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Craftsman 113.201392 Operating instructions

1. Figure 12 OVER LAPPED Figure 13 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 same 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 a light 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 well formed bead can be made with each size rod fig 14 Sheet metal up to 1 16 inch thick can be butt welded from BACK UP STRIP Figure 15 HOLD A LONG ARC ON UP STROKE ne QEPOSH METAL ON DOWN STROKE figure 17 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 welding The appecrance of a multiple pass horizontal weld can be improved by vertical down beads laid closely together Use a swift circular motion to the right slowly downward while welding fig 17 OVERHEAD WELDING Although overhead welding is generally considered diffi cult
2. 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 weld study it to find the cause of failure Corner welds are made on light sheet metal by running a single bead along the top after tack welding at three inch intervals to prevent warping fig 13 H numerous gaps are present a back up strip may be used On heavier metal two passes may be necessary and if the design permits a smaller pass can be laid on the underside Beveling may be used to advantage on the thicker metals 1 4 INCH 1 4 IN 1 4 INC DIRECTION 4 INCH any juar 1 4 INCH OF LOAD I Figure 5 i WELDS Both Sides BREAKING THE WELD Figure 4 this type should always be at least four times their size in length that is a 1 4 inch fillet weld should never be fess than one inch long The direction in which the load is applied to a weld greatly affects its strength which can be clearly demonstrated by breaking the weld fig 4 A joint so loaded should always 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
3. 2 Tack welds are small beads 1 4 to 3 8 inches 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 If the weld burns through in places reduce the welding cur rent or increase 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 a sound weld After laying a bead turn the work over and inspect the underside which should also have a smoli uniform bead 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 metal in the crater a chance to solidify fig 3 Butt welds on sheet metal hghter than 18 gauge should not be attempted by the beginner without the use of a 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 1 16 to 3 32 nch gap should be allowed between them fig 5 insert a wedge or screwdriver between the plates when tack welding fo main tain the gap then turn the piece over so the tack welds are on the underside Use enough current to melt edges of
4. with DC consequently it is usually necessary to touch the electrode to the work to start the arc For manual welding once the arc is started the electrode holder is held with the electrode positioned at an angle of about 75 degrees to the surface of the weld puddle as shown in figure 2 To start the welding the holder is usually moved in a small circle until a pool of molten metal of suit able size is obtained Once adequate fusion is achieved at any one point a weld is made by gradually moving the electrode along the parts to be welded to melt the adjoin ing edges progressively adding filler rod as required Solidification of the melted metal follows progression of the arc along the joint and completes the welding cycle Material thickness joint design and weld characteristics desired will determine whether or not filler metal should be added to the joints When filler metal is added during manual welding it is applied by hand feeding the filler rod from the side into the pool of molten metal in the region of the arc Filler rod ts added in essentially the same manner when welding by the oxyacetylene method 2 MOVE TORCH BACK 1 DEVELOP THE PUDDLE E DIRECTION WORK PIECE Figure 3 The filler rod is usually held at an angle of approximately 15 degrees to the work and slowly fed into the weld puddle One of the most commonly used techniques for feeding filler rod is shown in figure 3 Another method used most of
5. 55 65 to 75 DESCRIPTION The AWS E 6011 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 stable spray type penetrating arc is produced that is easy to start and restart after interruption It isa versatile electrode producing welds far beyond the requirements of its A W S classification It adapts to a wide variety of jobs 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 polarity 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 is just long enough to keep the electrode from touching the molten metal In the flat 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 and minimum warpage When welding overhead use a straight stringer bead or a circular motion Keep the molten pool as small as possible Use small electrodes overhead none larger than 5 32 diameter WELDING ROD SPECIFICATIONS AWS E 6013 MILD STEEL AC DC multi purpose alf position GENERAL AP
6. Before Welding 2 cece cee rena ees 14 Learn By Boing 4 aaa 1 5 Position Welding 0000 akon 1 11 Cast Iron Welding 0 ea aa aaa aaa 1 14 Hard Surfacing Worn Cutting Edges 1 15 The Twin Carbon Are Torch 1 16 Cutting and Other Miscellaneous Operations 1 17 Inert Gas Metal Are Wefding 45 1 19 Read this Manual carefully for additional welding information SEARS ROEBUCK AND COMPANY AND SIMPSONS SEARS LIMITED YOUR WELDER and what it willdo Your CRAFTSMAN Are Welder is a sturdily constructed and thoroughly tested machine engineered to give many years of efficient trouble free service It is fisted by Underwriters Laboratories incorporated which means that it passes all requirements of safety fire hazard and temperature rise limits as specified in their Standard for Transfer Type Arc Welding Equipment ELECTRODE Touches ELLEN EDE Special coating containing powdered iron forms a shell around wire core Core burns back from outside coating to keep proper Sap Easiest are welding method known a HOW THE 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 as the weld cools Spatter is almost non existent Craftsman Contact Electrode has an exceptionally
7. HEATS AMPS man ea a i 90m0 1301685 190210 Length Amperes Diameter O O ml gt amp S SPECIFICATIONS MEETS THESE American Welding Society Class E 7014 REQUIREMENTS American Bureau of Shipping Class 7014 Physical Properties of Deposited Meta As Welded Tensite Strength aerae pama nr raspa ka re 72 000 pst to 76 008 psi Yield Point eva ccc aaa oecaveea aka naaae one aaa nona sane a eas 60 000 ps to 69 060 psi Elongation in 2 inches 0 aaa eee okna ak o 17 to 28 DESCRIPTION The AWS E 7014 is an excellent electrode for the inexperienced or experienced welder Starts on contact with smooth surge free arc also restrikes 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 cools Ideal for fixture welding where weld appearance and lack of spatter is important The amount of slag permits use in ali welding positions WELDING PROCEDURES Weld materials should be clean Best results are obtained when fit up ts good Either AC or DC current may be used When arc is established deposit metal holding a short arc or place electrode in contact with work WELDING ROD SPECIFICATIONS MACHINABLE CAST IRON AC DC machineable welds on all cast irons GENERAL APPLICATIONS Cylinder Blocks Crankcases Valve Seats Defective Casti
8. a small pool of molten metal some of which is forced out by the blast of the arc and deposited along the weld path The depth of the crater thus formed is the distance the weld will extend into the base metal and is referred to as the penetration of the weld Some of the electrode which consists of a metal rod sur rounded by a flux coating is melted simultaneously with the base metal and is carried by the arc to the liquid pool This added metal combines with the base metal to form the deposited weld During 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 carried to the molten pool where it mixes with the metal to combine with various impurities lt 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 READ BEFORE WELDING SPECFAL LENS HELMET SWINGS UP TO CLEAR THE FACE 1 4 INCH STEEL PLATE GROUND WIRE BRUSH CABLE When operating a welder certain precautions must be taken to prevent minor injuries to yourself and others Although injuries may not be serious or per manent knowing how to use the protective equip ment to safeguard against them is the first step in learning to we
9. and gases 3 FLAMMABLE AND EXPLOSIVE MATERIALS a Remove flammable and explosive material at least 35 feet from the welding arc to prevent welding sparks or molten metal from starting a fire Keep a type ABC fire exunguisher within easy reach Welding on or near containers which hold combustibles can cause an explosion even when they have been cleaned For information purchase Safe Practices for Welding and Cutting Containers that Have Held Combustibles A6 0 65 from the American Welding Society 2501 Northwest Seventh St Miami Florida 33125 where parts or large areas of your body can be in c When not welding place the electrode holder where it contact with possible grounds is insulated from the work clamp work piece or Maintain the electrode holder work clamp welding work table Accidental grounding can cause cable and welding machine in good safe operating overheating of the cables and welder creating a fire condition hazard d Never connect the work cable or clamp to any object Do not use weiding electrode as a cigarette Inghter Connect the welder only to a source of electrical power meeting the requirements including grounding of the National Electrical Code ANS C1 and local codes Electrode coating may be electrically conductive use welding gloves when changing electrodes 2 EYE AND BODY PROTECTION a Use helmet filter and cover plate complying with ANSI 2871 to protect your eyes and
10. as for cutting At the place where the hole is to be pierced strike an are and hold it until a molten puddle is formed Then push the electrode down against the molten puddle and force it through the plate It is possible to hold the etectrode against the melted plate because the metal core melts 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 lf a larger 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 t fig 6 Holes of almost any diameter can be made To pierce a hole through material thicker than 1 4 inch work from the underside 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 temperature is reached Figure 5 INERT GAS METAL ARC WELDING Nonconsumable GROUNDED WORK PIECE ALL CABLES OR WORK TABLE MDA SHORT TO ELECTRODE AS POSSIBLE HOLDER Do not ex ceed 12 1 2 feet in length GROUND CLAMP HF ATTACHMENT WELDER GROUND CABLE GROUND i CABLE 230 VOLT sams 50 CYCLE SINGLE PHASE HIGH FREQUENCY WELDING CABLE TO WELDER ATTACHMENT Figure I HIGH FREQUENCY ATTACHMENT The Craftsman High Frequen
11. e Pead ond understand the manufacturer instructions sistant pides are NOT unbreakatie NE ee Sees a tee TE anc youremployer gt safety practices Pitted of suraicned mates reduce viSion SWS tees tele lt 7 and sengusly fete protection feplace immedialely 1 EE Inspect frequent and immediately er LE fepiace mmi of damaged parts ents rezziremenis ef ALLS ZBT t tee Ma ayo DO NUT REMOVE THIS LABEL REGARDING FiRE U Keon n ELE Keep your head out ot the fumes Us2 ensugh ventilation exhaust at the arc or got to keep tumes and uase lt eam your breathing cone and the general area Wear ccrrect eye ar and body protection Do not touch live electrical parts See American Mauondl tenaaru Z491 Safety on REGARDING EYE INJURY ra MET re Weldiic and utay puslohed by the a rencon te _ a Yeldinc Society 2501 M 7tk Sto ism Florida USE SNE ORAW wine TESE 43125 OSHA S fety anu Health Standacds 29CFR 1910 watable trom US Department of Labor LENS 40 295 30 260 I vashington DC 20210 AMP AMP DO NOT FEMU E THIS LABEL SHADE NO RANGE RANGE i WARNING ARC WELDING CAN BE INJURIOUS TO OPERATOR AND PERSONS IN WORK AREA READ AND UNDERSTAND OWNERS MANUAL BEFORE OPERATING WELDER FULL ONE YEAR WARRANTY ON CRAFTSMAN ELECTRIC WELDER If this Craftsman Electrie Weider fails to perform properly due to a defect in material or workmanship within one year from the date of purchas
12. from one end 3 Using the socketheed wrench supplied back out the Hex head set screw located near the end of electrode holder until the end of screw does not protrude into the wire socket in the end of holder 4 Make sure the wire strands on stripped end of electrode cable have not been frayed Twist together with fingers if necessary 5 Insert end of electrode cable into electrode holder and tighten the socket head set screw very firmly using the 1 4 Hex L Wrench furnished G Slide the handle back into place on electrode holder and position it until the hole in handle is directly over the head of handle locking screw Tighten the screw clockwise f GW just enough to secure the handle on electrode holder ATTACHING THE WORK CLAMP TO THE WORK CABLE 1 Attach the terminal on the end of the work cable to the work clamp 2 Do not use either of the holes in handie ends of work clamp 3 Tighten the screw firmly enough to insure good contact and prevent the cable terminal from slipping on the clamp 4 Remove octagon shaped electrica box from Loose Parts Bag Attach the box to the rear of the welder cabinet with the two sheet metal screws provided These screws must be tight Attach the ground terminal to the wall of the electrical box as shown ustng the 10 32 nut screw and lockwasher provided This connection must be tight CONNECTING WELDER TO POWER SOURCE CAUTION Do not attempt to connect this wel
13. good appearance With fine ripple unusually clean smooth appearance and reduced slag inclusions Craftsman Contact Electrode deposits more metal faster Because the powdered iron in the flux goes into the weld WHAT HAPPENS WHEN YOU WELD they melt and flow to gether forming one piece instantly 1 Both edges of the metal are heated hy the arc until 3 more molten metal and fills the crater and covers flux is added from the the top of the weld with rad which slag 5 This 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 orc then adding a sufficient amount of molten metal to provide reinforcement and fill any vacant space between the parts being joined as shown in the 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 welded The intense heat generated by the arc is ideally suited for welding as it can be directed to affect only the part of the metal to be welded Uniform heat from the arc is acquired by keeping its length the same for a given rod size and current setting At the instant an arc is struck a portion of the base metal directly beneath it is melted resulting in
14. it becomes an efficient method of cutting metals Although the edges of the cut surfaces ore 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 increase the speed of cutting but also increase the red burn off rate and width of the cut Za LTEN METAL STEEL CONTAINER Figure 1 MOVE ROD UP AND DOWN VERTICALLY ps eee Figure 2 To make a trial 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 red as shown in figure 1 and strike an arc on the top corner at the edge of the bar where the cut is to be made Feed the rod into the molten puddle and keep the crater burning through as the rod is moved across the bar To catch the molten metal place a metal container on the floor directly under the cut When cutting metal heavier than 1 4 inch the arc is started at the bottom corner and worked up and down vertically as shown in figure 2 advancing the bottom of the cut slightly ahead of the top of the cut fo permit molten metal fo run out more easily If a smooth edge is desired the pieces can be ground on an abrasive wheel Electrodes designed especially for cutting may also be used REMOV
15. 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 jobs can be done without pre heating this method will be considered first The part must be free of rust grease paint or dirt cleaned by wire brushing grinding or washing with solvent The crack should be beveled for penetration If the parts ore broken apart completely they may be ground on an abrasive wheel to a single 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 of the fractured surface to line up ihe two pieces Tack weld or clamp parts in position if the crack has not separated the casting a vee 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 cracked water jackets where only a seal is required the depth of the groove need only be one half 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 fong at one end of the crack and
16. peen it immediately with a cross peen hammer or blunt chisel 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 ete fig 1 Aliow 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 locked up stresses due to uneven cooling will cause the casting to fail after it is back in service Wire MISTER INDICATES SHARE HARO FACING HARD FACE OK UK ERSIDE BOTH SIDES CULTIVATOR SHOVEL CULTIVATOR SWEEP Figure 1 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 material is 1 4 inch thick or less use a 1 8 inch
17. released in a matter of seconds to avoid unnecessary heating of the welder or damage to the flux coating on the rod Figure 2 Should the rod stick or freeze bend it from side to side while pulling upward on the rod holder o Figure 4 Watch the weld puddle to keep the slag from flowing ine tront of it causing inciu sions and gas pockets To lay a weld head only two Movements are used down ward and in the direction the weld is to be laid If difficulty is experienced after repeated attempts to maintain an arc check the ground connection for proper contact with the work If this does not help increase the welding current Also check the red size as larger rods require higher current settings E Practice striking and maintaining an arc for a few seconds then snap it out by rapidly pulling the rod away from the work Repeat this operation until the arc can be started and the gap maintained as uniformly as possible in a short time you will find the arc length can be controlled by the crackling or frying sound which may be recognized by gradually shortening the arc until it sputters irregularly as though if were going to choke out and stick then slowly lengthening the arc by pulling the rod away from the work until it snaps out Somewhere between these two extremes the steady crackling sound of a proper arc length will be heard T
18. rod and as low a current as possible that will still permit the metal to flow out smooth and fairly thin 1 16 to 1 8 inch thick Weave the rod from side to side in a crescent shaped movement and de posit a bead about 3 4 to l inch wide Several passes laid side by side may be necessary where the worn sur faces are quite wide In some cases a small straight bead HARD FACING WORN CUTTING EDGES brush each bead before depositing the next Then continue to fill the groove with short weld beads as before working rapidly when depositing 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 cool 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 THIRD BEAD SECOND BEAD FIRST BEAL SORRA GRIND OFF WEAVE BEADS SOFT BASE METAL WEARS AWAY FASTER THAN HARO FACING 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
19. shape of the flame greatly influences the way in which it musi be used For example on beveled work the torch should be held parallel to the groove so the flame will reach the bottom fig 4 tf 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 INCORRECT FLAME POSITION Bre Figure 5 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 malleable 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 metal surrounding the joint When the casting has become warm concentrate the arc flame at the joint 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 should not exceed the melting point of
20. soldering welding 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 electrode hofders one of which is ad justable fo 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 built into the handle There are no valves or gauges that require fine adjustment as with an oxyacetylene torch The same protective equipment used for ordinary arc welding is used when operating the carbon arc torch A wide selection of flame heats may be had by varying the current and size of the carbon electrodes Although the actual temperature of the are remains the same for any current setting the volume of transferable heat increases with an increase in amperage However amperages in excess of those given below will only cause short carbon life 1 4 in carbons 5 16 in carbons 3 84n carbons 30 to 40 amperes 40 to 65 amperes 65 to 90 amperes CARBON ELECTRODES To prepare 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 on the handle in the off position insert two 3 8 inch car ben electrodes in the holders and clamp in place at approxi mately one half their length fig
21. views Move the rod at a steady even pace along the seam without ony side to side movement and deposit one inch of weld for each inch of rod melted The surface contour of a good weld 1 9 Figure 10 EXCESS WELD METAL SHEET METAL LAP WELDS gt Figure 14 Figure 15 should be nearly flat with a slight radius at the sides or toes Avoid excessive concave or convex surfaces of the fillet fig 7 Undercuts and cold laps are caused by not holding the rod in the center of the seam fig 8 If the desired fillet weld cannot be made with a single pass several passes are used to build it up to required size fig 9 Slag 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 fillet 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 in the vertical position particularly for small single pass welds where the work cannot be tilted For practice tack weld two pieces of scrap together to form a tee 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 length should be somewhat shorter than for flat fillet welding To assure penetration at the root use the highest welding current that can be hand
22. 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 foo much pressure on the carbons as they are very brittle and break easily Use only enough pressure to hold them firmly in place If the tips of the carbons do not line up with each other an adjustment may be made by turning the longest of the electrode holders slightly too much turning will loosen it and make t neces sary to disassemble the torch to again tighten it properly Do not make any turning adjustments with the siding 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 actual distance can be deter mined with a little practice When the carbons are too close the arc flame will have a sharp crackling noise As the distance betweer 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 ts by far the hottest having an estimated temperature of 9000 degrees Fahrenheit fig 3 The
23. 3 weld run a few practice beads to get the feel of the arc Tack weld a piece 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 plate laterally with the tip pointed up at 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 puddie can no longer be kept in place Then increase the speed slightly while watching the puddle arc length and angle of the rod A short arc provides better control of the molten metal Follow the same procedure with 3 32 and 5 32 inch rods H will be noted that the larger the rod the more difficult it is to contro the puddle For this reason smaller diameter rods are always used for position welding Lap or tee joints are made by simply directing the arc into the corner of the joint as in flat 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 light gauge material if this occurs continue until the seam is completed and patch the hole by chipping the slag and wire brushing until clean Then with slightly lower current st
24. EP COMBUSTIBLES CUT OF RANGE UF ELDING SFARK The name Duat Range arc welder is derived from the fact PE TRE MINIMUM UST ERR MOKIWA that your new arc welder is equipped with two separate welding ranges The beginner or less experienced welder will find the 30 200 amp range easier to use because it provides extra arc stability when welding with some of the more difficult to weld with specialty rods which are prone to pop outs The 40 295 amp range requires less line input current draw for any given amp setting and permits the use of the maximum amp settings with minimal effect on other electrical appliances motors and lights on your electrical system Either range may be used depending on operator preferences when the electrode diameter permits CONNECTING ELECTRODE AND WORK CABLES insert the tapered plug on the end of the electrode cable into the proper outlet jack depending on amperage required or operator preference To Insure a good electrical connection always twist the electrode plug slightly while inserting To remove the plug twist in the opposite direction while removing NOTE if you extend the welding cables beyond those already supplied they must be No 3 AWG or larger to avoid an undue drop in welding current Do not extend cables over 50 feet Connect the work clamp to the piece to be welded to complete the electrical circuit or to the welding table rtseif provided it is metallic or will
25. ING SEAMS In addition to cutting the electric welding 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 slightly toward the arc fig 3 Start at the bottom of the seam to be gouged out and work upward The rate of speed will depend upon the depth of the groove and the amount of metal removed Figure 4 BOLT AND RIVET CUTTING Removing rusty bolts or rivets is an easy job with an electric arc welder The arc is struck on the head or nut of the bolt and worked around in a slight circular movement until the head is completely melted off fig 4 A punch is then 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 Another useful application of the welding are 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 allow it to project over the edge as for arc cutting Use a 3 32 inch rod and the same current
26. Order Houses Transformer not replaceable poje konjo 295 AMP DUAL RANGE manua ARC WELDER SE RVICE Now that you have purchased your 295 amp 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 MO DEL NO The model number of your 295 amp arc welder will be found on a plate attached to your weider at the rear of the cabinet 113 201392 HOW TO ORDER WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE REPAIR PARTS FOLLOWING INFORMATION PART NUMBER PART DESCRIPTION MODEL NUMBER NAME OF ITEM 113 201392 295 AMP ARC WELDER All 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 Sold by SEARS ROEBUCK AND CO Chicago IL 60684 U S A Part No 61341 Form No SP4272 2 Printed in U S A 12 80
27. PLICATIONS Farm Equipment Car and Truck Sheet Metal e Pipe Tanks e Boilers Structural Steel e Maintenance Repairs General Repair Work SIZES AND HEATS AMPS se sar us see anme Flat 20 55 20 15 100 175 150 225 200 375 Vertical 20 55 20 65 160 150 150 200 Overhead 20 55 20 65 100 150 SPECIFICATIONS MEETS American Welding Society Class E 6013 THESE Military a 2 eae MIL E 15599C REQUIREMENTS amp MIL 6843A American Bureau of Shipping Class E 6613 Physical Properties of Deposited Metal As Welded Stress Relieved Tensile Strength 2 2 aa eee eee 75 000 to 80 000 psi 65 000 to 70 000 psi Yteld Pont naa nama 62 000 to 67 000 psi 50 000 to 60 000 psi Elongation in 2 inches a aa aasa ee een 20 to 29 27 to 35 Reduction in Area ooo aaan aa eee ee ww 40 ta 55 60 to 70 DESCRIPTION The AWS E 6013 ts a general purpose mild steel electrode for use with AC or DC It produces a very stable easily handied arc throughout a wide amperage range The moderately penetrating and easily directed arc provides excellent results m all positions flat vertical or overhead and s ideal for single pass horizontal fillet welds Spatter toss is low as the weld metal solidifies quickly producing a closely rippled deposit with good appearance Even though it ts designed for production welding in mild steel fabrication this rod is excellent for mul
28. Silver cladding Hard facing Cast iron Low carbon steel 0 015 to 0030 in t Low carbon steel 0030 to 0125 in High carbon steel 0 015 to 0 030 in High carbon steet 0 030 im and up Deoxidized coppert lt LALI LLLI LL ELA Where alternating Current is recommended as a second choice use about 25 higher current than that recommended for OCSP Do not use alternating current on tightly jigged parts 1 Use brazing flua or silicon bronze flux for 1 4 inch and thicker 1 20 WELDING ROD SPECIFICATIONS AWS E 6011 MILD STEEL AC DC GENERAL APPLICATIONS Farm Equipment Sheet Metal Car and Truck Body and Fender e Pipe e Tanks Maintenance Jigs and Fixtures Cabinets e General Repairs Structural Steel SIZES AND HEATS AMPS 5 32 1 3 16 Fiat 100 175 150 225 175 250 200 375 Vertical 100 150 150 200 Overhead 100 150 SPECIFICATIONS MEETS American Welding Society Class E 6011 THESE Military cscs e ae es ace cosa one pda MiL E 15599C REQUIREMENTS American Bureau of Shipping Class E 6911 Physicat Properties of Deposited Metal As Welded Stress Retieved Tensile Strength 24 ccc cece ne cere eer ee 70 000 to 75 000 psi 65 000 to 70 000 psi Vield Point ge s ap heaved ce ibaa seat 60 000 to 65 000 psi 55 060 to 60 000 psi Elongation in 2 inches 0 020 cece cece eee 23 to 25 30 to 35 Reduction in Area 0 eee cee eee eae 50 to
29. UCTIONS This Craftsman welder ts shipped complete in one carton In order to facilitate packaging certain items have been removed at the factory and must be assembled when received by the purchaser Remove ali tems from the carton and identify item as shown in the exploded view WELDER illustration These Loose Parts should be accounted for before discarding any packaging material LOOSE PARTS LIST Key No Part Name Welding Helmet Partially assembled Helmet band assembly Not Assembled Electrode cable assembly a Owners Manual Loose Parts Bag Containing the following items Electrode Holder wy ie 1 4 Hex L Wrench Work Clamp Electrical Qutlet Box Screw Pan Hd Ty AB No 10x 1 2 Outlet Box Cover da e Ground Terminal i Screw Pan Hd 10 32 x 1 2 Lockwasher No 10 Nut Hex 10 32 Connection Label NN TOOLS NEEDED a ws 7 16 inch wrench Screwdriver medium ATTACHING ELECTRODE HOLDER TO ELECTRODE CABLE 1 Grasp the electrode holder and locate the slotted head handle flocking screw near the mid point of the insulating handle Loosen this screw approximately two turns or until the handle can be slipped off the electrode holder DO NOT REMOVE THIS SCREW COMPLETELY 2 Slide the handle off electrode holder and insert end of electrode cable assembly through the handle The electrode cable is the one with insulation stripped
30. al fig 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 lop and tee jomnts Larger single pass fillet welds con 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 1 42 CORNERS OF Figure 10 weave fig 9 This will produce a shelf upon which additional metal is deposited intermittently as the welding progresses There should be a slight pause in the weaving motion at the toes of the weld 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 a wide 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 Hold a short arc making the bead approximately 3 4 inch wide and fairly light Multiple vertical welds may be made as shown in the series of diagrams figure 11 SZ me 1ST PASS
31. annot resist these forces and bends fig 22 The weld also contracts in width as well as in length tending to pull the plates together resulting in locked up stresses fig 23 This is not too serious when welding mild steel up to 1 2 inch 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 continuous welds 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 job with tack welds and install temporary braces tack welded to support parts that might bend The braces can be removed after the job is completed Lay the beads so the stresses will counteract or neutralize 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 place but space them to distribute the heat and stresses throughout the entire structure Use intermittent welds whenever possible If continuous welds are necessary to make a water tight compartment use the back step method as shown in figure 24 fusing each bead together at the end WELDING weld or the casting Because of low tensile strength and
32. conduct electricity OPERATING INSTRUCTIONS We feel that welding with your new Craftsman dual range arc welder is as ssmpleas 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 s for given thicknesses of metals You will note that a specific diameter of electrodes can be used on varying thicknesses of maternal This is accomplished by adjusting the heat selector for more or less amperage B Next verify the electrode diameter by placing the bare portion of the electrode into the electrode diameter gauge on the right side of the cabinet Because electrodes are mass produced there may be smali burrs on the bare end of the electrode Make sure the bare end of the rod is as clean as possible for accurate sizing Finally determine the type of electrode by the identification on the package or by the American Welding Society number stencilied on the coated portion of the electrode bearing In mind the type of electrode you have chosen 6013 or E7014 and also its diameter as previously determined Locate that band on the amp scale There are two E6013 bands and two E7014 bands use the band which coordinates with the amp range you have selected Now loosen the heat selector knob and move the pointer untif the fractional number matching your electrode diam
33. cy Attachment may be used with any Craftsman welder or other single phase trans former type welder of high quality construction having an AC or AC DC power output Tungsten inert gas T 1 G welding has many useful and advantageous applications as described in the following paragraphs In order to use the T G process with an AC welder a high frequency attachment must be provided Figure 1 shows a typical hookup using this high frequency attachment with a Crafts man welder When not using the T 1 G welding process the high frequency attachment also permits easy arc start ing and greatly improved results with many hard to weld rods low hydrogen rods as well as making the welding operation much easier to perform The use of a high frequency attachment makes possible the establishment of an arc without touching the electrode to the work Once the arc has been established it is stabilized by the high frequency output This is essential in the T I G process in order to avoid contaminating the tungsten elec trode or the work PRINCIPLES OF OPERATION The necessary heat for inert gas welding nonconsumable is produced by an electric arc maintained between the non consumable electrode and the work piece The electrode used for carrying the current is usually a tungsten or tungsten alloy rod The heated weld zone the molten metal and the nonconsumable electrode are shielded from the oxidizing effects of the atmosphere by a blanket
34. d base metal An extremely long arc causes the rod to melt off in globules with little or no penetration and a very irregular weld surface The are produces a hissing sound A good weld laid with correct current setting speed and arc length will produce a surface that is rippled uniformly with the same width throughout its length and well formed crater The cross sectional view shows it to have good pene tration and no undercut or overlap Figure 7 Figure 8 Lay the weld beads about one inch apart Remove the slag and examine each weld before starting the next A pad of weld metal is buiit up by running a series of heads in layers at right gt angles to each other CURRENT TOG LOW Arc is difficult to maintain Mall little penetration High CURRENT TOO HIGH Wide thin bead undercut Crater pointed and long Rod burns off very fast WN Si TRAVEL TOG SLOW Metal piles up making a wide heavy bead over lapped at sides in places Figure TRAVEL TOO FAST Smali bead undercut in some places Rough top and little penetration ARC T00 LONG Surface of weld rough Rod melis off in globules Are makes hissing sound NORMAL CONDITIONS Uniform ripples on surface of weld Arc makes steady crackling sound Practice laying beads approximately one inch apart until a good weld can be produced with all the different rod sizes the welder will handle fig 7 After becomin
35. der to a regular household outlet Make sure the power line voltage and frequency agree with PORE EL 197 GROUND BUSS powe ge quency ag IN POWER PANEL ratings shown on the selector plate attached to top of cabinet Electrical connections between the welder and 230 volt CONNECT so UOT WREDE single phase 60 cycle AC power source should be made by A SINGLE PHASE SYSTEM ONLY a qualified electrician All wiring must comply with the MAKE CONNECTIONS INSIDE National Efectrical Code ANS C1 and The Local OUTLET BOX AND Inora Electri f i PROPERLY IN ACCORDANCE WITH oa a LOCAL CODE INSTALL COVER 1 Install an individual separate line for the welder with a fuse block in the line For best results this circuit should be as short as possible The size of the leads will depend cycle in accordance with Article 630 of the National upon their length as shown in the table below Electrical Code ANSI C1 and may not be adequate for Supply Conductor Incl Extension Cords other loads Consult a qualified electrician before using for Upto 50 feet Se ina No 8 AWG Copper other loads Over 50 feet 0 2 2 eee le No 6 AWG Copper 2 Instalt 60 ampere fuses of the delayed action type such NOTE These conductor sizes are for use with a welder as Fustat or Fusetron in the fuse block having a rated input not more than 60 amps at 20 duty 3 Connect 230 volt power lines and ground as shown OPERATING CONTROLS Ee KE
36. 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 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 a straight line without any weaving or whipping 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 ap proximately 3 4 inch 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 i
37. e Sears will repair it free of charge Warranty service is available by simply returning 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 BSC 41 3 SEARS TOWER CHICAGO IL 60684 HEAT SELECTOR LOCKING KNOB MATERIAL THICKNESS GAUGE ELECTRODE DIAMETER GAUGE ON OFF SWITCH GETTING TO KNOW YOUR ARC WELDER DUAL RANGE OUTLET JACKS ELECTRODE CABLE AND ELECTRODE HOLDER WELDING HELMET WORK CABLE AND WORK CLAMP TABLE OF CONTENTS OPERATING INSTRUCTIONS Operating Controls 6 Safety Instructions to Operator 2 2 Operating Instructions T Warranty 5 3 Trouble Shooting 8 Getting to Know Your Welder 3 ARC WELD IT YOURSELF MANUAL 1 1 Unpacking and Check ine Contents 4 WELDING ROD SPECIFICATIONS 2 1 Assembly 4 REPAIR PARTS 2 5 Lo SPECIFICATIONS Weiding Range eee Hei 30 295 amps Primary Volts AC a eke a 230 Amps input Max D eid o ARGAE EPEAN 60 Fuse Required Delayed Action Type obs Ses 60 Phase ola deka dva Hert y Savka a e ei a nod Beet Ete ia 60 Open Circuit Volts Max anes ants Ae 80 Duty Cycle 0 aa ai aaa 20 to 100 Etectrode Capacity 1 16 thru 1 4 Over all Dimensions 21 x 14 x 15 UNPACKING AND CHECKING CONTENTS SET UP INSTR
38. e greatest benefits from your welder you should practice until you can make a welded joint in almost any conceivable position The ability to do this is especially 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 welding will be used the most and should be practiced first Skill gained in this type of weld 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 welded 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 position weld is keeping the molten metal in the puddle from falling out To prevent this the arc must be held as short as possible and the weld puddle kept fairly small so it will solidify rapidly Vertical down welding is the easiest to perform and is used on material up to 1 8 inch thick Before attempting a vertical VERTICAL Da WaR VERTICAL DOWN 52 ELECTRODES WELDING amp SHH ee DIRECTION Figure
39. edges at right angles to each other The size of such a weld is based on the leg length of the largest isosceles right 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 all dimensions under 3 16 inch and 1 16 inch from all over 1 4 inch fig 2 For example a 1 4 inch fillet weld should measure 5 16 inch This will offset any inaccuracy dve to the slight radius at the toe of the weld and allow for concavity of the bead When a fillet weld is stressed to its maximum capacity failure 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 weld Finished welds of Run the first pass on beveled plates with a 5 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 a straight 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 will completely cover preceding beads For the beginner the side to side movement with a slight hesitation at each end will produce a smooth top without undercut or overlap
40. eter appears in the pointer window Tighten the heat selector knob Insert the electrode cable into the proper jack depending on the range selected Connect the work clamp to the work Wear Welding Helmet Turn the On Off switch to the ON position and you are ready To weld Because metals vary in their make up and the technique of each operator is different you may find It necessary to increase or decrease the amperage output accordingly CAUTION Do not loosen and move heat selector while welding Bune The duty cycle ratings bracketing the amperage scales are minutes out of 10 minutes is a 60 duty cycle Tc aca provided for your convenience and protection of your new possible overheating of the welding transformer hr welder Duty cycle is the performance level of the welder could shorten the life of your welder Do Not exe tre based on a 10 minute time span For example welding for 6 duty cycles Usted an he nan entre TROUBLE SHOOTING WARNING REMOVAL OF THE WELDER CABINET TOP FOR ANY REASON MUST BE DONE BY A QUALIFIED SERVICE TECHNICIAN TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Fan and welder do not 1 Improperly fused or 1 Use 60 ampere fuses of the delayed operate or continually protected action type such as Fusetron or blow fuses Fustat or 60 ampere 240 volt circuit breaker 2 Blown fuse or open Replace fuse or reset the circuit circuit breaker breaker 3 ON OFF switch not ON Tu
41. face from sparks and the rays of the arc when welding or but the work piece or metal work table Connecting to other objects such as building ground can create a fire hazard 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 observing open arc welding b Before connecting the welder power cord to the receptacle check the followin Always wear safety goggles with side shields p i 9 complying with ANS 287 1 when in a welding area 1 Inspect the power cord and welding cables for cuts or when near slag chipping operation or burns and make sure blades and ground pin on Wear ol free protective garments such as leather the plug are straight gloves heavy shirt cuffless trousers and high shoes 2 Inspect On Off switch fever for cracks or broken Protect other near by personne with suitable parts non flammable screening 3 Inspect electrode holder jaw msulators for cracks Provide adequate ventilation in the welding area or broken parts particularly when welding on galvanized lead or c Never weid anything on or to the welder cabinet as a cadmium plated steel and other metal which produce burn through may cause transformer failure toxic fumes d For additiona
42. g pro ficient in running a 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 a pod approximately 1 2 inch thick has been built up This type of welding is used to build up round or flat 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 11 Clean off the slag after each bead then machine the shaft to proper size Figure 10 1 7 FLAT WELDING Figure 2 Flat welding includes all types of joints in which the weld is horizontai and the electrode is fed down 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 on light moterial should be practiced first on scrap stock Use 16 gauge mild steel sheet metal approxi mately 1 16 inch thick and 5 64 inch rods with the welder set at approximately 30 to 50 amperes Butt edges of metal together and tack weld approximately every three inches fig
43. iameter a more stable are at low current values and longer life with less deposit of tungsten in the welds TYPES OF GAS TO USE Either argon helium or a mixture of the two can be used with the T LG process Argon is used most frequently because 1 lt provides general suitability with a wide variety of metals 2 it mamtains a stabilizing influence on the welding arc 3 It costs less due to the lower flow rates required Helium is generally used when welding heavy metal sections because it provides greater weld penetration Mixtures of argon and helium are useful when a balance of these char acteristics is desired Argon is generally supplied in K cylinders having a capacity of approximately 238 cubic feet at a pressure of 2200 psi or in T cylinders having a capacity of approximately 330 cubic feet ot a pressure of 2640 psi Purity of commercial argon ranges between 99 95 and 99 99 Current Selection for Inert gas nonconsumable welding Magnestum castings Aluminum up to 332 thick Aluminum over 342m thick Aluminum castings Stainless steel Brass alloys Silicon copper Silver Magnesium up to wim thick Magnesium above M e in thick Alternating Current Stabilized Direct Current Straight Potarity Reverse Polarity Excellent Recommondeds Excallant Recommended Excellent Recommented Not 2 e Nat Se ZRELE lt lt lt LELE Kigh chromium nickel base high temperature alloys
44. l safety information purchase copies of When working above floor level protect yourself from a fall should you get a shock Never wrap the electrode cable around any part of your body Do not weld in locations close to chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat of the rays Practice for Occupational and Educational Eye and Face Protection ANS Z87 1 Safety in Welding and Cutting ANSI 249 1 and Fire Protection in Use of Welding and Cutting Processes ANSI NFPA No 51B from the American National Standards Institute 1430 Broadway New York N Y 10018 READ AND OBSERVE THE INSTRUCTIONS APPEARING ON THE WARNING LABELS FOUND ON THE INSIDE OF THE WELDING HELMET SELECTOR PLATE AND CABINET WARNING FOR YOUR SAFETY REGARDING 50 VOLT POTENTIAL SHOCK AT ELECTRODE Use onty for face and eye protection toute cer ele cE FOL oN eNe against My WOU rays from ze wading oe es AYER ua ed T Na r E a Te J PRE ot Tet a ar Lab t I vee E sm VARNING Protect yourselt and others Read and ang cultng Use proper shage fire understand thn label pate Impact resistant eye grolectan ra a sE FUMES AND GASES ean be dangerous to your health liter plale Bavk up plate of separate an E APC RA S can injure eyes and burn skin ELECTRIC Sately Spectacles snouki be worn SHOCK neil on anen using Iiis dence Impact re REGARDING POTENTIAL SHOCK ON CABINET
45. ld The effects of heat and light given off by the arc while electric welding may be compared to that of the sun s rays Even greater precautions are necessary for electric arc welding Before starting a weld caution anyone in the immediate vicinity against looking at the arc In case of accidental eye injury contact a physician immediately To protect the face and eyes a heat resisting fibreglass helmet is used The special lens 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 a tilting arrangement permits it to be swung up clear of rhe face When the welding is resumed a slight nod of the head tips the helmet down over the face To protect the eyes further while cleaning the weld goggles should be worn by the welder and others working around him Animals are also affected by the rays and should be kept at a safe distance To safeguard the hands against heat and weld spatter gauntlet type leather gloves should be worn A leather jacket will give betfer protection against the shower of 1 4 sparks than ordinary clothing High top shoes not oxford
46. led fig 11 Good penetration is of prime importance and appearance 3 10 UNDERCUT WW 9 SIS WELD ON BOTH SIDES AT END OF JOINT will come with experience If the arc is advanced too fast or held too close to the vertical plate undercutting may result fig 12 Too slow travel will cause overlapping and an extremely close arc or low current will produce a bead with a convex surface fig 13 To check the penetration and soundness of the bead break some of the welds for inspec tion as shown in figure 4 When making a lap weld care should be taken not to melt teo 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 are rapidly Welds of this type should be wider than they are high somewhat like a flat 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 pass with a 1 4 inch rod using a 295 ampere machine However with smaller machines the same weld or larger can be made by building up with a number of passes fig 16 When welding long narrow pieces stagger the welds in short intermittent beads first on one side then on the other side to minimize distortion fig 17 In order to derive th
47. metal cannot be filed or machined If shaping is required heat the weld metal and forge it Smoothing and sharpening can be accomplished by grinding For plow and lister shares cultivator shovels and similar cutting points deposit the weld metal on one side only which will result in a self sharpening edge fig 4 The softer base metal on the other side will wear away first ond 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 also be taken into consideration If the part requires a number of passes to bring it up to the desired thickness use mild steei welding 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 place with mild stee electrodes then hard faced fig 5 To prevent distortion when hard facing small parts peen the deposited weld metal before it cools THE TWIN CARBON ARC TORCH CARBON ELECTRODES CA ELECTRODE TIPS A C WELDER Figure 1 Work ordinarily done with a gas welding torch is possible with the twin carbon are torch connected fo an A C welder The carbon arc flame is similar to the Hame 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 welder for brazing
48. nch thick allowing a gap between them Burn in deep for good penetration with 1 8 and 5 32 inch rods varying the plate size and gap distances Figure 18 Figure 19 Fillet welds for lap or tee joints are most common in the overhead position Tack weld two pieces of scrap iron together to form a tee joint and clamp in the overhead position so one plate is held vertically fig 19 Hold the rod at angles indicated and deposit a light 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 3 13 Figure 20 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 fillet welds you will be able to make an overhead 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 on the end of a flexible shaft EXPANSION AND CONTRACTION Metals expa
49. nd when heated contract when cooled In arc welding the deposited metal and edges being joined are molten and the metal surrounding the weld is heated suf ficiently to cause expansion When the deposited metal solidifies it becomes a part of the plates but being unre stricted in its expansion in the molten state it tends to contract more than the heated surrounding metal If the i CAST t 2 2 gt ar mase po ee e e IRO Previous experience in handling the arc plus good judg ment regarding expansion and contraction will enable you to weld gray cast tron 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 a file soft weld that can be drilled or machined to close tolerances Non machinable rods are used for most repair jobs such as cracked motor blocks water jackets pump and gear hous ings etc If the weld must be made across a machined surface that need not be refinished to a close tolerance the face of the weld may be ground flush with an abrasive wheel As cast iron is very brittle care must be taken to control expansion and contraction and thus avoid cracking of the 1 14 N METAL BENDS WHEN COBLED DISTORTION TRENDS WHEN COOLING NEGO RC 232229 1933323227 G22323752 22229990 S E pyreci0n OF TRAVEL Figure 24 surrounding metal is free to move not clamped or tacked it c
50. ngs Gears Sprockets e Casting Repairs in General e Garages e Farms Shops SIZES AND HEATS AMPS Diameter 3y39 1 8 5 32 3 16 DESCRIPTION This electrode uses a nickel core wire and produces a fully machinable weid without pre heating the casting Cast irons can be joined to steel nickel alloys and copper This electrode operates with AC or DC reverse polarity tt 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 all 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 scale and then seals in any oil soaked into the cast iron Use the lowest amperage that gives good fusion During cooling peen hammer the weld to relieve strain and stress i CUTTING ROD AC DC quick inexpensive easy cuts through all metals GENERAL APPLICATIONS Cutting Piercing e Gouging Scarfing Beveling etc SIZES AND HEATS AMPS Diameter 3 32 Amperes AC 80 150 50280 DESCRIPTION 5 32 100 150 3 16 130 175 For piercing gouging cutting and scarfing Excellent for removing old weids in preparation
51. nob Bushing 3 8 x 1 Washer 3 8 x 1 3 8 x 3 64 Cabinet Top Nut Hex 1 4 20 Lockwasher 1 4 Internal Washer 17 64 x 47 64 x 1 16 Nut Hex 6 32 Screw Pan Hd 10 32 x 1 2 Ring Outlet Box External Cover Outlet Box Terminal Ground Bracket Guide Screw Type T Pan Hd 10 32 x 3 8 Slide Shunt Guide Shunt Spring Core Assembly Moving Transformer Assembiy Motor Bracket Fan STD 501102 61315 STD 551208 STD 541008 61264 61190 STD 551025 STD 522507 61342 STD 510805 STD 512507 STD 510607 61310 30332 61171 61086 61338 61269 STD 551010 61311 161115 161116 61117 61265 37435 61307 61341 Standard Hardware Item May be Purchased Locally Description Screw Socket Set 10 32 x 1 4 Blade Assembly Fan Lockwasher No 8 Ext Tooth Nut Hex 8 32 Holder Electrode Clamp Work Includes Key No 36 amp 37 Washer 17 64 x 47 64 x 1 16 Screw Hex Hd 1 4 20 x 3 4 Cabie Assembly Work Screw Pan Hd 8 32 x 9 16 Screw Sf Tr Hd 1 4 20 x 5 8 Screw M Pan Hd 6 32 x 3 4 Cable Assembly Electrode Insulator Plug Plug Selector Relief Strain Cabinet Bottom Switch Washer 13 64 x 3 4 x 1 32 Lead Primary Block No 2 Contact Mounting Contact Selector Plug Block No 1 Contact Mounting Helmet Wrench Hex 1 4 Bag Assembly Loose Parts Owners Manual not iHustrated Stock Item May be secured through the hardware department of most Sears Retail Stores or Catalog
52. o lay a weld bead only two movements are used a steady downward feeding of the rod to maintain the correct arc length and a slow travel in the direction in which the weld is to be laid fig 3 Watch the weld puddle and are length and move the rod steadily ina straight line as the back end of the crater fills up fig 4 The slight angle of the rod will keep the flux or slag flowing over the deposited weld metal to form a protective coating if the rod is moved too slowly the slag will flow in front of the puddle and be trapped in the weld producing inclusions and gas pockets 2 ao 5 Lay a bead approximately four inches long After allowing it to cool slightly remove the slag coating which covers the top of the weld by scraping along each edge of the weld with a cold chisel folowed by wire brushing until it is bright and clean 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 are length If the scrap plate used is small it will become very hot after laying a few beads This will alter welding conditions which could be very confusing to a beginner Have several scrap pieces handy so each may be allowed to cool before laying a second bead When starting with a new rod chip slag from the crater and strike the arc at the forward end as shown at A in figure 5 Then move
53. of inert gas fed through the T 1 G torch and the weld is made by applying the arc heat until the abutting edges of the work pieces are melted adding filler rod if necessary The resultant pool of molten metal upon solidifying joins the edges of the members together The process may also be used for adding metal to surfaces locally melting and spot joining parts A thorough cleaning of the surface to be welded is required ANY CRAFTSMAN WELGER MAY BE USED WITH HF ATTACHMENT WELDER CABINET MUST BE GROUNDED DIRECTION OF WELD AC OR DC WELDER Figure 2 All oi grease paint rust dirt or other contaminants must be removed either by mechanical means or by the use of vapor or liquid cleaners Files chisels and stainless wire brushes may be used Grinding s not recommended Liquid cleaners such as naphtha mineral spirits alcohol acetone and methyl ethyl ketone can be used All surfaces must be wiped dry with a clean cloth Cleaners should not be used after a joint is assembled prior to welding Striking the are may be accomplished as follows 1 Touching the electrode to the work momentarily and quickly withdrawing it a short distance DC power source 2 Use of an apparatus which will cause a spark to jump without touching the electrode to the work AC power source with high frequency unit attachment The high frequency are stabilizer provides for this latter method of starting the arc Such devices are not required
54. owners anual MODEL NO 113 201392 Serial Number Model and serial number may be found at the rear of the cabinet You should record both model and serial number in a safe place for future use CRAFTSMAN 295 AMP am DUAL RANGE sOi ARC WELDER rae assembly INSTRUCTIONS e operating carefully e repair parts Sold by SEARS ROEBUCK AND CO Chicago IL 60684 U S A Part No 61341 Printed a U Yo D ft SAFETY INSTRUCTIONS TO OPERATOR of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products For your own protection read and observe all instructions included in this manual as well as the following specific safety precautions 1 PROTECTION FROM ELECTRICAL SHOCK h a Do not iet bare skin or wet clothing come between Unprotected specators must be kept clear of the welding area due to the harmful nature of ultra violet and infra red arc rays welding sparks and welding the following combinations Electrode and Electrode Holder 1 Work Clamp Work Piece Metal Work Table 80 volts exist between these parts when welder is on Wear dry hole free clothing gloves and shoes to protect and insulate the body Take special care to insulate yourself from ground using dry insulation such as dry wood of adequate size when welding in damp locations on metal floors or gratings and tn positions such as sitting or lying fumes
55. plates to a depth 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 1 8 SLIGHT BACK UP STRIP Figure 4 a ED dh yy TA 1 t6 INCH E Sas wey ght Figure 5 D EDGES Figure 8 i e GAP FIRST PASS 2 X50 bovete vweLo THIRD PASS a_ Figure 9 REINFORCING PASS WEAVE 453 SINGLE BEVEL WELD Figure 10 4 PASS BUTT WELD over and weld a similar bead on the other side fig 7 A higher welding current can be used on this side as there ts 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 295 ampere machine using 1 4 inch rod the same results can be obtained with the 180 and 230 ampere machines if edges 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 top of the other until the groove is completely filled If the plate can be welded from both sides always use a double bevel fig 9 If only one plate is beveled the angle should be at 45 de grees fig 10 UNDERCUT GAS POCKET TRAPPED SLAG INSUFFICIENT PENETRATION Figure H Figure 13 FILLET Fillet welds are used to join two pieces of metal with sides or
56. rike an arc on the weld directly above the hole and quickly bring the rod down to the lower rim of the hole to deposit a small 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 If this happens repeatedly lower the welding current Leave a slight gap between pieces for butt welds on material over 3 32 inch thick Inspect the back side after welding for small bead along 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 ON BACK SIDE INDICATES COMPLETE PEHETRATIOH LONS ARE AT TOP OF STROKE wpm MOTION VERTICAL UP WELDING Figure amp 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 1 4 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 down welding but tilted just slightly approximately five degrees so the tip of the electrode point
57. rn switch ON Welding current low 1 Low line voltage Have a voltage check performed by or weak the local power company 2 Welding current Check current recommended for setting too low the electrode betng used 3 Poor connections Check electrode holder work and electrode cable connections Can t hold an arc 1 Using a D C welding Use AC or AC DC rods rod 2 Low hydrogen rod Use rod of 3 16 inch maximum diameter or smaller on 30 200 amp range or lower SERVICE TIPS FAN MOTOR No provision has been made for lubricating the fan motor as extra large oil reservoirs provide lubrication for the life of the motor SELECTOR PLUGS OR CONTACTS WARNING BE POSITIVE YOU HAVE DISCONNECTED THE POWER SUPPLY TO THE WELDER DO NOT REMOVE CABINET TOP OR SELECTOR PLATE If for any reason the selector plugs or mating contacts become burned or pitted they should be cleaned witha fine grade of emerycloth or dressed very lightly with a fine file Form No SP574 4 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 1 3 amp si Gre REA Te my Ra Te 3 id F fiata re pe Vode ZL RS LA ETO TABLE OF CONTENTS Page Your Welder and What It WilDo_ a 1 3 How the Craftsman Contact Rod Simplifies Welding 1 3 What Happens When You Weld 1 3 Read
58. rome Carbon rod is a hard surfacing alloy steel electrode with a coating of powdered metals and flux When welding this special coating combines tn the arc with the steel core wire to give 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 forged to any desired shape Deposited metal has a very fine grain and s free of slag and porosity The metal ss tough and highly resistant to wear and smpact The rod ts 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 vertical 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 24 WELDING ROD SPECIFICATIONS AWS E 7014 CONTACT AC DC for welding of mild stee GENERAL APPLICATIONS Sheet Metal Fabrication and Repairs Machinery Fabrication Construction Equipment Repairs e Storage Tanks Shipbuilding Fabricating Structural Shapes and Heavy Equipment e Equipment and Heavy Pipe Welding SIZES AND
59. s should be worn If a great deal of welding is to be done foundrymen s shoes are best Precautions must also be taken to protect property and equipment against fire A large fire extinguisher should be within easy reach The welding area should have a concrete or cinder floor kept dry and clear of inflammable rubbish Sometimes it is necessary to weld close to a fuel tank If practical remove the part to be welded If not drain the tank and completely fill it with water Few tools in addition to those supplied with the welding machine are needed and most of them can be found in the average shop Two sawhorses supporting a 1 4 inch steel plate makes an excellent welding table A permanent bench using the same steel plate can be made of angle iron or pipe A chipping hammer is used to clean slag off a weld and pliers will be useful for handling hot metal A wire brush ts used to clean the work before welding and remove small pieces of slag after chipping Small pieces of mild steel scrap iron reasonably free of rust and paint should be used for practice welding Angle iron bar stock or plate steel are good examples Do not use scrap cast iron high carbon or hardened steel as these metals require special electrodes and welding techniques These should be set aside for future practice after com pleting elementary practice lessons LEARN BY DOING Experience has proven that short periods of practice at regular intervals are
60. s the work If regular welding rod is not available strips of the parent metal may be used A back up strip should be used when welding thin material Small diameter carbons and low amperage setting are used for soldering The torch is held so the 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 joined then press them together and reheat adding more solder at the edges of the joint One of the most practical uses of the are 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 not visible through the dark welding glass the helmet must be raised periodically so the work can be inspected to avoid overheating To pro tect 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 metal is too thin for regular metallic are welding CUTTING and other miscellaneous operations CUTTING WITH THE ELECTRIC ARC Arc cutting 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
61. s upward Strike and hold a short arc until a smali amount of metal is deposited then quickly raise the rod upward with a wrist movement 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 a long are is to prevent any metal from being deposited except when the rod is held at the crater If globules of molten metal drop from the tip of the rod when the arc is lengthened either the current is too high or the rod has remained away from the crater too long Care should be taken not to break the arc at the top of the stroke Do not deposit too much metal at one time as this will 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 a butt weld using the whipping motion Leave a gap between the plates and use a 5 32 inch rod with a fairly high current determined by experimenting The whipping motion will melt the corners of the plate and form a pocket in which to deposit the weld met
62. strike an arc scratch the end of the rod on the plate and then quickly raise ap proximately 1 8 inch first attempting to weld Insert a small miid 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 1 8 inch gap between the rod and the work will start an arc The easiest way for a beginner to strike an arc is io scratch the tip of the rod a short distance on the surface of the work as you would a match then lift it quickly the re quired 1 8 inch fig 1 Another method is to strike the work a hard blow with the tip of the rod and allow it to bounce up to form the are gap The important thing is to strike the arc quickly and not allow the rod to remain in contact with the work A common mistake often made by a beginner is to point the rod toward the work and after lowering the helmet feel 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 hoider fig 2 H this fails turn the welder off The electrode must be
63. ten in multiple pass welding of vee joints is to press the filler rod into the vee groove in line with the weld and melt it along with joint edges Still another method used fre quently in making large welds is to feed filler metal con tinuously into the weld puddle by oscillating the filler rod and arc from one side of the weld to the other The filler rod moves in one direction while the are moves in the opposite direction buf the filler rod is at all times in close proximity to the arc and feeding into the weld puddle Joints may be welded by the T 1 G process include all standard types such as square abutting edge vee butt tee and fap connections It is seldom necessary to bevel edges of material 1 8 inch or less although heavier materials are usually beveled Whenever joints are beveled filler ma terial must always be added The accompanying table provides a guide to the type of current recommended for welding some typical materials Electrodes used for the T 1 G nonconsumable process may be pure tungsten or tungsten alloy Pure tungsten electrodes were formerly used exclusively At this time however mony 3 ADD FILLER METAL a 15 gt ADDITION OF FILLER METAL VERTICAL POSITION 5 MOVE TORCH 2 TO LEADING EDGE OF PUDDLE DIRECTION OF WELD electrodes are alloyed with small percentages of thorium or zirconium Such electrodes have the advantage of greater current carrying capacity for a given d
64. the best way to teach yourself how to weld As learning to weld is simply a process of trial and error all practice work should be done on scrap metal that can be discarded Do not attempt to make repairs on valuable equipment until you have satisfied yourself that your practice welds are of good appeorance 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 lack of control Sit on a low stool and grasp the electrode holder in one hand with the cable drawn across the lap Allow enough slack to move the holder freely and yet keep the weight and drag of a long length of cable from becoming tiring The ground connection is as much a part of the welding circuit as the cable and electrode holder A poor ground connection can render the best welding equipment ineffi cient When using a table with a steel top fasten the lug of the ground cable to it securely with a bolt or C clamp so that any piece of iron placed on the table top will be properly grounded If a steel table is not used connect the ground cable directly to the work with a ground clamp or bolt Select a fairly large piece of steel plate approximately 1 4 inch thick and clamp it to the table top to prevent it from lifting should the electrode stick or freeze when Figure 1 To
65. the filler rod The carbons are held as close to the work as possible without causing the metal 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 the 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 fill 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 joint 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 aluminum alloy use aluminum flux The filler rod should be of the same analysis a
66. the rod to B and back to C at about twice the normal rate of travel to give the rod and base metal time to heat up for proper fusion 16 Figure 6 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 To widen the bead work the rad from side to side slight ly with a slow zigzagging crescent shaped motion After laying a number 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 hissing sound and the rod becomes red hot before it is half used If travel is too slow it will pile up a wide heavy bead with good penetration but with overlap of the weld metal on sides without fusion A large area surrounding the weld is heated to a 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 melte
67. ti purpose use where sound durable welds are required The arc is eastly started even at low amperage settings for light gauge steel yet is stable at the high amperages needed for higher welding speeds and for heavier sections Use with AC or DC see recommended amperages Hold a short arc just long enough to keep the electrode from touching the molten metal In flat position single pass fillets or butt welds may be made with or without weaving Weld from bottom up on vertical welding of heavy sections Welding down on light material or fillets produces excellent results Use 5 32 inch or smaller electrodes for overhead work making either stringer or weaving beads 2 2 WELDING ROD SPECIFICATIONS HARD SURFACING AC DC medium chrome carbon electrode GENERAL APPLICATIONS Tractor Grousers and Rollers e Scraper Blades e Agri cultural Implements Plow Shares e Hitches e Power Shovel Dipper Teeth and Drive Sprockets e Coal Cutters Conveyor Rolls e Mining Buckets Rock Crushers o etc SIZES AND HEATS AMPS Diameter 3 32 1 8 5 32 316 7 32 1 4 Amperes 55 85 100 130 130 150 175 200 175 250 225 275 SPECIFICATIONS Military ia za MIL E 19141C REQUIREMENTS Physical Properties of Deposited Metai As Welded Condition Rockwell C 46 50 2 2 2 ayaa 3 450 500 Brineit Hardness After Cold Working Rockwell C 50 54 Suits haa ter Reje ele 500 550 Brinell Hardness DESCRIPTION The Medium Ch
68. to rewelding Also used for beveling cracks in castings or removing sharp edges prior to welding Needs no oxygen or special equipment to cut carbon steels stainless steel manganese steel cast iron etc Recommended for the owners of all arc welders AC or DC WELDING PROCEDURE Place electrode in holders so that it s positioned like a lance in the direction of travel The angle between the electrode and work metai should not exceed 15 Strike arc at starting point Push electrode along the line of cut forcing the molten metal ahead and away If deeper gouge is required repeat procedure until the desired depth has been reached Amperes 48 85 75 130 100150 130 175 in REPAIR PARTS PARTS LIST FOR CRAFTSMAN 295 AMP ARC WELDER MODEL 113 201392 9 Y x i z l6 i6 e3 i me a ka A x s u Q k Gi i Ps i eo lt 5 52 es 2 37 20 2 6 OOO U Boon gt PARTS LIST FOR CRAFTSMAN 295 AMP ARC WELDER MODEL 113 201392 STD 541110 STD 551210 STD 611005 61339 61276 STD 551008 STD 511110 61300 61278 61279 60325 61280 STD 541025 STD 551225 STD 551025 STD 541006 STD 511105 37525 37526 30298 61335 STD 601103 61332 61333 61334 61385 o 61314 61302 Always Order by Part Number not by Key Number Description Nut Hex 10 32 Lockwasher No 10 Internal Screw Type AB Pan Hd No 10 x 1 2 Plate Selector Spacer Washer 3 16 x 3 8 x 1 32 Screw Pan Hd 10 32 x 7 8 Pointer K

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