise ap-

proximately 1/8-inch.

first attempting to weld. Insert a small, mild-steel welding

electrode in the electrode holder and connect the welding

cables to produce the heat specified by the CONTROL

panel. Connect the ground cable to the work and set the

indicator in the current range recommended for the

diameter of rod used.

Any method of bringing the tip of the rod in contact with

the work, then quickly raising it until there is approximately

a I/8qnch gap between the rod and the work, will start an

arc. The easiest way for a beginner to strike an arc is to

scratch the tip of the rod a short distance on the surface of

the work, as you would a match, then lift it (qu;ckly) the re-

quired 1/8-inch (fig. !). Another method isto strike the work

a hard blow with the tip of the rod and allow it to bounce

u_ to form the arc gap. The important thing is to strike

the arc quickly and not allow the rod to remain in contact

Mth the work.

A common mis{ake often made by a beginner is to point

the rod toward the work an.d, after lowering the helmet,

feet slowly about until the tip of the rod touches the work.

This always results in sticking or "freezing" of the rod

which produces a direct short circuit, When this occurs the

rod can be loosened by bending it from side to side while

pulling on the holder (fig. 2}. If this fails, turn the welder

off, The electrode must be released in a matter of seconds

to avoid unnecessary heating of the welder or damage to

the flux coating on the rod.

F;gu_e 2

Should the rod stick or

"freeze" bend it from side

to side while pulling upward

on the rod holder.

1-5

i i 1 i

Fi_re .3 Figure 4

1o lay a weldbeadonlytwo Watchthe wold puddleto

movementsare Used,down- keep the slag fromflowing

wardandin the directionthe in frontof it, causinginciu-

weldis to be laid. sionsandgaspockets,

Figure 5

Fill the crater, when starting

a new rod, by striking the

arc at A then moving to B

and back to C position.

[[ _1 i

I I

Figure 6

1"owiden the bead, work the

rod from side to side slight-

ly, with astow, zigzagging

crescent-shaped motion.

Ifldifficult:y is experienced after repeated.attempts t9

maintain an arc, check ithe work connection for proper

contact with the work; If this does not help, increase the

welding current. Also check the rod size, as larger rods

requi re higher current settings.

Practice Striking and maintaining an arc for a few seconds,

then snap it out by rapidly pulling the rod away from the

Workl Repeat this Operation until the arc can be started

and the gap maintained as uniformly as possible. In a

find the:arc iength can be controlled by

the_::cra(_kiingor.:_:frying :,sound:which may be recognized

by gradua!ly shi_tening the arc until it sputters irregularly

aS though.lt wei:e going to: choke out' and stick-then

slowly lengthening the arc by pulfing the rod away from

the work unt;i it snaps out. Somewhere between these two

extremes the steady crackling sound of a proper arc length

will; be heard.

To lay only two movements are used, a

stead}(.downwa_d feeding of the rod to maintain the correct

arc |ength;.and aislowtrave|: in the direction in which the

weld: 3).iWatch the weld puddle and

arc length_andim0_e theil.rod Steadi|y in a straight line as

the back end 0f:ilffieCrate_ fi!ls:up (fig. 4). The Slight angle

of the rod wiii keep the flux or slag {lowing over: th:e

dep0slted weidmetal 'to: farina protective coating, if:the

rod is moved too lsl0wly the stag will flow in front of the

puddle ancl be trapp:ed :i'n the weld,: producihg' ini:lusions

and gas pocketSi :.... " i....

Lay a bead. approximately fou_ incheslong. After allowing

it to cool SligF_tly,remove the: Slag Coating; which Coversthe

top of the weld; by:scraplng along each edge of the weld

with a cotd:.cF_isetf0!owed by wii_ebrushing until:it is bright

and dean_ Inspect the Surface Of the weld carefully before

starting another. The surface of a good weld is rippled

uniformly, which results from a steady rate of travel and

uniform arc length.

If the scrap plate used is small, it will become very hot after

laying a :few beadS. This will alter welding conditions

Which €ou'ld be;very Confusing to a beginner. Have several

scrap pieces handy so each may be allowed to cool before

After laying anumber of beads, try "'working" the rod

from side to side slightly (fig. 6). This movement should

be slow and not wider than the diameter of the rod being

used. Experiment with different current settings, rod sizes

and rates of travel. Compare results with welds shown in

the diagrams (fig. 9).

Too low a current setting tends to deposit the bead on top

of the plate with very little penetration. The arc sound will

be an intermittent crackle with irregular sputtering. Too

high a current setting (for the size of the rod being used)

will provide sufficient penetration but the bead will be thin

and undercut in places. The arc makes a hissingsound and

the rod becomes red hot before it is half used.

if travel istoo slow it"will pile up a wide, heavy bead with

good penetration but witk overlap of the weld metaI on

sides without fusion. Alarge area surrounding the weld is

heated to o high temperature which produces distortion,

even on a simple weld. If the rod is moved too fast the

small bead will result with little more than melted base

metal An extremel)_ ]0ng arc causes the rod to melt off in

globules, with little Or no penetration, and a very irregular

weld Surface. The arc produces a hissingsound.

Agood weld laid with correct current setting, speed and arc

length?.willproduce a sUrface that is rippled uniformly, with

the same width throughout its length, and wel] formed

crater.. The cross-sectional view showsit to have good pene-

tration and no undercut or overlap.

laying a seCOnd:bead.

IlU Jl

When starting with a new rod, chip slag from the crater Figure7

and strike,the arc at the forward end aS shown ;at "'A" in

figure 5. Then move the rod to "B" and back to "C," at Lay the weld beadsabout

one ineh apart. Removethe

about twice the normal rate of travel to give the rod and slagandexamineeachwed

base metal time to heat up for proper fusion, before starting the nexL

Figure 8

A pad of weld metal is built

up by running a series of

beads in layers at right

angles to each ether.

1.6

CURRENTTOO LOW

Arc is difficult to maintain,

Very fittte penetration. High

bead.

TRAVELTOO FAST

Small bead undercut in

some pisces. Rough top

and little penetration.

CURRENTTOONIGH

Wide thin bead, undercut.

Crater pointed and long.

Rod burns off very fasL

ARCTOO LONG

Surface of weld rough,

Rod melts off in globules,

Arc makes hissing sound,

TRAVELTOO SLOW

Metal piles up, making a

wide heavy bead, over-

lapped at sides in places.

NORMALCONDITIONS

Uniform ripples on surface

of weld. Arc makes steady

crackling sound.

Figure 9

Practice laying beads approximately one inch apart until

a good wetd can be produced with afl the different rod

sizes the welder will handJe (fig. 7). After becoming pro-

ficient in running o bead, build up a pad of weld metal.

Clean each bead before laying the next and make sure

they are fused together (fig. 8). Run the second layer at

right angles to the first and the third at right angles to the

second, etc., until apad approximately 1/2-inch thick has

been built up. This type of welding is used to build up

round or fiat surfaces or reinforce parts that are rusted thin.

To avoid distortion when building up the end of a shaft,

run the beads parallel to the axis and lay each successive

bead on the opposite side as shown by the numbered steps

in figure 10. Cover the entire shaft with weld metal for

the desired length. If the place to be welded is not at the

end of the shaft, weld around it and turn the shaft slowly

to keep the weld puddle in the flat position _fig. 1t). Clean

off the stag after each bead, then machine the shaft to

proper size.

®®

/i, ,,,,, ,,

Figure !0

ell_l,

1-7

FLAT

TACK

Flat welding includes all types of joints in which the weld

ishorizontal, and the electrode is fed clown as in the practice

welds of previous pages. The five types of joints in figure 1

can be welded in the flat position.

Butt welds 0n light materlal should be practiced first on

scrap stock. Use 16_gauge mild steel sheet metal (approxi-

mate]y 1/16-inch thick) and 5/64-inch rods with the wetder

set at approximately 30 fo 50 amperes. Buttedges of metal

together and tack;weld approximately every three inches

(fig.::2). (Tack welds are small beads t/4 to 3i8-1nches in

length.) Place bars of scrap iron under ends of the work to

provide an air space above the table. Simply move the rod

in a straight line directly above the edges to be joined.

tf the Weld burns thro_ughin places, reduce the welding cur-

rent or irlcrease the rate_of travel. Some difficulty may be

experienced in starting the arc at these low current settings.

However, once the arc is started, there will be sufficient

heat to make asourtdweld. After laying a bead, turn the

work over and inspect the Underside which should als0 have

a sinai] uniform bea;€i_:To prevent burning through where

the edges are not butted tightly together, move the rod back

and forth with short quick Strokes in the direction of the

weld to bridge the gap and give the metaf in the crater a

chance to solidify (figL 3).

Butt welds on sheet metal lighter than 18 gauge should

not be attempted by the beginner without the use ofa

back-up strip (fig. 4). This consists of a bar of copper

clamped tightly against the underside of the seam to absorb

the heat of the arc and prevent the weld from burning

through. To assure complete penetration with butt welds

on 8*gauge metal or heavier, a t/t6 to 3/32-inch gap

should be atlowed between them (fig. 5). Insert a wedge or

screwdriver between the plates when tack-weldlng to main-

tain the gap, then turn the piece over, so the tack welds are

on the underside.

Use enough current to melt edges of plates to adepth Of

at least one-half their thickness. Clean off the slag and

inspect it for smoothness, penetration and height of rein-

forcement. A good weld should have a reinforcement slightly

more than flush with the_ surface (fig. 6). Turn the plate

WELDING

SHEET

METAL

BACK-UP

STRIP

Figure 4

Figure 3

6-1#CH

R_KFORCEMENT

Figure 6 _Figure 5

Figure 7

FIRSTP,ASS V-WELD

REINFORCING

4-PASSBUTTWELD

rll

Figure 9

_45_y SINGLE-BEVELWELl)

Figure 10

over and weld asimitar bead on the other side (fig. 7). A

higher welding current can be used on this side as there is

no danger of burning through and fusion with the first

bead will be assured.

Although butt welds can be made on steel plates up to

3/8-inch thick, with a 29_ampere machine using 1/4-inch

rod, the same results can be obtained with smaller welders

if eages of plates are beveled (fig. 8). Metal of almost any

thickness can be welded in this manner by depositing a

number of beads, one on _op of the other until the groove

is completely filled. If the plate can be welded from both

sides, always use adouble bevel (fig, 9), If only one plate is

beveled, the angle should be at 45 degrees (fig. 10).

I-8

UNDERCUTGASPG_CKET

TRAPPEOSLAG PENETRATION

Figure 11

figure 13

Run the first pass on beveled plates with a5/32-inch rod

and use as high a current as you can handle to obtain a

small bead on the underside. If this is not done, insufficient

penetration will result, as shown in figure 11. Be sure to

clean each pass before laying on the next. All beads are

laid by moving the rod in astraight line with no weaving

or side-to-side movement. On the last or reinforcing pass,

a weaving motion must be used to obtain a wide weld that

wilt completely cover preceding beads. For the beginner,

the side-to-side movement (with aslight hesitation at each

end) wi!l produce a smooth top without undercut or overlap.

Select several practice welds of different thicknesses and

cut them into 1-1/2-inch strips. Clamp each strip in a vise

and bend it at the weld (fig. 12). If it breaks through the

we_d, study it to find the cause of failure.

Corner welds are made on light sheet meta] by running

a single bead along the top, after tack-welding at three-

inch intervals to prevent warping (fig. 13). If numerous gaps

are present, a back-up strip may be used. On heavier

metal two passes may be necessary and, if the design

permits, asmaller pass can be laid on the underside.

Beveling may be used to advantage on the thicker metals.

FILLET WELDS

BREAKING

THEWELD

Figure 4

Figure 6

Fillet welds are used to ioin two pieces of metal with sides or

edges at right angles to each other. The size of such a

weld is based on the leg length of the largest isoscelesright

triangle that can be inscribed within the cross sectional

area, as shown by the dotted-line triangle (fig. 1). The

size of a fillet weld may also be measured with a square

and ruler, subtracting 1/32-inch from aH dimensions under

3/16-inch and 1/16-inch from all over t/4_inch (fig. 2).

For example, a 1/4-inch fillet weld should measure 5/16-

inch. This will offset any inaccuracy due to the slight radius

at the toe of the weld and allow for concavity of the bead.

When a filtet weTd is stressed to its maximum capacity,

faiture will usually occur through the throat section (fig. 3).

Therefore, the strength is determined by the throat dimen-

sion multiplied by the length of the we_d. Finished welds of

this type should always be at least four times their size in

length; that is, a 1/4-inch fiffet weld shoufd never be less

than one inch tong, The direction in which the load is applied

to a weld greatly affects its strength, which can be dearly

demonstrated by breaking the weld (fig. 4). A joint so

loaded should atways be welded on both sides with fillets

equal to the plate thickness (fig. 5). If this cannot be done,

bevel the plate to assure complete penetration and position

the work at a 45_degree angle if possible.

For practice, tack-weld three pieces of scrap iron together

to form a cross (fig. 6). Use a 5/32-inch rod with high current

and hold it as indicated in the front and side views. Move

the rod at a steady even pace along the seam without any

side-to-side movement and deposit one inch of weld for

each inch of rod meffed. The surface contour of a good weld

1-9

Figure 1!

Figure 8

Figure 9

Figure TO

Figure 13

LAPWEL|)S

Figure 14

Figure: 16

LAP:WELDS

Figure 15

i ii iiiiiiii

iNTERMITTENT

WELDS

Figure I7

WELD ON BOTH SIDES

ATENDOFJOINT

i i

STAGGERED

INTER-

MffTENT

WELDS

should be nearly flat with aslight radius at the sides or

toes. Avoid excessive concave or convex surfaces of the

fillet (fig. 7). Undercuts and cold-taps are caused by not

holding the rod in the center of the seam (fig. 8): ;If the

desired fillet weld cannot be made with aSingle pass,

severat passesore usedto build it up to required size (fig, 9);

Stag must be cleaned from each pass before depositing

the next. Fillet welds over 1/2÷inch in size are rarely used

because joints requiring more strength can be made more

economically by beveling and groove-welding, followed

by a small concave fitlet weld to provide a radius in the

corner.

.HoriZontal fillet welding is used when the side or edge of

one member of the joint is inthe vertical position particularly

fay small single-passwelds where the work cannot be tilted.

For practice, tack-weld two pieces of scrap together to

form atee-joint (fig. 10). Use a 5/32-inch rod held at

angles indicated, and direct the arc into the corner of the

joint. The arc tength should be somewhat shorter than for

flat fillet welding. To assure penetration at the root, Use:the

highest welding current that can be handled (fig. 11).

Good penetration is of prime importance an_dappearance

Wi|l _:coi_ewith experience. If the arc is advanced too fast,

o_:_eld:too close to:the Vertical plate, undercutting may

tbsu]f (fig_ 12). Too Slow travel will cause overlapping and

_iti:extre_nely close arc or low current will produce a bead

witha Convex surface (fig. 13). To check the penetration and

S0undnessof the bead, break some of the welds for inspec-

tion, as shown in figure 4.

Whe_ making a lap weld, care should be taken not to melt

too much of the upper corner on the top plate (fig. 14).

Some melting will take place, but proper advance of the

rod will cause the weld metal to build up and blend into the

top surface. On sheet metal hold the 3/32-inch rod almost

perpendicular and move the arc rapidly. Welds of this

type should be wider than they are high, somewhat like a

f|at bead (fig. 15). A slight discoloration on the underside

of the lower sheet indicates good penetration. On heavy

metal, a :3/8-inch fillet weld can be laid in one passwith a

1/4-inch rod using a295-ampere machine. However, with

Smaller machines, the same weld or larger can be made by

building up with e number of passes (fig. 16). When

welding 10rig narrow pieces, stagger the welds in short

intermittent beads, first on one side then on the other side,

to minimize distortion (fig. 17).

1-10

POSITION WELDnNG

]n order to derive the greatest benefits from your welder,

you should practice until you can make a welded ioint

in almost any conceivable position. The abitlty to do this

_sespecially useful when making repairs on machinery as

the amount of welding in most cases is small and does not

warrant disassembling the parts to weld them in the flat

position. Welds of this type have been classified into three

groups according to their location and are referred to as

vertical, horizontal and overhead welds (fig. 1). Of the

three positions, vertical we]dlng will be used the most and

should be practiced first. Skill gained in this type of we|d

will make horizontal and overhead welding easier.

VERTICAL WELDING

The two methods of welding in the vertical position are

commonly known as "vertical-down" and "vertical-up"

welding (fig. 2). In the former the bead is started at the

top and wetded in a straight line downward, in the latter

the bead is started at the bottom and welded up, usually

with a weaving motion.

The chief difficulty encountered with any posit_on weld is

keeping the molten metal in the puddle from failing out.

To prevent this the arc must be held as short as possible and

the weld puddle kept fairly small so it wifl solidify rapidty.

Vertical-down welding is the easiest to perform and is used

on material up to 1/8-inch thick. Before attempting avertical

weld, run a few practice beads to get the "feel" of the

arc. Tack-weld apiece of scrap iron to an old practice plate

so it is positioned vertically (fig. 3). Use 1/8-inch rods for

the first welds and a current of about 75 to 115 amperes.

Experiment with various amperage settings until you are

using the highest current you can handle, Hold the rod at

right angles to the ptate laterally, with the tip pointed up

c_t the angle shown in figure 3. Start the weld at the top

of the plate and move the rod in a straight line downward.

The correct rate of travel can be determined by gradually

reducing the speed until molten metal in the puddle can no

longer be kept in place. Then, increase the speed stightiy

while watching the puddle, arc length and angle of the rod.

A short arc provides better control of the moffen metal.

Follow the same procedure with 3/32 and 5/32-inch rods.

It witl be noted that the larger the rod the more difficult it

is to control the puddle. For this reason smaller diameter

rods are always used for position welding.

Lap or tee-joints ore made by simply directing the arc into

the corner of the ioint as in fiat welding and moving the

rod down the seam at a steady pace. Butt welds may require

more practice, as there is a tendency to burn through on

tight gauge material, if this occurs, continue until the seam

is completed and patch the hole by chipping the slag and

wire brushing until dean. Then, with slightly lower current,

strike an arc on the weld directly above the hole and quickly

bring the rod down to _he lower rim of the hole to deposit

a smafi amount of metal. Raise the rod for an instant to

let the metal solidify and repeat until the hole is welded.

Hold a long arc when raising, so there will be no metal

deposited except when the rod is lowered. Any hesitation

in the rate of travel will cause a "burn through." tf this

happens repeatedly, lower the welding current.

Leave a slightgap between pieces for butt welds on materlal

over 3/32-inch thick, inspect the back side after welding

for small bead aJong the seam, indicating complete pene-

tration (fig. 4). Butt joints on material around 3/16-inch

thick should be welded on both sides.

Vertical-down welds may be made on heavier material by

laying in a number of passes (fig. 5), however, this practice

is not recommended as it takes longer than a heavier single-

pass weld made by the vertical_up method.

¥ERTICAL-

_OWNWELD

LECTRDOES;

.Lgt_CTnO_._,J,

VERTICAL-gOWN

WELDING

Figure 3 Figure 4

VERTICAL.UP

WELDING

Figure 6

WELD

Figure 9

Use 1/8 and 5/32-inch rods for all vertical-up welds and

start by running practice beads from bottom to top of a

3/16 or I i4-inch plate, tack-welded in a vertical position.

Hold the rod as shown in figure 6, noting that the angle

of the rod is not as steep as for vertical-dawn welding, but

tilted just stlghtly (approximately five degrees) so the tip

ofthe electrode points upward. Sffike and hold a short arc

Until a small amount 0f metal is deposited, then quickly

raise the rod upward with a Wristmovement to increase the

length of the arc at the top of the stroke (fig. 7). As soon

as the metal deposited in the crater has solidified, bring the

rod down :and deposit more metal. Keep repeating this

whipping motion, while gradually moving the rod upward

and toward the plate as the electrode burns off. The length

of the Stroke will depend upon the amount of metal de_

......... posited and the welding current used. Keep the rod in

constant motion :once it has left the crater. The purpose

of along arc is to prevent any metal from being deposited

except when the rodi_ held at the Crater,;If globules of

molten metal drop from the tlp of the rod when the arc is

lengthened, either the current is too high or the rod has

remained away from the..... ......Crater t0o long. Care Should be

taken not to break the:arc at:the :top Of the strokel Donot

deposit too much metal at One time as this wilt Cause the

weld to sag and result: in a high narrow bead undercut

along the sides. Better penetration can be had by the

vertical-up method_ This can be. demonstrated _by joining

two pieces of 3/16-inch metal with abutt weld, using the

whipping motion. Leave agap between the plates and use

a5/32-inch rod with a fairly high current, cletermined by

experimenting. TEe whipping motion will melt the corners of

the plate and form a pocket in which to deposit the weld

metal Ifig. 8).

Burn the rod in deep so the crater extends through to the

back side. After completing the weld, inspect the back

side for the small bead, which indicates 100_percent pene-

tration. Butt welds on heavier materials should be welded

on both sides:

On materials up to 1/4-inch thick, use the whipping motion

on small single-pass fillet welds for lap and tee-ioints_Larger

single-passfillet welds can be made by the whipping motion

with a slight side-to-side weave added and combined with

the up and down movement to make a triangular shaped

weave (fig. 9). This will produce a "shelf" upon which

additional metal is deposited intermitter_flyas the welding

progresses. There should be a slight pause [n the weaving

motion at the toes of theweld to avoid making a bead that

is too convex. Materials 1/4-inch and thicker must be bev-

eled on one or both sides,depending upon the joint.

Practice making awide bead using a side-to-side weaving

motion with a very slight whipping action at each end to

give the metal at each end a chance to solidify and avoid

undercutting along the sides of the weld (fig. 10). This type

of bead is used on welds that require more than one pass

and is called the finish bead or "wash" pass. Hotd a short

arc, making the bead approximately 3/4-inch wide and

fairly light. Multiple verticai welds may be made as shown

in the series of diagrams, figure 11.

Figure 11

1-12

UNDERCUT

OVER-LAPFED

_gure 13

Figure 14

BACK-UP STRIP

Figure ]5 Figure 16 Figure I7

HORIZONTAL WELDING

Horizontal welding refers to one type of butt weld between

two plates in a vertical plane. For practice, set up a plate

as for vertical welding and run straight beads across from

left to right (fig. 12). Use the some current settings as for

vertical-down welding and hold the rod as indicated with

a short arc. Move the rod in a straight line and deposit

alight bead. The rate of travel will depend upon the current

used. Too slow a travel will cause the bead to sag (fig. 13).

Practice with 3/32, 1/8 and 5/32-inch rods until a weft

formed bead can be macle with each size rod (fig. 14).

Sheet metal up to 1/16-inch thick con be butt welded from

one side. If the seam has numerous gaps, use a back-up

strip, allowing a slight gap between edges of 1/8-inch

thick metal and weld from both sides (fig. 15). All metal

3/16-inch thick and over should be beveled and welded

with a number of passes (fig. 16). Thoroughly clean each

bead before laying the next and use higher current than

for single-pass welching.

The appearance of a multiple-pass horizontal weld can be

improved by vertical down beads laid closely together.

Use a swift circular motion to the right; stowly downward

while welding (fig. 17).

OVERHEAD WELDING

Although overhead welding is generally considered diffi-

cult, do not become discouraged, as it is being done every

day by people who have taught themselves. Once the art

of maintaining a short arc has been mastered, the rest

will be easy.

Since there will be a shower of sparks, wear a leather jacket,

tight fitting cap and ear plugs and keep the practice plate

slightly higher than the top of your head when standing. To

keep sparks out of your glove, grasp the electrode holder as

indicated in figure 18 and hold the rod in a nearly vertical

position with a slight tilt to the right. Drape the cable over

your shoulder so its weight will not interfere with the use

of the electrode. Use 1/8-inch rods and a current setting the

same as for vertical welding, and move the rod in astraight

line without any weaving or whippir_g motions. A

reasonably fast rate of travel must be used_ to prevent the

bead from sagging and undercutting along the edges. Vary

the rate of travel and notice its effect on the size and

appearance of the weld. When you feel you can run a

satisfactory bead, try the side-to-side weaving motion and

deposit a thin weld approximately 3/4-i:nch wide. The

movement must be somewhat faster than for other

positions to keep the bead from sagging. (This method of

weaving is used only for the last pass on heavy welds where

improved appearance is necessary,)

The whipping motion is used where a gap exists between

the plates as it provides better penetration with higher

welding current. For practice work, set up two plates ap-

proximately 1/8-inch thick, allow|ng agap between them.

Burn in deep for good penetration with 1/8 and 5!32qnch

rods, varying the plate size and gap distances.

Figure 18

Figure 19

Fillet welds for tap or tee-joints are most common in the

overhead position. Tack-weld two pieces of scrap iron

together to form a tee-ioint, and clamp in the overhec_d

position so one plate is held vertically (fig. 19). Hotd the

rod at angles indicated and deposit a [ight bead from left

to right without weaving or whipping movements. A slightly

higher current than used for overhead butt welds will be

necessary to get good penetration at the root of the weld.

1-13

Figure 20

Figure 21

To simulate actual conditions tack-weld a piece with an

irregular edge to another piece leaving numerous gaps

along the joint. Use the whipping motion and deposit a

fairly heavy bead, slowing down the rate of travel where

the gaps are widest to build up a weld of uniform size

throughout its length. If the gaps are rather wide, fill them

first, clean off the slag and lay in a fillet weld the entire

length of the joint (fig. 20_).

When you can lay single-pass butts and fiffet welds you will

be abie to make anoverhead weld of any size, as it is

simply a matter of fusing a number of straight beads to-

gether, one on top the other (fig. 21).

Weld appearance can be improved by grinding with a

prOperly guarded abrasive wheel mounted or= the end of

a flexible shah.

EXPANSION AND _CONTRACTION

METAL BENDS

• eLrff _L_

$'IAilr tST _LD HER(. 2N_' W[tD B£_, ETC,

F;gure 24

surrounding metal is free to move (not clamped or tacked)

it cannot resist these forces and bends (fig. 22).

The weld also contracts in width, as well as in length,

tending to pull the plates together, resu)ting in locked.up

stresses(fig. 23). This is not too serious when welding mitd

steel up to l/2-_nch thick, as the ductility and elongation of

the metal will permit it to deform slightly to compensate

for these forces, and prevent cracking. On sheet metal and

light structural members, long continuouswelds may cause

considerable bending and result in a badly distorted weld-

ment. Fortunately most of this can be avoided by studying

the effects of expansion and contraction, as related to the

job before welding and working out a procedure to follow.

For example: first assemble the iob with tack welds, and

install temporary braces tack-welded to support parts that

might bend. The braces canbe removed after the iob is

completed. Lay the beads so the stresseswill counteract

or n_utralize one another, by running a short pass first on

one side then on the other, etc. Often the neutralizing weld

is at the other end of the job. Do not concentrate too many

welds in one ptace but space them to distribute the heat

and stressesthroughout the entire structure.Use intermittent

welds whenever possible, if continuouswelds are necessary

to make a water-tight compartment, use the back-step

method as shown in figure 24, fusing each bead together

atthe end.

CAST IRON WELDING

Previous experience in handling the arc, plus good judg-

ment regarding expansion and contraction, witl enable

you: to weld gray cast iron successfully in a short time.

Two types of electrodes are used, namely: non-machinable

for use in cases where the weld does not have to be

machined, and machinable which deposits afile-soft weld

that can be drilled or machined t01rclose tolerances. Non-

machinable rods are Used for mast repair jobs such as

cracked motor blocks, water jackets, pump and gear hous-

ings, etc_ tf the weld must be made across a machined

surface that need not be refinlsbed to a close tolerance,

the face of the weld may be ground flush w_thon abrasive

wheel.

As cast iron is very brittle, care must be taken to control

expansion and contraction, and thus avoid cracking Of the

weld or the casting. Because of tow tensile strength and

lack of ductility it cannot bend, stretch or distort itself to

conform to the contraction of the weld metal In some cases

it may be necessary to pre-heat the entire casting before

welding. However, as most cast iron welding iobs can be

done without pre-heating, this method will be considered

first.

The part must be free of rust, grease, paint or dirt; cteaned

by wire brushing, grinding or washing with sotvent. The

crack should be beveled for penetration. If the parts are

broken apart compteteb!,they may be ground on an abrasive

wheel to asingle or double bevel, depending upon the

thickness of parts and whether or not the joint can be

welded from both sides. Do not bevel to a sharp edge along

the entire crack. Instead, allow approximately 1/16-inch

ofthefracturedsurfacetolineupthetwo pieces. Tack-weld

or clamp parts in position. If the crack has not separated

the casting, a yea-groove can be chipped out with a dia-

mond-point chisel. Chip an inch or so beyond the visible

ends of the crack as it may extend under the surface. On

crocked water jackets, where only a seal is required, the

depth of the groove need only be one-hatf the thickness

of the casting.

Keep the casting as cool as possible and do not expect to

complete a weld in cast iron as rapidly as in the same length

in mild steel. Use a smaller rod and a slightly higher current

than for the same thickness of steel. Lay a short bead, about

an inch long, at one end of the crack and peen it immediately

with a cross-peen hammer or blunt chise] to spread the

weld metal and relieve locked-up stresses. Do not strike the

edges of the casting. Place the second bead at the opposite

end of the crack and the next in the center, etc (fig. 1).

Allow enough time between welding to permit your bare

hand to be held on it. Never use water or a blast of air

to cool the casting. Although cracks may not show up

immediately, the tacked-up stresses due to uneven cooling

will cause the casting to fail after it is back in service. Wire

brush each bead before depositing the next. Then continue

to fill the groove with short weld beads as before, working

rapidly whe ndepositing and peening the bead. Allow plenty

of time for cooling. Examine the casting for cracks that may

develop during cooling periods. If any of the beads crack,

chip them out and re-weld. If cracking persists, preheat

the entire casting slowly to a dull red heat with an oxyacety_

lene torch or blow-torch. When the preheated method is

used, the welding can be continuous. After completing the

weld, cover the casting with warm dry sand or slaked lime

so it will coot slowly.

Malleable iron is ordinary gray cast iron that has been heat

treated to give it a tough ductile outer skin. The method of

welding is the same as for cast iron.

FIRST BEAD THIRD BtAD SECOi_D BEAD

HARD FACING WORN CUTTING EDGES

CULTIVATOR

SHOVEL

Figure 1

CULTIVATOR

SWEEP

Excavating equipment, earth-cutting farm machinery or

others such as plow shares, lister shares, cultivator shovels,

sweeps, subsoilers, spike harrow teeth, tractor treads, ex-

cavating buckets, or any surface subject to abrasive action

will last much longer and require less sharpening when

their cutting edges are hard faced with hard surfacing

electrodes. The arc welding process consists of depositing

a layer of abrasion resisting weld metal on the worn cutting

edges as indicated in red on the parts shown in figure 1.

Prepare the part for welding by cleaning the surface to be

welded by grinding it approximately 1-1/2 inches back

from the edge (fig. 2). Position the part so weld metal can

be deposited in the flat position. If the materia! is 1/4-inch

thick or less, use a 1/8-inch rod and as low a current as

possible that will still permit the metal to flow out smooth

and fairly thin (t/t6 to I/8-1nch thick). Weave the rod

from side-to-side in a crescent-shaped movement and de-

posit a bead about 3/4 to 1-inch wide, Several passes

0aid Side-by-side) may be necessary where the worn sur-

faces c_re quite wide. In some cases a small straight bead

GRIN1)OFF

Figure 2 HARDFAC_fNG

W'F._V_BEAgS

F_gure 4

SOFT BASEMETAL

WEARSAWAYFASTER

THAN HARD rACING

STEEL

MtL_-STEEL PATCH

WELDS Figure 5

must be deposited along the edge to build it up (fig. 3).

Make beads heaviest where the wear will be greatest, but

avoid excessive build-up as the metal cannot be filed or

machined. If shaping is required, heat the weld metal and

forge it. Smoothing and s_harpening can be accomplished

by grinding.

For plow and lister shares, cultivator shovets and slmifar

cutting points, deposit the weld metal on one side only

which will result in a serf-sharpening edge (fig. 4). The

softer base metal on the other side wil! wear away first and

leave a knife-like edge of hard facing material. Parts that

must wear uniformly on both sides should be hard faced

on both sides. The condition of the worn part must atso be

taken into consideration. If the part requires a number of

passes to bring it up to the desired thickness,use mild-steel

wetding rods first; then cover with deposited metal from

hard surfacing rods. If the edge is entirely worn away, a

steel patch (cut to fit) may be welded in ptace with mild-steel

electrodes, then hard faced (fig. 5). To prevent distortion

when hard facing small parts, peen the deposited weld

metal before it cools.

i. ¸¸. :,-

THUMB KNOB

CONNECTTO

GROUNDAND

SCREWS ]ELECTRODE

CABL.£SOF

EL,1ECTRODETIPS A.C. W)E.LD[R

Figure !

Work ordinarily done with agas welding torch is possible

with the twin-carbon arc torch connected to an A.C, welder.

The carbon-arc flame is similar to the flame of a gas weld;

ing torch in that it provides heat by radiation, rather than

by direct arc between work and electrode. This flame heat

greatly widens the scope of Work possible with the arc

weldei" for brazing, soldering, wetding of non-ferrous metals

and localized heating for bending; forging and hardening.

The arc torch (fig.: 1)Consists of an insulated handle with

two projecting carbon eiectr0de holders, one of which is ad-

justable to permit striking and breaking an arc at the carbon

tips. A thumb knob on the handle performs the adjustment

and operates a shut-off switch bui|t into the handle; There

are nO valves or gauges that:, require fine adjustment as

with an 0xyacetylene t0rch. The same proteCtiveequipment

used for Ordinary arc welding is used: when Operating the

carbon'.arc:torch; ........

Awide selection Of flame heats may be had by varying

the current and size of the carbon electrodes. Although the

actua| temperature of the arc remains :the Same for any

current setting, the vo|ume of transferable heat increases

with an increase in amperage. However; amperages in

excess of thosegiven below will only Causeshort carbon llfe.

1/4-in. Carbons................ 30 tO 40 amperes

5/16-in. carbonsL ........ ...40 to 65 amperes

3/8-1n. carbonS. ........... 65 to 90 amperes

-I]1 ii i II i

iFigure 2

[. , , ,,

RC TORCH

To pre|0are the torch for use, connect its two cables to the

ground and electrode cables of the welding machine.

Grounding of the work is not necessary as the operation of

the arc flame is entirely independent. With the thumb knob

or_the handle in the "off" posltion, insert two 3tS-inch car-

bon electrodes in the holdersand damp in place at approxi-

mately one-half their length (fig. 2). Do not clamp them

on or near the ends opposite from the arc as this will cause

overheating of the carbons. When tightening the clamping

screws, be careful not to apply too much pressure on the

carbons, as they are very brittle and break easily. Use only

enough pressure to hold them firmly in place, tf the tips

of the carbons do not line up with each other, an adiustment

may be made by turning the longest of the electrode holders

sllghfly; too much turning will loosen it, and make it neces-

sary to disassemble the torch to again tighten it properly.

Do not make any turning adjustmentswith the sliding holder

as this would spoil the contact tension in the switch.

To strike the arc, turn on the welding machine and set it for

approximately 70 amperes. Lower the welding helmet and

hold the torch up to silhouette it against the light of a win-

dow. Slowly move the thumb knob forward until contact

is made between the tips of the carbons, This will start the

arc. Then immediately move the knob back to increase the

gap between the carbons. The actua} distance can be deter-

minect with a little practice. When the carbon sare too close

the arc flame will have asharp crackling noise. As the

distance between the carbons is increased, the crackling

will change to a soft purring sound which indicates the best

arc flame. There are two heat zones and the small inner

zone is by far the hottest, having an estimated temperature

of 9000 degrees Fahrenheit (fig. 3).

The shape of the flame greatly influences the way in which

it must be used. Forexample: on beveled work the torch

should be held parallel to the groove so the flame will reach

the bottom (fig. 4). If held at right angles to the groove, the

flame straddles the groove and the heat will not reach the

bottom (fig. 5). Filler rods, as for gas welding, must be used

on joints of this type.

The soft, bushy flame is pressureless and has no tendency

to blow the molten metal. This is a distinct advantage when

welding thin sheet metal. Joints on light material should be

CORRECT FLAME POSITION

Figure 4

IIII! II1! III

,i ii

INCORRECT FLAME POSITION

Figure 5

I I I ,lit,,,,,,,,,,, ...... I

bent and edges fused together by melting down the excess

metal to form a bead (fig. 6). No filler rods are required.

The carbon-arc torch is ideally suited for brazing and

soldering small tubing.

Cast and mat_eable iron can be brazed with excellent

results. A bronze filler rod and common brazing flux are

used. Rust, paint or grease must be cleaned from the area

to be brazed. If it is a butt joint, such as a crack in a casting,

grind or chip out a beveled groove as for arc welding.

Apply the heat from the arc flame gradually by passing

it over the metat surrounding the ioint, When the casting

has become warm, concentrate the arc fiame at the ioint.

The important thing to remember when brazing cast iron

is never to heat the edges of the joint to the melting point.

The temperature of the work shoufd not exceed the melting

point of the filler rod. The carbons are held as close to the

work as possible without causing the meta_ to bubble. Hold

the filler rod in the left hand and heat the end of it slightly

by passing it through the arc flame. Then dip the heated

end in brazing flux. Raise the torch slightly and deposit

some of the flux at the part of the joint being heated. When

the surface of the heated metal takes on a shiny or wet

appearance, the filler rod can be applied.

Do not put the rod directly in _he flame, but hold it on the

work and let the heat of the edge of the flame and the work

melt the rod. Deposit only enough metal to fi!l the part of"

the joint that has been coated with flux. As the metal is

being deposited, move the torch along the joint slowly,

applying flux to the rod and joint as required.

Copper and copper-base alloys such as bronze and brass

may also be brazed, but as their melting temperatures are

so close to the melting point of the filler rod, the process

in many cases becomes one of welding rather than brazing.

A bronze filler rod and common brazing flux are used.

Most non-ferrous metals can be welded by manipulating

the torch and filler rod in the same manner as for brazing,

with the exception that the edges of the ioint are heated to

the melting point before depositing the filler metal. If the

work is a copper alloy, use common brazing flux. If it is an

....... ii ill i i .......... iiii

Figure 6

Figure 7

aluminum alloy, use aluminum flux. The filler rod should

be of the same analysis as the work. tf regular welding

rod is not available, strips of the parent metal may be used.

A back-up strip shoutd be used when weldlr_g thin material.

Small diameter carbons and low amperage setting are

used for soldering, The torch is held sothe work is just within

the visible edge of the flame. Apply the soldering flux and

play the flame over the work until it is just hot enough to

melt the solder. If the joint is to be sweat-soldered, tin the

surfaces to be ioined, then press them together and reheat,

adding more solder at the edges of the ioint.

One of the most practical uses of the arc torch is heating

metal for bending, forging, etc. Set the torch for a wide,

enveloping-type flame and apply the heat to the bottom of

the work (fig. 7). Since a red heat is nat visible through the

dark welding glass, the helmet must be raised periodically

so the work can be inspected to avoid overheating. To pro_

tact the eyes from the rays of the arc, hold the torch to

one side and above your head. The carbon-arc torch is

not recommended for welding mild-steel. However, it may

be used for brazing mild-steel if the metaf is too thin for

regular metallic-arc welding.

CUTTING

and other miscellaneous operations

CUTTING WITH THE ELECTRIC ARC

Arc cuffing is simply the continuation of a "'burn through"

such as you probably experienced when practicing with

light sheet-metal welding. When this action is accelerated

by using extremely high currents, it becomes an efficient

method of cutting metals. Although the edges of the cut

surfaces are not as smooth as when cut with a saw or

oxyacetylene torch, there are many cases where such pre-

cision is not required, Ordinary mild-steel welding rods

may be used. The current will vary with the type and thick-

ness of the material, In general, high currents i_crease the

speed of cutting but also increase the rod burn-off rate and

width of the cut.

START

CUT

HERE

Figure T

.v,..-MOLTEN IA_AL

STEEL

HTAIN£R

1.17

BOLT AND RIVET CUTTING

MOVeeOoUr ANO:--_....

OOWNVERTICALLY: _: .._o'>- ""

-_ f,_._ Removing rusty bolts Orrivets isan easy iob with an electric

_:: :,_ arc welder. The arc is struck on the head or nut of the bolt

i: ":" _ and worked around in a slight circular movement until the

_ ___,, __:I,_°_- .... _ head is completely melted off. (fig. 4). Apunch is then

i|/"_" \

"__L- t START

CUT

HERE

Used to drive out the remaining part. The bolt or rivet can

be removed by heating the head almost to the melting point,

then quickly shearing it off with a cold chisel. Care must be

taken not to cause the bolt to become welded to the metal.

HOLE PIERCING

Figure 2

TO make atrial cut, place a bar of steel approximately

1/4-inch thick on the table so that one end projects over

the edge. Use a 3/32-inch rod and a current setting of

around 140 amperes. Hold the rod as shown in figure 1 and

strike an arc on the top corner at the edge of the bar where

the cutis to be made. Feed the rod into the molten puddle

and keep the crater burning through as the rod is moved

acrossthe bar. To catch the molten metal, place a meta_

container on the floor directly under the cut.

when cutting metal heavier than 1/4-inch, the arc is started

atthe bottom €orner and worked Up and down vertically

aslshown in figure 2, advancing: the bottom of the cut

slightlyahead of the top Of the cut to permit molten metal

to run out more easily_ Ira smooth edge is desired, the

pieces carl be ground on an abrasive wheel Electrodes

designed especially for cuttir_g mc_yalso be used.

REMOVING:SEAMS

In addition to cutting; the electric weldlng arc can be used

for beveling the edges of material to be welded, gouging

out cracked welds for rewelding or removing tack_welds.

The surface of the metal being worked Upon should be ap-

proximately in the vertical position;or tipped slightiy toward

t_e arc (fig. 3). Start atthe bottom Ofthe:seam to b_ gouged

out and Work upward; The rate of speed Will depend Upon

the depth of the groove and the am0untof metal removed.

Another useful application of the welding arc is piercing

holes in metal. Coated metallic electrodes are best for

this purpose because of their small size and insulation

afforded by the coating. The process is extremely fast and

a surprisingly clean circular hole can be made. For practice,

place a piece of scrap iron 1/4-inch thick (or less) on the

table and altow it to proiect over the edge as for arc

cutting. Use a 3/32-inch rod and the same current as for

cutting. At the place where the hole is to be pierced, strike

an arc and hold it until a molten puddle is formed. Then

push the electrode down against the molten puddle and

force it through the plate. ]t is possibleto hold the electrode

against the melted plate because the metal core meffs off

faster than the coating. The coating (not the rod) touches

the molten metal (fig. 5), The gap maintained by the pro-

truding coating prevents the metal core of the electrode

from sticking or freezing to the plate.

Ifalarger diameter hole is desired, first pierce a hole as

described. Then, holding a fairly long arc, melt the edges

of the hole away by moving the rod around it (fig. 6). Holes

of almost any diameter can be mode. To pierce a hole

through material thicker than 1/4-inch, work from the

Onderside.

HEATING

The carbon arc provides a convenient method for localized

heating of all metals. Simply strike an arc on the part to be

heated and "play'" it across the surface until the required

temperatbre is reached.

Figure 3

IIIIi

I II pll r

UNTtL

IT BU_

THRO_H,_

Figure 5Figure 6

1.18

NOTES

1-19

NOTES

,,,,

q_q

1-20

W#ELDING ROD $PECIFmCATIONS

..... _"................ _ .................. -_ _: _ -- "";"'";'"'"_ i--

A% /S E-6011 MILD STEEL AC-DC

GENERAL APPLICATIONS: Farm Equipment e Sheet Metal • Car and Truck •

Body and Fender o Pipe e Tanks o Maintenance _ Jigs and Fixtures o Cabinets

• General Repairs oStructura_ Steel

SIZES AND HEATS (AMPS)

Diameter ....

Flat

Vertical

Overhead

! I I '

1/16" 3/32- !I8", 5/32" _ 3/16" t 7132"

20-55 I 20.80 75130 100-175 i t50-225 i 175.250

20-55 20-65 75415 I00-150 !

1t4-

200-375

SPECl F ICATIONS

Physical Properties of Deposited Metal: As Welded

"tensile Strength ................................. 70,000 to 75,000 psi

Yield Point ..................................... 60,000 to 65,000 psi

% Elongation in 2-inches ........................... 23% to 25%

Reduction in Area ................................ 50% to 55%

Stress Relieved

65,000 to 70,000 psi

55,000 to G0o000 psi

30% to 35%

65% to 75%

DESCRIPTION

The AWS E-601 1 is an AC-DC (reverse polarity} electrode with a special coating that provides strong

fluxing action for high quality welds, even in dirty, rust covered, galvanized or plated steels. An extremely

stabte, spray type penetrating arc, is produced that is easy to start and restart after interruption. It is a

versati;e electrode. It adapts to a wide variety of iobs due to the wide range of amperage settings at which

top quality results are obtained.

Features: Deeper Penetration Fast Freeze Puddle - Greater Arc Stability.

WELDING PROCEDURE; Weld with AC or DC (reverse polarityt. Strike the arc by brushing rod tip lightly

at the point where weld is tO be made. After the arc is established and weld material is deposited,

concentrate on holding a short arc that _sjust tong enough to keep the electrode from touching the molten

metal. In the fiat position, use a slight oscillating motion as you advance, In vertical position, on sheet steel

start at the top of the seam and weld down. This provides a more rapid speed of travel, lower penetration,

arid minimum warpacje. When welding overhead use a straight stringer bead or a circular motion. Keep the

molten pool as small as possible, Use smatl electrodes overhead, none larger than 5/32 diameter.

2-1

W E[01NGiRO:D SPECiFiCATiONS

AWS E-60131:Ni0LD STEi=L AC-DC

multi-purpose al! position

GENERAL APPLICATIONS: Farm Equipment eCar and Truck • Sheet Metalo

Pipe o Tanks - Boders •Structural Steel o Maintenance Re_)a_rs o General Repair

Work

SIZES AND HEATS (AMPS)

Diameter, ..... 5/64- 3t32" 1/8"" 5/32"' 3/1 6" 114""

i ' .......

Flat 20+55 20-75 75-130 100-175 150-225 200.375

Vertical 20-55 20-65 75+115 100-150 150-200

Overhead 20-55 20-65 75+115 100+150

SPECI FICATIONS

Physecal pfopert+es of Deposited Metal: As Welded

Tensile Siren gth ................................ 75,000 to 80,000 psi

Yield Point : .-.................................. 62.000 to 67.000 ps_

% Elongationin2-inches ........................... 20% to 29%

Reduction in Area +_ .............................. 40% to 55%

St reSS R et !eyed

65,000 to 70,000 psi

50,000 to 60,000 psi

27%to 35%

60% to 70%

DESCRIPTION

The AWS. E-60t3 isa general purpose mild steel elect+ode for use w_th AC or DC. tt produces a very stable.

easily handled arc thr0ugh0:Ut a wide amperage range: Th:e moderately penetrating and easily directed arc

providesexCeilent resuitsin ail positions fiat Wrticai 0roverhead) and is ideal for singIe pass horizontal

fiilet:welds_ as {he weld metal: solidifies quickly producing a closeIy ri ppled deposit w,th

good appearance.

Even though it is designed for production welding in mild steel fabrication, this rod is excellent for

mUlti-purpose use where So:un:ddurable welds are required.

The arc fs easily Started. even at: low amperage settings foi" ,light gauge steel, yet is stable at the high

amperages needed for higher Welding speeds and for heavier se_tiOns::

Use with AC o_ DC [see recommended amperages)+ Hold a short arc, lust !ong enough to keep the electrode

from touching the molten metal, tn flat position single pass fitlets or butt welds may be made with or

without weaving: Weld from bottom up on vertical welding of heavy sect+ons. Welding down on light

material or fiI]ets produces excellent results. Use 5i32+mch or smaller efectrodesfo_ overhead work, making

rather stringer or weaving beads.

2+2

VV'ELD0 G ROD SPECIFiCATiONS

HARD SURFACING AC-DC

medium chrome-carbon electrode

GENERAL APPLICATIONS: Tractor Grousers arrcl Rollers • Scraper Blades • Agri

cultural Implements • Plow Shares e Hitches • Power Shovel • Dipper Teeth and

Drive Sprockets e Coal Cutters o Conveyor Rolls e Mining Buckets o Rock Crushers

o etc.

Diameter .... _ 3/32"Amperes 55-85

SIZES ANDHEATS (AMPS)

118" 5/32" 3116"

100-130 t30-150 t75-200 7/32" { 1/4"'

t75-250 225-275

SPECl FICATIONS

Phys_cat Properties of Deposited MetaJ

As Welded Condition (Rockwell "C" 46_50} ........................................ 450-500 B_ineli Hardness

After C0ld Working (Rockwell "C'" 50-54) ......................................... 500-550 B_inell Hardness

DESCRIPTION

The Medium Chrome-Carbon rod is a hard-surfacing alloy steel electrode with a coating of powdered metals

and flux. When welding, this special coating combines in the arc with the steel core w,re to gwe an

extremely hard weld-metal deposit. Deposited weld metal requires no heat treatment for maximum

strength, ductility, and wear resistance. Annealing or heat treating will not soften the metal deposit, which

is not machinable, but may be hot for£ad to any desired shape. Deposited metal has a very fine grain and is

free of stag and porosity. The metal is tough and highly resistant to wear and impact.

The rod is designed for use with either AC or DC (either polarity). Hold a medium short arc and deposit the

metal with a weaving motion. Excellent welding results are obtained in either the verticat or flat position.

WELDING PROCEDURE: Grind the surface to clean and remove shallow cracks, rust, or other foreign

material. Cracks too deep to be removed by grinding should be gouged out with a cutting torch or cutting

rod. Use the "drag" technique to deposit weld metal, to thin edges when desirable or weave a wider bead,

or use a "free" arc.

2_3

ROD SPECIFICATmONS

AWS E.7014 CONTACT AC-DC

for welding of mild stee|

GENERAL APPLICATIONS: Sheet Metal Fabrication and Repairs • Machinery

Fabrication = Constr=uction EquDpment Repairs • Storage Tanks e Shipbuilding

Fabricating Structural Shapes and Heavy Equipment eEquipment and Heavy Pipe

Welding.

SIZES AND HEATS (AMPS}

: Diameter .... 1/16"

:: Length I 12"

Amperes

3/32"

t4"

90-1t0

I18" 5/32"

t4" 14"

t30-165 190-210

3t16" I t!4"

18" 1 18"

200-250 J250-350

SPECIFICATIONS

Physical Properties of Deposited Metal: As Welded

Tensile Strength .............................................................. 72,000 psi to 76,000 psi

Yield Point .................................................................. 60,000 psi to 69,000 psi

%EI0ngation in 2-inches .................................................................. 17% to 28%

DESCR IPTION

The AWS :E_r7014 iS an excellent electrode for the inexperienced or experienced welder. Starts on contact

w_Ih smooth'sUrge-flee arc, also restr_kes instantly. This Craftsman electrode has powdered iron in the

coating which:makes welding easier and faster. The slag is easy to remove in most cases self-peeling as the

weld €oolsl

Ideal for fikture welding where weld appearance and lack of spatter is imoortant. The amount of slag

::: permits use ir_alt wel:ding positions.

wELDING PROCEDURi_S}: _eldmaterials should be ctean, Best results are obta,ned when fit-up is good.

Either AC or DC current may: be used: When arc is established, deposit metal holding a short arc or place

electrode in do#tact with work:

2-4

WE m ROi NG D SPECaF,CATJONS

...., , , , , .... ,,, ,, . -

MACHmNABLE CAST IRON AC-DC

machineable welds on all cast irons

GENERAL APPLICATIONS: Cylinder Blocks eCrankcases ®Valve Seats eDefective

Castings • Gears eSprockets • Casting Repairs in General • Garages •Farms o Shops

SIZES AND HEATS (AMPS)

Diameter I 3/32" I

Amperes l 48-85 1118"

75-130

5!32"' l 3/t6"

100-150 I 130175 i

DESCRIPTION

This electrode uses anickel core wire, and produces a fully machinable weld without

pre-heating the casting, Cast irons can be joined to steel, nickel alloys and copper.

This electrode operates with AC or DC (_everse polarityl. It has very stable arc

characteristics.

It is recommended for automotive repairs, such as cylinder blocks, crank cases, valve seats

and other cast iron parts, In maintenance and repairs it is used on gears, sprockets, and

many farm machinery parts.

WELDING PROCEDURE: Remove a!l dirt and grease from work piece before starting to

weld, A cutting electrode may be used to burn a groove along the break where the weld is

to be made. This cutting electrode removes the grease and sca_e, and then seals m any oi!

soaked into the cast iron.

Use the _owest amperage that gives good fusion. During cooling, peen hammer the weld to

relieve strain and stress.

', ,_........... ' .... ._,_--- -,,_:;i:_...............

CUTTING ROD AC-DC

quick, inexpensive, easily cuts through all metals

GENERAL APPLICATIONS: Cutting o Piercing •Gouging e Scarfing *Beveling ,* etc.

SIZES AND HEATS (AMPS)

Diameter ...... 3/'32"

Amperes -AC 80150

Amperes BC ]50-250

-L 1/8'" i 5132" _ 3/16"

DESCRIPTION

For p_erong, gouging, cutting, and scarfing.

Excellent for removing old welds in preparation to rewelding. Also used for beveling

cracks in castings or removing sharp edges prior to welding, Needs no oxygen or special

eo,uJpme*_ to cut carbon steels, stainless steel, manganese steel, cast _ron, etc,

Recommended for the owners of all arc we_ders. AC or DC.

WELDING PROCEDURE: Ptace electrode in holders so that it's positioned like a lance in

_he direction of travel, The angle between the electrode and work metal should not

exceed 15 °. Strike arc at s_.artmg point. Push electrode along the line of cut, forcing the

molten metal ahead and away, tf deeper gouge is required, repeat procedure until the

desrred .d(,pth has be_:,n reached.

2_5

.... PARTS LIST FOR CRAFTSMAN AC 230 AMP/DC 140 AMP WELDER MODEL 113.201892

..-.---4O

32 \30 /

\_ 29

I26

I11

18 19

_20

24 25

PARTS LiST FOR CRAFTSMAN AC 230 AMP/DC 140 AMP WELDER MODEL 113.201892

Always order by Part Number -Not by Key Number

• •:i:i :¸¸

Key Part

No. No.

161435

2 61276

3 61424

4 60359

5 61350

6 61279

7 60325

8 STD601103

061335

61355

11 61356

t2 61334

13 --

14 61391

15 61347

17 61434

18 S']'D522510

19 61430

20 61428

21 61431

22 61432

23 61426

24 STD501102

25 61315

26 STD541006

27 S'TD551208

28 S-rD611007

29 60446

30 61433

Description

Cabinet, Top

Spacer

Pointer

Screw, Pan Rec. Type AB

No. 10 x 1-1/4

Knob Assembly

Bushing

Washer, 3/8 x 1-3/8 x 3/64

*Screw, Pan Rec. Type "T"

10-32 x 3/8

Bracket, Guide

Slide Assembly

Guide Assembly, Shunt

Spring

®Transformer

Pin, Guide

Shunt Assembly

®Choke Assembly

Suppressor Assembly

*Screw, Hex 1/4-20 x 1

Rectifier, 70 Amp 300 Volts

Lead

Rectifier, Reverse 70 Amp

300 Volts

Sink, Heat Right

Bracket, Fan

*Screw, Set Hex Cup

10-32 x 1/4

Blade Assembly, Fan

*Nut, Hex 6-32

*Lockwasher, External No. 8

*Screw, Pan Type AB

No. 10 x 3/4

Grommet, Screw

Sink, Heat Left

Key Part

No. No. Description

31 60444

32 STD541325

33 STD541025

34 61429

35 61314

36 STD611005

37 61470

38 STD551225

39 STD551010

40 51439

41 STD510607

42 447845

43 61295

44 30332

45 61171

46 61438

47 STD600603

48 61474

49 STD541008

50 61478

51 60362

52 i61115

53 61116

54 STD551025

55 61117

56 61475

57 STD510805

58 61423

59 L9-1321

60 STD522507

61477

-- 61351

Washer, Spring

*Nut, Hex 1/4-28

*Nut, Hex 1/4-20

Lead

Motor

*Screw, Pan Rec. Type AB

No. !0 x 1/2

Holder, Electrode

*Lockwasher, Internal 1/4

*Washer, 13/64 x 5/8 x 1/32

tClamp, Work

i*Screw, Pan Hd. 6-32 x 3/4

Screw, Type "T" 1/4-20 x 1/2

Cable Assembly, Electrode

Insulator, Plug

Plug, Selector

Cable Assembly, Work

*Screw, Pan Hd. Ty "T"

6-32 x 7/16

Cabinet, Bottom

*Nut, Hex 8-32

Switch

Relief, Strain

Block, Contact Mounting

Contact, Selector Plug

*Washer, 17/64 x 1 x 1/16

Block, Contact Mounting

Cord

*Screw, Pan Rec. 8-32 x 5/8

Block, Contact Mounting

tHeimet

*Screw, Hex 1/4-20 x 3/4

Owners Manual (Not lllus.)

Bag of Loose Parts (Not Illus.)

* Standard Hardware item -- May be purchased

locally.

1"Stock Item -- May be secured through the hard-

ware department of most Sears Retail Stores or

Catalog Houses.

® Not replaceable.

2-7

•:• I_IL

SERVICE

MODEL NO.

113.201892

HOW TO ORDER

REPAIR PARTS

Sold by SEARS,

Part No. 61477

AC 230 AMP/DO 140 AMP

TRRPLE RANGE

ARC WELDER

Now that you have purchased your arc welder, should a

need ever exist for repair parts or service, simply contact

any Sears Service Center and most Sears, Roebuck and

Co. stores. Be sure to provide all pertinent facts when you

call or visit.

The model number of your arc welder will be found on a

plate attached to your welder, at the rear of the cabinet.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE

FOLLOWING INFORMATION:

PART NUMBER PART DESCRIPTION

MODEL NUMBER

113.201892 NAME OF ITEM

AC 230 AMP/DC t40 AMP

ARC WELDER

Al! parts listed may be ordered from any Sears Service

Center and most Sears stores. If the parts you need are not

stocked locally, your order will be electronically

transmitted to a Sears Repair Parts Distribution Center for

handling.

ROEBUCK AND CO,, Chicago,

Form No. SP5081

IL 60684 U.S.A.

Printed in U.S.A. 3/87 : ii

Craftsman 113201892 User Manual TRIPLE RANGE ARC WELDER Manuals And Guides L0904586

CRAFTSMAN Welder Manual L0904586 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

Navigation menu

Versions of this User Manual:

Views

Navigation