Save this Manual For Future Reference S_ AJRS MODEL NO. 113.201892 Serial Number Model and serial number at the may be found rear of the cabinet. You should model record both and seriaI number in a safe place for future use. A C 230 AMP/DC TRIPLE RANGE ARC WELDER CAUTION: 140 AMP Read ® assembly SAFETY iNSTRUCTIONS • operating carefully = repair Sold by Part No. 61477 ,i SEARS, ROEBUCK AND COl, parts Chicago, i L 60684 U.S.A.
.... -:%. :. ': SAFETINST.UCT IONS:TO: : i Fail_re:i!t_:;:!f0i 0w these ::instructions may result in sedods personat!njury_ :. :::i;i::: : FIJME'S ND G A S ES :iMAY B El :D AN G E ROU S TO _O'U R :NEAETH::: ::: ,' :i:'i ::iN:_iIjR E:::EYE S :A:ND :BEl RN S KIN.: SH O : ::::i:::: cooling louvers in the welding cabinet. If these objects contact the internal parts of the welder they couid damage the welder or result in an electrically hazardous condition. 2.
e. Neverconnectthe workcableor clamptoany objectbut the work pieceor metalworktable_ Connectingto otherobjectssuchasbuilding ground can cause stray currents to flow, resultingin overheatingor fire. 4. PREVENTATIVE Z49_!);_and "Fire Prevention in Use of Cutting and Welding Processes" (ANSI/NFPA No. 51B) from the American National Standards Institute, t430 Broadway, New York, New York, 10018. Purchase copies of "OSHA Safety and Health Standard" 29 CFR 1910 from the U.S.
-TABLE :i-....... ,,:. OF CONTENTS ::2 Operating: Coriti;o s: .,. Troube:Sh0oting:i:i.:::.: Warrantv _............... : ..... '::i_:::::. ,...:.......... ::.i i:::i !:::. 4 6 8 ......... REPAIR AND CHECKING PARTS :... ::.:i:i i, ..... 2-1 ..... 2-6 CONTENTS ELECTRODE DIAMETER GAUGES OUTLET ON-OFF WORK JACKS CABLE ;K DO OUTLET4 WELDING HELMET / / WORK CABLE WORK CLAM AND P WARNING: FOR YOUR OWN PLUG WELDER IN IF PARTS DAMAGED. SAFETY, DO NOT ARE MISSING OR Key_ . N0.
4. Back out the slotted-head screwtocated near the end of the electrode holder until the cable end can be placed under the rectangular clamp plate. 5. Insert the end of the cable under the clamp plate so that the forked end of the cable passes on each side of the screw. 6. Tighten the slotted head screw very firmly. 7. Slide the handle back into place on electrode holder and position it until the hole in handle is directly over the handle locking screw hole.
ii:!:i::i:_:i == v !::O JNTRO:L:S @ welder: is derived from is equipped with ranges two :AC ranges and our ::tt j P one suitable for electrodes The 50-230amp AC range requi_:es less line (input current) draw for any given amp setting and permits SELECTING DC RANGES Your new arc welder has a DC range which makes it possible for youto weld aluminum using al uminum welding rods. You will find this increasing_.
For DC Straight Polarity: The electrode cable is: plugged into the negative DC jack and the work cable is plugged into the positive DC jack. In this mode the electron flowwill be from the electrode to the work. This mode is used for hardsurfacing, mild steel welding, cutting and burning holes. For more polarity the table provided Welds Aluminum ELECTRODE C detailed information regarding the current to use with specific welding rods, refer to provided on the welder and to information with welding rods.
: i/: ..:Now !oosen tlie heat selector knob and move the pointer urtti/_i_ecommehded Setting: appears_:: i n thep0i ::i _i:!: .:::i: ,:i i: : :' .nob: :: : :: i: i selected)::_ Connect.the Work Clam p to the w6rk Wear Turn:the • lower your:Welding: to:weld,:- . 'ON" position, He!meL, and you are ready .... up and the technique of each operator fsdifferent, you may find it necessary to increase or decrease the amperage setting; accordingly. CAUTION: Donot loosen and move amp selector while welding.
f A COMPREHENSIVE GUIDE FOR YOUR NEW CRAFTSMAN ARC WELDER AND WHAT iT WiLL DO CONTAINS: INFORMATION = VARIOUS = USEFUL ABOUT TYPES OF RODS ACCESSORIES ° TIPS ON CUTTING, AND BRAZING WELDING J Form No.
•ii:i•I;•• •• TABLE OF CONTENTS Page YourWelderandWhat It Will Do ............. 1-3 Howthe CraftsmanContactRod SimplifiesWelding 1-3 WhatHappensWhenYou Weld? .............. 1-3 ReadBeforeWelding ...................... 14 LearnBy Doing............................ 1-5 PositionWelding ......................... 1-11 Cast-IronWelding ........................ 1-14 HardSurfacingWore CuttingEdges .......... 1-15 TheTwin CarbonArc Torch ............... 1-16 Cuttingand OtherMiscellaneousOperations .,.
YOUR WELDER and what it will do.., Your CRAFTSMAN Arc Welder is a sturdily constructed and thoroughly tested machine engineered to give many years of efficient trouble-free service. It is listed by Underwriters' Laboratories, incorporated, which means that it passesall requirements of safety, fire hazard and temperature rise limits asspecified in their Standard for Transfer-Type Arc-Welding Equipment. HOW THE CRAFTSMAN ELECTRODE SIMPLIFIES WELDING Craftsman restarting...
When operating a welder, certain precautions must be taken to prevent injuries to yourself and others. Knowing how to use the protective equipment to safeguard against them is the first step in learning to weld. :The effects Of heat and light given off by the arc, while electric We ding, may be corollated t0 that of the S_Jh;S r:_ys. Even greater precautions are necessary for electric arc welding.
LEARN BY E:)O NG OFWELD DIRECTION 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.
I i i Fi_re .3 1o lay a weldbeadonlytwo movementsare Used,downwardandin the directionthe weldis to be laid. 1 [[ _1 i i Figure 4 Watchthe wold puddleto keep the slag from flowing in frontof it, causinginciusionsandgas pockets, Ifldifficult:y is experienced after repeated.attempts t9 maintain an arc, check ithe work connection for proper contact with the work; If this does not help, increase the welding current. Also check the rod size, as larger rods requi re higher current settings.
CURRENTTOO LOW Arc is difficult to maintain, Very fittte penetration. High bead. TRAVELTOO FAST Small bead undercut in some pisces. Rough top and little penetration. CURRENTTOO NIGH Wide thin bead, undercut. Crater pointed and long. Rod burns off very fasL Surface of weld rough, Rod melts off in globules, Arc makes hissing sound, ARC TOO LONG TRAVELTOO SLOW NORMALCONDITIONS Metal piles up, making a wide heavy bead, overlapped at sides in places. Uniform ripples on surface of weld.
FLAT WELDING ,= SHEET METAL BACK-UP STRIP Figure 4 TACK Figure 3 6-1#CH R_KFORCEMENT Flat welding includes all types of joints in which the weld ishorizontal, and the electrode is fed clown as in the practice welds of previous pages. The five types of joints in figure 1 can be welded in the flat position. Figure 6 _ Figure Butt welds 0n light materlal should be practiced first on scrap stock.
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 wilt completely cover preceding beads.
Figure 8 Figure Figure Figure 9 1! TO iNTERMITTENT WELDS Figure STAGGERED INTERMffTENT WELDS 13 Figure: 16 Figure LAP: WELDS LAPWEL|)S I7 WELD ON BOTH SIDES ATENDOFJOINT Figure 14 Figure 15 i ii iiiiiiii 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-taps are caused by not holding the rod in the center of the seam (fig.
POSITION WELDnNG ]n order to derive the greatest benefits from your welder, you should practice until you can make a welded ioint in almost any conceivable position. The abitlty to do this _sespecially useful when making repairs on machinery as the amount of welding in most cases is small and does not warrant disassembling the parts to weld them in the flat position.
VERTICAL.UP WELDING WELD Figure Figure ......... 6 Use 1/8 and 5/32-inch rods for all vertical-up welds and start by running practice beads from bottom to top of a 3/16 or I i4-inch plate, tack-welded in a vertical position. Hold the rod as shown in figure 6, noting that the angle of the rod is not as steep as for vertical-dawn welding, but tilted just stlghtly (approximately five degrees) so the tip ofthe electrode points upward.
UNDERCUT Figure OVER-LAPFED _gure HORIZONTAL 13 14 BACK-UP STRIP Figure Figure Figure 16 I7 WELDING Horizontal welding refers to one type of butt weld between two plates in a vertical plane. For practice, set up a plate as for vertical welding and run straight beads across from left to right (fig. 12). Use the some current settings as for vertical-down welding and hold the rod as indicated with a short arc. Move the rod in a straight line and deposit a light bead.
METAL BENDS • eLrff _L_ $'IAilr tST _LD HER(. 2N_' W[tD B£_, ETC, Figure 20 F;gure Figure 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.
ofthefractured surface tolineupthetwo pieces. Tack-weld or clamp parts in position. If the crack has not separated the casting, a yea-groove can be chipped out with a diamond-point chisel. Chip an inch or so beyond the visible ends of the crack as it may extend under the surface. On crocked water jackets, where only a seal is required, the depth of the groove need only be one-hatf the thickness of the casting.
IE i. ¸¸. : RC ,- To pre|0are the torch for use, connect its two cables to the ground and electrode cables of the welding machine. Grounding of the work is not necessary as the operation of the arc flame is entirely independent. With the thumb knob or_the handle in the "off" posltion, insert two 3tS-inch carbon electrodes in the holders and damp in place at approximately one-half their length (fig. 2).
....... ii ill i i .......... bent and edges fused together by melting down the excess metal to form a bead (fig. 6). No filler rods are required. The carbon-arc torch is ideally suited for brazing and soldering small tubing. Cast and mat_eable iron can be brazed with excellent results. A bronze filler rod and common brazing flux are used. Rust, paint or grease must be cleaned from the area to be brazed.
BOLT AND MOVeeOoUr ANO:--_ .... OOWN VERTICALLY : _: .._o '>- "" -_ f,_._ _:: : ,_ i: ":" _ _ ___,, Removing rusty bolts Or rivets isan easy iob 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 Used to drive out the remaining part. The bolt or rivet can head is completely melted off. (fig. 4). A punch is then be removed by heating the head almost to the melting point, then quickly shearing it off with a cold chisel.
NOTES 1-19
NOTES 1-20 q _ q ,,,,
W#ELDING ..... ROD $PECIFmCATIONS _"................ _ A% /S E-6011 GENERAL Body • APPLICATIONS: and General Fender o Pipe Repairs MILD Farm e oStructura_ STEEL Equipment Tanks e Sheet o Maintenance .................. -_ _: _ -- "";"'";'"'"_ i-- AC-DC Metal • Car and Truck _ Jigs and Fixtures o • Cabinets Steel SIZES AND HEATS (AMPS) Diameter .... 1/16" 20-55 Flat ! I 3/3220.80 I !I8", 75130 I 5/32" 100-175 _ i I00-150 ! 3/16" t50-225 ' t i 1t4- 7132" 175.
SPECiFiCATiONS W E[01NGiRO:D AWS E-60131:Ni0LD STEi=L multi-purpose GENERAL APPLICATIONS: Pipe o Tanks Work - Boders Farm • Structural AC-DC al! position Equipment Steel e o Car and Truck Maintenance • Sheet Metalo Re_)a_rs o General Repair SIZES AND HEATS (AMPS) Diameter, ..... 5/64- 3t32" 1/8"" l 5/32"' i ' 3/1 6" 114"" ....... Flat 20+55 20-75 75-130 100-175 150-225 Vertical 20-55 20-65 75+115 100-150 150-200 Overhead 20-55 20-65 75+115 100+150 200.
VV'ELD0 G ROD HARD SURFACING medium GENERAL APPLICATIONS: cultural Implements • Plow Drive Sprockets o etc. e Coal Cutters ....
ROD AWS SPECIFICATmONS E.7014 CONTACT for welding GENERAL APPLICATIONS: Fabrication = Fabricating Welding. Sheet Constr=uction Structural Shapes of mild Metal stee| Fabrication EquDpment Repairs and Equipment Heavy AC-DC • and Storage e Repairs Tanks Equipment • e and Machinery Shipbuilding Heavy Pipe SIZES AND HEATS (AMPS} : Diameter ....
WE ...., , , , , m ROD i NG .... , , MACHmNABLE Castings APPLICATIONS: • Gears e Sprockets , ,, .
.... PARTS LIST FOR CRAFTSMAN AC 230 AMP/DC 140 AMP WELDER MODEL 113.201892 8 I 11 l 52 41 5O 14 48 47 41 46 15 44 16 17 18 19 _ 20 21 23 24 32 \ 30 \_ / 29 I 28 ..-.
PARTS LiST FOR CRAFTSMAN AC 230 AMP/DC 140 AMP WELDER MODEL 113.201892 Always order by Part Number - Not by Key Number • Key No. Part No. 1 2 3 4 61435 61276 61424 60359 5 6 7 8 61350 61279 60325 STD601103 0 61335 61 355 61356 61334 -61391 61347 11 t2 13 14 15 16 17 18 19 20 21 61434 S']'D522510 61430 61428 61431 22 23 24 61432 61426 STD501102 25 26 27 28 61315 STD541006 S'TD551208 S-rD611007 29 30 60446 61433 Key No. Description Cabinet, Top Spacer Pointer Screw, Pan Rec.
•:• I_IL AC 230 AMP/DO TRRPLE RANGE ARC WELDER SERVICE MODEL NO. Now that you have need ever exist for any Sears Service Co. stores. Be sure call or visit. 140 AMP purchased your arc welder, should a repair parts or service, simply contact Center and most Sears, Roebuck and to provide all pertinent facts when you The model number of your arc welder will be found on a plate attached to your welder, at the rear of the cabinet. 113.
