Serial Number ............ ModeJ and serial number may be found at the rear of the cabinet. You should model record both CRRFTSMRHo and serial number in a safe place for future use. 295 AMP DUAL RANGE ARC WELDER CAUTION: Read SAFETY ® assembly iNSTRUCTIONS ® operating carefully • repair Sold by SEARS, Part No. 61341 ROEBUCK AND parts CO., Chicago, IL 60684 U,S.A. _ :'_ ' .
SAFETY For your own protection, mcluded nn this manual safety precautions. 1. PROTECTION iNSTRUCTiONS TO OPERATOR read and observe all instructions as well as the following specific FROM ELECTRICAL SHOCK a. Do not let bare skin or wet clothing come the following combnnatlons Electrode and Electrode Holder of the arc can react with solvent vapors phosgene, a highly toxic gas, and other products. h.
READ AND OBSERVE THE INSTRUCTIONS APPEARING ON THE WARNING LABELS FOUND ON THE INSIDE OF THE WELDING HELMET, SELECTOR PLATE, AND CABINET, WARNING _AFTSMRn -- FOR REGARD;NG _HOCK YOUR SAFETY 80 VOLT pO'_ENTIAL AT ELECTRODE 12_ 0_fy for €_c1_ _ _ Pr_ecb0n a_,_hr_l _nlU_o_ rays from _C _dhng _ARNIrJG Pro_e_t _ou,_lf and un_,stalld thl_ Idbel _ther_ R_d and _U',IES _rJD GASE_ _arl be _l_r,ge,v_s to _,l_r ne_h_ _pC RA' g _an 1nitre eves _nd bdrr, ,kin _LECTRIC SHOCK, n r,ll • _ead _rd understand th
SPECIFICATIONS Welding Range .............. Primary Volts (AC) Amps Input (Max.) ................... 30 - 295 amps ........ 230 60 Fuse Requ=red (Delayed Act=on Type) Phase ....................... UNPACKING .........
6 Slide the handle back into place on electrode holder and pos_t_on tt untd the hole m handle _s d_rectly over the head of handle locking screw TLghten the screw clockwise electrode _ holder lust enough to secure the handle on ATTACHING THE WORK CLAMP TO THE WORK CABLE 1 Attach work 2 the terminal on the end of the work cable to the clamp• Do not use e_ther of the holes m handle ends of work clamp. 3 T_ghten the screw hrmly enough and prevent the cable terminal clamp.
CONNECTING WELDER TO POWER SOURCE CAUTION: 0o not attempt to connect this welder to a regular household outlet. Make sure the power-line voltage and frequency agree with ratings shown on the selector plate attached to top of cabinet. IN Electrical connections between the welder and 230-volt, single-phase, 60-cycle AC power source should be made by a qualified electrician, A_| wiring must comply with the National Electrical Code (ANSI C1) and The Local Electrical Code, 1.
OPERATING iNSTRUCTiONS We feel that weldtng wtth your new arc welder is as s_mple as A B. C. A Determine what diameter Craftsman electrode should dual range be used by gauging the piece to be welded on the material thickness gauge.
TROUBLE SHOOTING WARNING:REMOVAL OF THE REASON MUST BE TECHNICIAN. TROUBLE WELDER CABINET TOP DONE BY A QUALIFIED PROBABLE Fan and welder do not operate, or continually blow fuses. 1. Use 60 ampere fuses of the delayed action type such as "'Fusetron" or "'Fustat" or 60 ampere 240 volt mrcutt breaker. fuse, or opeR breaker. 3. "ON-OFF" Can't hold an arc. SUGGESTED REMEDY 1. Improperly fused or protected. 2. Blown circuit Welding current low or weak. CAUSE sw=tch not "ON". 2.
t:RRFTSMRNo A COMPREHENSIVE GUIDE FOR YOUR NEW CRAFTSMAN ARC WELDER AND WHAT iT WiLL DO CONTAINS: INFORMATION • VARIOUS • USEFUL ABOUT TYPESOF RODS ACCESSORIES • TIPS ON CUTTING° AND BRAZING WELDING J Form No.
r.._o_.;__ _,_ __ ,_j_ ___,_ ,L_ TABLE . OF CONTENTS Page Your Welder and What It Will no ............. 1-3 How the Craftsmen Contact Rod Simplifies Welding Wkat Happens When You Weld? .............. 1-3 1-3 Read Before Welding 14 Learn By Doing ...................... .......................... 1-5 Position Welding ......................... Cest-lron Welding ........................ t-t 1 1.14 Hsrd Surfacing Worn Cutting Edges .......... The Twin Carbon Arc Torch ..............
YOUR WELDER and what it will do.., Your CRAFTSMAN Arc Welderisa sturdilyconstructedandthoroughlytestedmachineengineeredto give many years of efficient trouble-free service. It is listed by Underwriters' Laboratories, incorporated,which meansthat it passes all requirementsof safety, fire hazardandtemperaturerise limits asspecifiedin their Standardfor Transfer-TypeArc-WeldingEquipment. HOW THE CRAFTSMAN ELECTRODE SIMPLIFIES WELDING Craftsman Contact Electrode is self-starting--plusautomatic restarting...
READ BEFORE _ _ /VELD|NG BAND HEA, D GASKET LENS AiUSTABLE SPECIAL CET_R HEb_ET ,/ / LEATHER GLOVES SPECTACLE HELMET SWINGS UP TO CLEAR THE FACE TYPE GOGGLES 1/4-INCH STEEL SHOES C-CLAMP SAW HORSE W1RE BRUSH GROUND CABLE o 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.
LEARN BY DOING 90 OF WELO OiRECTIOH Expe_ience 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.
I I t_ *_ _._ _ // // X.,'///J//I///'/f////_ F_ger_3" To lay a weld beadonlytwo movements are used, downwardandin the directionthe weldis th be laid. Figure 4 Watch the Weld puddle to keep the slag from flowing in front of it, causing inclusions and gas pockets. If difficulty is experienced offer 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.
CURRENT TOO LOW Arcis difficult to maintain. T_AVELTOO FAST Sman bead undercut in some p_aces. Rough top and little penetration. Very little penetration. High bead. CUREEHTTOO HIGH Wide thin head, undercut. Crater pointed and long, Rod burns elf very fast. Surface ef weld rough. Rod melts off in globules. Are makes hissing sound. TRAm/ELTOO gLOW Metal piles up, making a wide heavy bead, overtapped at sides in places. Uniform ripples on su_ane of weld. Arc makes steady crackling sound.
FLAT WELDING SLIGHT GAP nff 'lffiff.g_ SHEET METAL f p,.JLET WIELD L____I\ RACK-UP STRIP Frgure 4 vrt19 LAPWELD TACK Figurel i i ]lr Figure 3 WELOS Fcgure Fiat welding includes all types of joints in which the weld is horizontal, and the electrode is fed down as m 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 material should be practiced first on scrap stock.
Run the first pass on beveled plates with a 5/32-inch rod and Jse 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 mowng the rod in a straight line with no weaving or side-to-slde movement. On the last or reinforcing pass, a weaving motion must be used to obtain a wide weld that will completely cover oreceding beads.
Figure Figure Figure Figure tO _ 9 11 _UTTING INTERMITTENT WELOS Figure 12 _ 8 EXCESS WELD_ STAGGEREO iNTER+ Figure 13 Figure+ 16 WELDS 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 cold-laps are caused by not holding the rod in the center of the seam (fig. 8).
POSUTION WELDING WELD In order to derive the 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.
VERTICAI..UP90° WELDING Figure 7 Figure 8 Figure 6 F;gure TO r_ Use 1/8 and 5/32-inch rods for all verticabup welds and sta_" by running practice beads from bottom to top of a 3/16 or 1i4-1nch 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 vertlcal-down welding, but tdted just slightly (approximately five degrees) so the tip of the electrode points upward.
i il Figure 14 ) Figure 12 + OVER-LAPPED Figure HORIZONTAL 13 BACK-UP STRIP Figure 15 Figure 16 Figure 17 WELD|NG 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 tFe same current settings as for vertical-down welding and hold the rod as indicated with a short arc. Move the rod in a straight llne and deposit a light bead.
DISTORTION WHEN TRENDS COOLING BUTT W£L_ Figure _T Figure IST mLBH_ T_ yRt9 _. ET_ 20 Figure Figure When you can lay slngle.pass butts and hllet 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 together, 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.
of the fractured surface to llne up the two pieces. Tack-weld or clamp parts in position. !f the crack has not separated the casting, a vee-g_oove can be chipped out with a dlamond-point chisel. Chlp 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 on!y be one-half the thickness of the casting.
THE TWIN-CARE]ON Figure I The arc torch (fig. t) consists of an insulated handle with two projecting carbon electrode holders, one of which is adjustable to permff striking and breaking an arc at the carbon tips. A thumb knob on the handle performs the adjustment and operates csshut-off swltch built into the handle.
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 sinai] 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 buff joint, such as a crack in a casting, grind or chip out a beveled groove as for arc welding.
BOLT AND MOVI[ ROe Lip 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.
INERT-GAS METAL-ARC GROUNDED WORN PIECE ALLCABLES ORWORN TABLE SHOULD BE / NEPTSHORT TOELECTRODE ASPOSSIBLE (Donot exceed12-U2 feetin length) H E ATE GROONDCABLE J _ - WELDING (Nonconsumabme) ANYCRAFTSMAN WELDER MAYBEUSEO WITHHF ATTACHMENT ( WELDER GROUND I CABLE o o 230 VOLT WELDER CABINET MOST BE GROUNDED _HOCYCLE SINGLE PHASE / WELDINGCABLETO WELDER HIGHFREQUENCY ATTACHMENT F_ure HmGH FREQUENCY \ Figure 2 I ATTACHMENT The Craftsman, High-Frequency Attachment may be used with any
(11 DEVELOP (2) MOVE (31Ann THE P.OOL TO C. FILLERMETAL DIRECTION _ f_///I///77///////////3 f WORKPIECE (5) MOVETORCH TO LEADING EI)GE_ (4)REMOVE ROE} _Lf .OO\ @ ADDITIONOF FILLERMETAL (VERTICAL POSITION) o,PUODL _"s°"i _////S////////////////_;'//////_///////A Figure 3 "[he 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 techniquesfor feeding filler rod is shown in figure 3.
WELDING ROD AWS GENERAL Body • E-6011 APPLICATIONS: and Fender General Repairs MBLD Farm e Pipe • SPECJFICATmONS Tanks STEEL Equipment • o Maintenance Sheet • AC-DC Metal • Car and Truck Jigs and Fixtures e e Cabinets oStructuralSteel SIZES AND HEATS (AMPS) Diameter ....
WELDmNG AWS ROE) E-6013 SPECIFiCATiONS MILD STEEL multi-purpose GENERAL P_pe • Work APPLICATIONS: Tanks = Boilers • AC-DC all position Farm Equipment Strucl_ural Steel • t Car and Truck Maintenance Repairs • Sheet Metal • General o Repair SIZES ANO HEATS (AMPS) 5164" 20-55 20-55 20-55 D la i,tl_ret Flat Vertical Overhead I 20-75 20-65 3132" 20-65 1 5t32" 100-175 100-150 100-150 75-130 75-115 1/8" 75-115 3/16" 1/4" 150-225 200-375 I 150-200 SPECI FICATIONS MEETS TH
WELDING ROD HARD SPECmFICATaONS SURFACING AC-DC medium chrome-carbon electrode GENERAL cultural APPLICATIONS Implements Drive Sprockets o e Tractor Plow Shares Coal Cutters • Grousers e and Rollers Hitches Conveyor • Power Roils e Scraper Shovel o o MmmgBuckets Blades e Agri- D=pper Teeth e Rock and Crushers • etc SIZES AND HEATS (AMPS) Otameter 3/32" 1/8" 5/32" 3/15" 7/32" 1/4" Amperes 55-85 100-130 130-150 175 200 175-250 225-275 I I SPECl FICATIONS MEETS
WELDING ROD AWS E-7014 SPECIFnCAT|ONS CONTACT for welding AC-DC of mild steel GENERAL APPLICATIONS: Sheet Metal Fabrication and Repairs a Machinery Fabrication e Construction Equipment Repairs e Storage Tanks e Shipbuddmg Fabricating Structural Shapes and Heavy Equipment e Equtpment and Heavy Pipe Welding. SIZES AND HEATS Diameter ....
WELDING ROD SPECiFmCATnONS MACHINABLE CAST machineable GENERAL APPLICATIONS: Castings e Gears e Sprockets welds on iRON all cast AC-DC irons Cylinder Blocks e Crankcases e ValveSeats e Defective e Casting Repairs in General e Garages • Farms ® Shops SIZES AND HEATS (AMPS) i 0iameter I 3/32" Amperes 1/8" 75-130 i 48-85 5/32" 100-150 3/16" 130-175 DESCRIPTION This electrode uses a nickel core wire, and produces a fully pre-heating the casting.
REPAIR PARTS LIST FOR CRAFTSMAN PARTS 295 AMP ARC WELDER MODEL 113.201392 12 53 54 41 21 52 37 24 45 42 14 \ \ 28 25 30 31 -,.®24+ \ 32 33 34 35 2-6 29 32 16 26
PARTS LIST FOR CRAFTSMAN Always Key No. 1 '2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 295 AMP ARC WELDER Order by Part Number Pert No. STD 541110 STD 551210 STD 611005 61339 61276 STD 551008 STD 511110 61300 61278 161279 60325 61280 STD 541025 STD 551225 STD 551025 STD 541006 STD 511105 37525 37526 30298 61335 STD 601103 61332 61333 61334 61385 @ 61314 61302 Description *Nut, Hex 10-32 *Lockwasher, No. 10 Internal ;*Screw, Type A8 Pan Hd. No.
295 AMP DUAL RANGE ARC WELDER $ERVmCE 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. The model number of your 295 amp arc welder will be found on a plate attached to your welder, at the rear of the cabinet.
