Save This Manual For Future Reference MODEL NO. 113.201480 Serial Number Model and serial number may be found at the rear of the cabinet. You should model record • •i•: i•i::̧:_:::: : ; :• :; : both and serial number in a safe place for future use. 50-295 AMP DUAL RANGE VARIABLE CONTROL ACARC CAUTION: Read SAFETY INSTRUCTIONS e assembly carefully ® operating ® repair Sold by SEARS, Part No. 61421 ROEBUCK AND CO., parts Chicago, IL 60684 U.S.A. Printed ;inU.S.
a:. Never permit the electrode or live metal parts of:the eiectrodeholder t0_t0uch bare sk nor any: damp:o_ W_eti::covering of the body. The electrede:cbating slioutd be considered as an electrical conducltor_ Do n0t insert electrode in electrode hotde_iWith your bare hand -- wear pr0pergloVes on both hands.
e. Neverconnectthe workcableor clamptoany objectbut the workpieceor meta_worktable. Connectingto otherobjectssuchasbuilding ground can cause stray currents to flow, resultingin overheatingor fire. 4. PREVENTATIVE MAINTENANCE a. Never apply power to the welder with any part of the ,cabinet" removed. Position on-off switch in "off" position and disconnect welder from the power supply before doing maintenance work inside the machine.
OPERATING!I_INSTR_CTI ONS Warranty _ : ii !:.! : i _.:_i:::.: ... :.:;_:.:. _.i _. !., _i 3 Getting tO ::'.. :,:_:i. :. 4 Unpacking and C_cki"gGontents :; : .!;;...... 4 GETTING Operating ContrOls ................. 0 ........................ T ................. ARC ..... WELDING ROD SPECIFICATIONS ......... REPAIR PARTS ............................
ASSEMBLY TOOLS NEEDED @ 7/16-inch , , wrench Screwdriver (small) ATTACHING ELECTRODE HOLDER TO ELECTRODE CABLE Grasp the electrode holder and locate the slotted head, handle locking 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. Slide the handle off electrode holder and insert end of electrode cable assembly through the handle.
CONNECTING WELDER TO POWER SUPPLY CAUTION: Do not attempt to connect this welder to a regular household outlet. Make sure the power-line voltage and frequency agree with the ratings shown on the selector plate attached tothe cabinet_ Electrical connections between the welder and 230-volt, single-phase, 60-cycle AC power source should be made by a qualified electrician. All wiring must comply With the National Electrical Code (ANSI Ct)a'nd theLocal Electrical Code. 1.
Connectthe work clamp to the piece to be welded, (to complete the electrical circuit) or to the welding table itself provided it is metallic or wilt conduct electricity! OPERATING INSTRUCTIONS 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.
weld. Because metals vary {n their make up and the technique of each operat0r is different, you may find it necessary to: increase: or decrease the amperage output accord!ngly. CAUTION: Donol loosen and move amp se|ector while welding.. The duty cycle scales bracketing the amperage sca':les are provided for your convenience and protection of your new weGder. Duty cycle is the performance level of the welder based on a 10 minute time span.
fl A COMPREH ENSIVE GUIDE FOR YOUR NEW CRAFTSMAN ARC WELDER AND WHAT iT W=ILL DO CONTAt NS: INFORMATION o VARIOUS o USEFUL ABOUT TYPES ACCESSORIES e TIPS ON CUTTING, AND BRAZING %_ Form No. SP574+5 OF RODS WELDING ,,J t.
_i_?/:-: ¸ _:!. ...... TABLE OF _cONTENTs Page _iii_!i. i___ Your WelderandWhat it Will Do ............. 1-3 Howthe CraftSmanCOntactRod SimplifiesWelding 1-3 WhatHappensWhenYou Weld? .. .......... 1-3 RoadeefareWeiding .:i._._,.!..:,....i.,.... 1-4 LearnBy Doing ........................... 1-5 PositionWelding ......................... 1-11 Cast4ronWelding....; .... ...... . 1-14 .a,dSu ,,=jn.Wor,,C. .gEd,IIZ 1-15 TheTwin CarbonArc Torch 1-16 ...............
YOUR WELDER and what H wil/ do . . Your CRAFTSMAN Arc Welderisa sturdily constructedandthoroughlytestedmachineengineeredto give many years of efficient trouble-free service. It is listed by Underwriters' Laboratories, incorporated,which meansthat it passesal! requirementsof safety, fire hazardand temperaturerise limits asspecifiedin their Standardfor Transfer-TypeArc-WeldingEquipment.
When operating a welder, certain precautions must be taken to prevent injuries to yourseff and others. Knowing ha w to use the protective equipment to safeguard against them is the first step in learning to weld. The effects of heat arid:tight given off by the arc, while electr €I welding, may belcompared 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.
LEARN BY DO|NG I 90': OFWELD DIRECTIOH Experience has proven that short periods of practice at regutar 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 arid free of slag or gas inclusions.
Figure 3 ..... Figure 4 TO lay a weld:bead _nly two movements are ,sod. down* ward andin the eirectiOnthe weld is to be:laid. i ....: : ....... :, i _ " _: ;' Watch the weld puddle ta keep the slag from flowing in front of it.
CURRENT TOO LOW Arc is difficult to maintain. Very little penetration.High bead. TRAVELTOO FAST Small bead undercut in some places. Rough top and little penetration. T ......... CURRENTTOO HIGH ARC TOO LONG Wide thin bead, undercut. Crater pointed and tong. Rod burns off very fast. Surface of weld rough. Rod melts off in globules. Arc makes hissing sound. TRAVELTOO SLOW NORMAL COHOITIONS Uniform ripples on surface of wetd. Arc makes steady crackling sound.
STRIP Figure 4 Figure 3 1/16-INCH REIKFORCEMENT Flat welding includes all types of joints in which the weld ishorizontal; and the electrode is fed d own as in the practice Welds Of previous pages_ The five types of ioints in figure 1 can b_ welded in the flat position.
! i •¸ • • •• UNDERCUT GASPOCKET TRAPPEDSLAG PENETRATION Figure T! F_gure Figure !2 13 FJLLEET 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 wit] result, as shown in figure 11. Be sure to clean each pass before laying on the next. Aft beads are laid by moving the rod in a straight line with no weaving or side-to-side movement.
LAP WELDS LAP WELDS Figure _14 Figure 15 ..... i• should be nearly flat with a slight radlus at the SidesOr 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 cen_r! 0f the :seam: (fig; 8). ff the desired fillet weld cannot be ma_e with a Sing!e pass, several passesare used to build it up to required size (fig_ 9).: Slag must be cleaned from each pass before depositing the next.
POS}ITtON WELDING BUTT WELl) In order to derive the greatest benefits from your we{der, 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.
WELOING Figure F.;gure 9 8 Figure 6 Figure r Use 1/8 and 5/32qnch rods for all vertical-up welds I0 , and of the electrode points upward, Strike and hold a short arc until a small amount of metaf is deposited, th,en quickty 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 Clown and deposit more metal.
,p,JlL Figure HORIZONTAL WELDING Horizontat welding refers to one type of butt weld between two plates in a ve_tica] plane. For practice, set up a plate as for vertical welding and run straight beads across from ]eft to right (fig. t..'2). Use the same current settings as for verffcal-down welding and hold the rod as indicated with a short arc. Move the rod in c_ straight line and deposit a light bead. The rate of travel will c_epend upon the current used.
To simulate actual conditions tack-weld a piece with on irregular edge to another piece leaving numerous gaps along the ioint. 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 cramp parts in position. If the crack has not separated the casting, a vee-groove can be chipped out with a dlamond_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.
TH TIWIN iCAR B O N I:A R C TO R C H 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 carbon electrodes in the holders and damp in pIace at approxi- CAH_ON ELECTRODES mately one-half their length (fig. 2).
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 results. malleable A bronze iron filler can rod and be brazed common with excellent 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.
BOLT AND RIVET CUTTING Removing rusty botts Or rivets is an easy i0b with an electric arc welder. _The arc is struCk on the head or nut of the bait and w0rkedaround in a slight circular movement untll the head s complete]y meffed 0ff(fig. 4)° A punch is then L_sedto drive out the remaining part. The bolt or rivet can be removed byheating the head almost to the melting point, then qu!ckly shearing it off With a coJd chisel.
NOTES
• ,,__,;,i_:_i,i i NOTES 1-20
WELDING ROD AWS GENERAL Body and e General E-6011 APPLICATIONS: Fender Repairs .... l _ 1/16" 20-55 MiLD Farm Equipment ._ AND II 20+55 20-55 • HEATS Sheet AC-DC Meta/ _ Jigs and • Car and Truck Fixtures • • Cabinets lAMPS) 3/32" 20-80 75-130 Vertical Overhead STEEL ® Pipe • Tanks e Maintenance e Structural Steel SIZES Diameter Flat SPECJF|CATiONS ! 20.6,5 20-65 100+175 I 150+225 i 175-250 200-375 7,-,,5 i ,50.2o0 i 75.,15 l _ 1oo.
II I AWS E-6013 MILD STEEL multi-purpose GENERAL Pipe • Work APPLICATIONS: Tanks • Boilers Farm o all position Equipment Structural Steel = e . _-..
i :: : i¸ : L :¸ :: . 'i _ • _: WELD,NG //:: i•: I ::/•: ROD , , ::•::•::i: •i¸'¸ ':_'?_ :_ _i :_•:': _:::•••:,?• ¸'¸ ::: SP;=CUF,CATIONS ..... __ HARD _! •i•/:i•::••::: SURFACmNG __.'---____! ...... AC-DC medium chrome-carbon electrode Coal Cutters SIZES I Diameter ....
CIFICATION$ AWS E,70141CONTACT f0r welding AC-DC of mild steel GENERAL. APPLICATIONS: Sheet Metal Fabrication and Repairs = Machinery Fabrication o Construction Equipment Repairs e Storage Tanks e Shipbuilding Fabricating Structural Shapes and Heavy Equipment e Equipment and Heavy Pipe Welding. SIZES AND HEATS {AMPS) Diameter Lengtl_ :Amperes .... ,.... 1/16" 12-: : 70-90 3/32" , ....
MACHINABLE CAST rnachineable GENERAL Castings APPLICATIONS: e Gears e Sprockets welds iRON on all cast Cylinder Blocks • Casting Repairs in General AC-DC irons • Crankcases = Valve e Garages Seats e Defective e Farms e Shops SIZES AND HEATS (AMPS) I Oiameter 3/32" 48-85 / t Amperes t I/8" 75-130 5/32" | J.
• _ i,,,_:_ ,_ I_ 145 56 :47 49 1 42 19 19 18 17 23 24 25 / 28 _ / • _32 34 2_ /
PARTS LIST FOR CRAFTSMAN 50-295 AMP DUAL RANGE ARC WELDER MODEL 113.201480 Always order Key No, Pa rt No. by Part Number Description -- not by Key Number Key No. Part No.
Sears 50=295 AMP DUAL RANGE: ARC WELDER SERVICE MODEL NO. 113o201480 HOW TO ORDER REPAIR PARTS 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 afl pertinent facts when you call or visit. The model number of your arc welder will be found on a plate attached to your welder, at the rear of the cabinet.
