MODEL N_ ° 113.201372 _ Serial Number Model and serial number may be found at the rear of the cabinet. You should record both model and serial number in a safe place for future use, 230 AMP DUAL RANGE ARC WELDER CAUTION: Read ® assembly SAFETY UNSTRUCTIONS e operating carefully ® repair parts Sold by SEARS, Part No. 61337 ROEBUCK AND CO., Chicago, IL 60684 U.S.A.
SAFETY gNSTRUCTIONS TO OPERATOR For your own protection, read and observe all instructions included in this manual as well as the following specific safety precautions: 1, PROTECTION FROM ELECTRICAL hydrocarbon vapors coming from degreasing, cleaning, or spraying operations The heat of the rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products SHOCK a_ Do not let bare skin or wet clothing come between the following combinations: h Electrod
READANDOBSERVE THEINSTRUCTIONS APPEARING ONTHEWARNING LABELSFOUNDONTHEINSIDE OF THEWELDING HELMET, ANDONTHESELECTOR PLATE, CABINET ANDELECTRODE HOLDER.
SPECIFICATIONS Input Volts (AC): ........... Hertz (Cycles): ................ Output Amperage: ........ Rated Short Input Amps: Circuit Input ............... Amps: ......... UNPACKING SET-UP Fuse or Circuit Breaker Required: ......... Arc Voltage: ............... KVA: .................... KW: ...........................
_i_i ii _' _ i 6 Slide the handle back into place on electrode holder and position it until the hole in handle is directly over the head of handle locking screw Tighten the screw clockwise @ just enough to secure the Inandle on electrode holder ATTACHING THE WORK CLAMP TO THE WORK CABLE SCREW 1.
OPERATnNG CONTROLS _TAL The name "dual range" arc welder is derived from the fact that your new arc welder is equipped with two separate welding ranges, The beginner or less-experienced welder will find the 30-140 amp range easier to use because it provides extra arc stability when welding with some of the "more difficult to weld with specialty rods" which are prone to pop-outs The 40-230 amp range requires less line (input current) draw for any given amp setting and permits the use of the maximum amp set
OPERATING RNSTRUCTIONS We feel that welding with your new Craftsman dual range arc welder is as simple as A B C A Determine what diameter electrode should be used by gauging the piece to be welded on the material thickness gauge The fractional number directly beneath the bar chart dictates what the proper electrode diameter is for given thicknesses of metals You will note that a specific diameter of electrodes can be used on varying thicknesses of material.
TROUBLE SHOOTING WARNING: Removal of the welder cabinet top for any reason must be done by a qualified service technician. TROUBLE TROUBLE Fan and welder do not operate, or continually blow fuses. Welding current low or weak, Can't hold an arc. PROBABLE SHOOTING CAUSE CHART SUGGESTED REMEDY 1. Improperly fused or protected_ 1. Use 50 ampere fuses of the delayed action type such as "'Fusetron" or "Fustat" or 50 ampere 240 volt circuit breaker.
f A COMPREHENSIVE GUIDE FOR YOUR NEW CRAFTSMAN ARC WELDER AND WHAT iT W_LL DO CONTAINS: INFORMATION o VARIOUS o USEFUL ABOUT TYPES OF RODS ACCESSORIES TIPS ON CUTTING, AND BRAZING WELDING ,,,J Form No SP574-4 1-]
IJELD gT Y©U SELF TABLE OF CONTENTS Page Your WelderandWhat It Will Oo ............. 1-3 How the CraftsmanContactRodSimplifiesWelding 1-3 What HappensWhenYou Weld? .............. 1-3 ReadBeforaWelding ....................... 14 LearnBy Doing .......................... 1-5 PositionWelding ......................... 1-11 Cast-IronWelding ........................ 1-14 HardSurfacingWornCutting Edges .......... 1-15 TheTwin CarbonArc Torch ............... 1-16 CuttingandOther Miscellaneous Operations ..
YOUR WELDER and what it will do = °. Your CRAFTSMAN Arc Welderis a sturdilyconstructedend thoroughlytestedmachineengineeredto give many years of efficient trouble-free service.
READ 5EFORE WELDI NG When operating a welder, certain precautions must be taken to prevent minor injuries to yourself and others, Although injuries may not be serious or permanent, knowing how to use the protective equipment to safeguard against them is the first step in learning to weld_ The effects of heat and light given off by the arc, while electric welding, may be compared to that of the sun's rays_ Even greater precautions are necessary for electric arc welding.
LEARN BY DOBNG I 90 OFWELG OIRECTiON Experience has proven that short periods of practice at regular intervals are the best way to teach yourself how to weld. As learning to weld is simply a process of trial and error, all practice work should be done on scrap metal that can be discarded. Do not attempt to make repairs on valuable equipment until you have satisfied yourself that your practice welds are of good appearance and free of slag or gas inclusions.
Figure 3 To lay a weld bead only two movements are used, dowfiward and in the direction the weld is to he laid.
CURRENTTOO LOW Arc is difficult to maintain. Vurylittle peflctrationHigh bead, TRAVELTOO FAST Small bead undercut in some places. Rough top and little penetration CURRENTTOO HIGH ARC TOO LONG Wide thin bead, undercut, Crater pointed and long, Rod hurns off very fast, Surface of weld rough Rod melts off in globules Arc makes hissing sound. TRAVELTOO SLOW NORMAL CONDITIONS Metal piles up.
FLAT WELDING SLIGHT / / GAP / , St;EEl" METAL k___J\ Figure TACK • Figure BACK-UP STKIP 4 3 WELOS REINFORCEMEHT Flat welding includes all types of joints in which the weld is horizontal, 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 llght material should be practiced first on scrap stock_ Use 16-gauge mild steel sheet metal (approxi= mately 1/16-inch thick) and 5/64-1ech rods with th
Run the first pass on beveled plates with a 5/32-1rich rod and use as high a current as you can handle to obtain a small bead on the underslde_ 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 la_d by moving the rod in a straight llne with no weaving or slde-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.
ROD SIZE UNBERCUT f _P _,,-CENTER _OF SEAM Figure 8 Figure 9 Figure Figure 11 10 INTEBMII_ENT WELOS I'_ !EXCESS BLA Figure 13 Figure 16 STAGGERED INTERMITTENT WELOS Figure 17 LAPWELDS Figure 14 LAPWELDS 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 colddaps are caused by not holding the rod in the center of the seam (flg_ 8)_ if the desired fillet weld cannot be made with a single p
_i_ _¸ _ POSMTION BUTT WELD in order to derive the greatest benefits from your welder, you should practice until you can make a welded iolnt in almost any conceivable position.
VERTICAL*UP 90° WELOIHG Figure Figure 9 6 4", J Figure Use 1/8 and 5/32-1nch 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 vertlca_ 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 points upward.
_/_ Figure UHRERCUT Figure 12 DEPOSITMETAL OH GOWHSTROKE OVER-LAPPED Figure HORIZONTAL 14 13 I]ACI(-Up STRIP Figure WELDING Horlzontal welding refers to one type of butt weld between two plates in a vertlcal 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 vertlcal-down welding and hold the rod as indicated with a short arc. Move the rod in a straight line and deposit a light bead.
METAL BENDS WHEN COOLED DISTORTION Figure 22 WHEN TRENOS COOLING Egff W[LO [RtH F Y_LO Figure 23 Figure 20 Figure Figure To simulate actua! 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.
of the fractured surface to line up the 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 dlamond-polnt 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 sea! is required, the depth of the groove need only be one-half the thickness of the casting.
To prepare the torch for use, connect its two cables to the ground and electrode cables of the welding machine.
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 red 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
BOLT AND MOVERODUPANO--_. DOWN VERTICALLY _:..., ,_ --' _" 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.
mNERT-GAS METAL-ARC WELDING (Nonconsumabne) GROUNDED WORK PIECE ANYCRAFTSMAH WELDER ALLCABLES ORWORK TABLE MAYBEUSED WiTHHF, SHOULD BE / ATTACHMENT KEPT SHORT TOELECTRODE / ASPOSSIBLE HOLDER / GROURB CLAMP (Donotexceed12-f/2 feet[nlength) [] D O_ _/\ K.F.
THE PUDDLE DIRECTION (1) DEV_.LOP OF WELD"._ (2) MOVE (3) ADD TORCH TILLERMETAL '_ _,/,//////////,',/,/,,'/,,////,,/ _/27_ _///I/I///f////////////J f WOREPIECE (5) MOVETORCH TO LEADING EDGE_ (4) REMOVE ROD OT POD L /7 ADDITION OF FILLERMETAL (VERTCAL POSITIO_ -_s°'_ I _////////////_;///////////_/_ 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.
WELDgNG RGD AWS E-6Gll $PEC FmCATmONS MILD STEEL AC-DC GENERAL APPLICATIONS: Farm Equipment o Sheet Metal o Car and Truck • Body and Fender = Pipe o Tanks o Maintenance o Jigs and Fixtures o Cabinets o General Repairs oStructuralSteel SIZES AND HEATS Diameter ....
AWS E-6013 MBLD multi-purpose STEEL AC-DC all position GENERAL APPLICATIONS: Farm Equipment o Car and Truck o Sheet Metal o Pipe o Tanks e Boilers = Structural Steel o Maintenance Repairs o General Repair Work SIZES AND Diameter 5/64'" 20-55 20-55 20-55 ...... Fiat Vertical Overhead 3/32" 20-75 20-65 20_65 HEATS (AMPS) 118" 75-130 75-115 75-115 5/32" 100-175 100.150 100-150 3/16" 150-225 150-200 1/4" 200"375 SPECl FICATIONS MEETS THESE REQUIREMENTS _) Physical Properties Military ........
WELDWNG ROD HARD SPECIJFICATiONS SURFACING medium chrome-carbon AC-DC electrode GENERAL APPLICATIONS: Tractor Grousers and Rollers o Scraper Blades o Agricultural Implements o Plow Shares o Hitches • Power Shovel o Dipper Teeth and Drive Sprockets = Coal Cutters e Conveyor Rolls • Mining Buckets • Rock Crushers o etc, SIZES AND HEATS Diameter ....
WELDmNG AWS ROD E-7014 SPECmF CATmONS CONTACT for welding GENERAL Fabrication Fabricating Welding of mild AC-DC steel APPLICATIONS: Sheet Metal Fabrication and Repairs e Machinery • Construction Equipment Repairs = Storage Tanks e Shipbuilding Structural Shapes and Heavy Equipment = Equipment and Heavy Pipe SIZES AND HEATS Diameter ....
Jm=LDBNG ROD SPECNF CAT ONS MACHINABLE CAST machineable GENERAL APPLICATIONS: Castings o Gears o Sprockets AND 3/32" 48-85 Amperes AC-DC on all cast irons Cylinder Blocks o Crankcases o Valve Seats e Defective e Casting Repairs in General o Garages o Farms o Shops SIZES Diameter welds RON HEATS (AMPS) 1/8" 75-130 5/32" 100-150 3/18" 130-175 DESCRIPTION This electrode uses a nickel core wire, and produces a fully machinable weld without pre-he.
REPAIR PARTS PARTS LIST FOR CRAFTSMAN 43 27 45 42 230 AMP WELDER MODEL 113o201372 15 45 34 41 \ 27 \ 44 \ / 35 11 32 \ \ 10 23 24 27 13 \ 12 = 29 28 2-6 Transformer not replaceable° 19
PARTS LIST FOR CRAFTSMAN 230 AMP WELDER MODEL 113.201372 Always Order by Part Number - not by Key Number Key No. 1 2 3 4 5 6 7 Part No.
ISears I 230 AMP DUAL RANGE ARC WELDER SERVICE MODEL NO. 113.20137 2 HOW TO ORDER REPAIR PARTS Now that you have purchased your 230 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 The model number' of your 230 amp arc welder will be found on a plate attached to your' welder, at the rear' of the cabinet.
