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AC-225-GLM IM347
April, 1998
WELDING POWER SOURCE
by
LINCOLN Âź
ELECTRIC
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MAN-
Contents Page
UAL AND THE SAFETY PRE-
CAUTIONS CONTAINED Safety Precautions ...............................................................................................2
THROUGHOUT. And, most
Installation and Operating Instructions
importantly, think before you act
for AC-225-GLM Dual Voltage Type (K1327)............................................7
and be careful.
Includes safety, installation, operating instructions
and parts lists.
Learning to Weld .................................................................................................9
Using the Carbon Arc Torch..............................................................................17
Includes for heating metal, welding aluminum or
brazing with an arc torch.
Selecting Electrodes ..........................................................................................19
Welding Books and Teaching Aids ...................................................................23
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
â? Sales and Service through Subsidiaries and Distributors Worldwide â?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of âSafety in Welding & Cutting - ANSI Standard Z49.1â? from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of âArc Welding Safetyâ? booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler 2.d.3. Do not place your body between the electrode and
by pushing on the throttle control rods while work cables. If the electrode cable is on your right
the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar â?95
â?2â?
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically âhotâ? when the welder is on. plates to protect your eyes from sparks and
Do not touch these âhotâ? parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
3.b. Insulate yourself from work and ground using dry insulation.
material to protect your skin and that of your helpers from
Make certain the insulation is large enough to cover your full
the arc rays.
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if welding
screening and/or warn them not to watch the arc nor expose
must be performed under electrically hazardous
themselves to the arc rays or to hot spatter or metal.
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
can be dangerous.
the following equipment:
5.a. Welding may produce fumes and gases
â? Semiautomatic DC Constant Voltage (Wire) Welder.
hazardous to health. Avoid breathing these
â? DC Manual (Stick) Welder.
fumes and gases.When welding, keep
â? AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
fumes and gases away from the breathing zone. When
electrode reel, welding head, nozzle or semiautomatic
welding with electrodes which require special
welding gun are also electrically âhotâ?.
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
3.d. Always be sure the work cable makes a good electrical
cadmium plated steel and other metals or coatings
connection with the metal being welded. The connection
which produce highly toxic fumes, keep exposure as
should be as close as possible to the area being welded.
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
3.e. Ground the work or metal to be welded to a good electrical
confined spaces or in some circumstances, outdoors, a
(earth) ground.
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
3.h. Never simultaneously touch electrically âhotâ? parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturerâs instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employerâs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar â?95
â?3â?
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to âSafety in Welding and Cuttingâ? (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
â? Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
â? A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically âhotâ? parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been âcleanedâ?. For information, purchase âRecommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substancesâ?, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
âPrecautions for Safe Handling of Compressed Gases in
Cylinders,â? available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturerâs
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerâs recommendations.
Mar â?95
â?4â?
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRĂCAUTIONS DE SĂRETĂ prĂ©venir tout risque dâincendie dĂ» aux Ă©tincelles.
Pour votre propre protection lire et observer toutes les instructions
7. Quand on ne soude pas, poser la pince à une endroit isolé de
et les précautions de sûreté specifiques qui parraissent dans ce
la masse. Un court-circuit accidental peut provoquer un
manuel aussi bien que les précautions de sûreté générales suiv-
Ă©chauffement et un risque dâincendie.
antes:
8. Sâassurer que la masse est connectĂ©e le plus prĂ©s possible de
SĂ»retĂ© Pour Soudage A LâArc
la zone de travail quâil est pratique de le faire. Si on place la
1. Protegez-vous contre la secousse Ă©lectrique:
masse sur la charpente de la construction ou dâautres endroits
éloignés de la zone de travail, on augmente le risque de voir
a. Les circuits Ă lâĂ©lectrode et Ă la piĂ©ce sont sous tension
passer le courant de soudage par les chaines de levage,
quand la machine Ă souder est en marche. Eviter toujours
cĂąbles de grue, ou autres circuits. Cela peut provoquer des
tout contact entre les parties sous tension et la peau nue
risques dâincendie ou dâechauffement des chaines et des
ou les vétements mouillés. Porter des gants secs et sans
cĂąbles jusquâĂ? ce quâils se rompent.
trous pour isoler les mains.
b. Faire trĂ©s attention de bien sâisoler de la masse quand on
9. Assurer une ventilation suffisante dans la zone de soudage.
soude dans des endroits humides, ou sur un plancher met-
Ceci est particuliérement important pour le soudage de tÎles
allique ou des grilles metalliques, principalement dans
galvanisées plombées, ou cadmiées ou tout autre métal qui
les positions assis ou couché pour lesquelles une grande
produit des fumeés toxiques.
partie du corps peut ĂȘtre en contact avec la masse.
c. Maintenir le porte-Ă©lectrode, la pince de masse, le cĂąble de
10. Ne pas souder en présence de vapeurs de chlore provenant
soudage et la machine à souder en bon et sûr état defonc-
dâopĂ©rations de dĂ©graissage, nettoyage ou pistolage. La
tionnement.
chaleur ou les rayons de lâarc peuvent rĂ©agir avec les vapeurs
d.Ne jamais plonger le porte-Ă©lectrode dans lâeau pour le
du solvant pour produire du phosgéne (gas fortement toxique)
refroidir.
ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
parce que la tension entre les deux pinces peut ĂȘtre le total
le code âCode for safety in welding and cuttingâ? CSA Standard
de la tension Ă vide des deux machines.
W 117.2-1974.
f. Si on utilise la machine Ă souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-Ă©lectrode sâapplicuent aussi au pistolet de
soudage.
PRĂCAUTIONS DE SĂRETĂ POUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
LES MACHINES Ă SOUDER Ă
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le cĂąble-Ă©lectrode autour de nâimporte quelle partie du
TRANSFORMATEUR ET Ă
corps.
REDRESSEUR
3. Un coup dâarc peut ĂȘtre plus sĂ©vĂšre quâun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi 1. Relier à la terre le chassis du poste conformement au code de
quâun verre blanc afin de se protĂ©ger les yeux du rayon- lâĂ©lectricitĂ© et aux recommendations du fabricant. Le dispositif
nement de lâarc et des projections quand on soude ou de montage ou la piece Ă souder doit ĂȘtre branchĂ© Ă une
quand on regarde lâarc. bonne mise Ă la terre.
b. Porter des vĂȘtements convenables afin de protĂ©ger la peau
de soudeur et des aides contre le rayonnement de lâarc. 2. Autant que possible, Iâinstallation et lâentretien du poste seront
c. ProtĂ©ger lâautre personnel travaillant Ă proximitĂ© au effectuĂ©s par un Ă©lectricien qualifiĂ©.
soudage Ă lâaide dâĂ©crans appropriĂ©s et non-inflammables.
3. Avant de faires des travaux Ă lâinterieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont Ă©mises de lâarc de er Ă lâinterrupteur Ă la boite de fusibles.
soudage. Se protĂ©ger avec des vĂȘtements de protection libres
de lâhuile, tels que les gants en cuir, chemise Ă©paisse, pan- 4. Garder tous les couvercles et dispositifs de sĂ»retĂ© Ă leur place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec Ă©crans lateraux dans les
zones oĂč lâon pique le laitier.
Mar. â?93
â?5â?
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product âąâ?ąâ??
as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
â?6â?
OPERATING INSTRUCTIONS This rated current of 140 amps will reduce the capability of
using larger electrodes and special techniques such as
punching holes due to the lower output current. Only elec-
Input Power and Grounding Connections
trodes and techniques up to the 140 amps rating can be used
Before starting the installation, check with the power com- with this reduced voltage input.
pany to be sure your power supply is adequate for the volt-
age, amperes, phase and frequency specified on the welder For supply lines, use three #10 or larger copper wires when
nameplate. Also, be sure the planned installation will meet using conduit. If supply line run requirements exceed 100â?,
the National Electrical Code and all local code require- #8 or larger wire will be needed to prevent excessive volt-
ments. This welder may be operated from a single phase age drops.
line or from one phase of a two or three phase line.
The unit is shipped with a five foot length input cable only.
WARNING
No plug or receptacle is supplied from the factory.
Before attaching the electrode cable to the electrode
Place the welder so there is free circulation of air in through
holder or the work cable to clamp, be certain the welder
the louvers in the back and sides of the case and out of the
is turned off or the input power is disconnected.
bottom on all four sides.
Attaching Electrode Cable to Holder
WARNING 1. Loosen locking screw and slide handle off holder. Place
handle over electrode cable.
These installation instructions apply to the input wiring
and overload protection installed to supply one AC-225-
2. Remove insulation from electrode cable 1â? ± 1/16â? from
GLM and comply with the United States National
end.
Electrical Code as it applies to electric welders. Other
equipment should not be connected to this supply with- 3. Back out cable connecting screw until end is flush with
out consulting the input power requirements for that inside surface of jaw body.
equipment, the United States National Electrical Code,
4. Remove cable connecting clamp from holder jaws. Place
and all local codes.
clamp over bare end of electrode cable and insert into
holder with clamp centered against connecting screw.
WARNING
Only qualified personnel should make the input power
connections. Turn the input power off at the disconnect
switch before attempting to connect the input power
lines to the welder.
Using the following instructions, have a qualified electri-
cian connect the unit to a fuse box or disconnect switch. For
60 Hz. operation use 50 Amp Superlag Fuses. For 50 Hz.
operation use 60 Amp Superlag Fuses. Fuse the two hot
lines of the circuit. A green wire in the input cable connects
to the frame of the welder and to a ground in the fuse box.
This insures proper grounding of the welder frame. If a sep-
arate disconnect switch is used, it should have two poles for 5. Tighten cable connecting screw securely against clamp.
the two hot lines and both should be fused as specified
6. Slide handle into position and secure with locking screw.
above.
When installing, turn the locking screw in until it is tight.
The dual voltage 50/60 Hz. AC-225-GLM is shipped from The threaded end of the screw will then press against the
the factory connected for the higher (230/220) nameplated inside of the handle and the head of the screw will be
voltage. For use on the lower (115/110) voltage, remove the completely inside the handle.
welder top and side cover and reconnect and insulate the
leads at the power switch according to the wiring diagram
pasted inside the cover. Finally, replace the cover.
When connected to 115 volt 60 Hz. or 110 volt 50 Hz. input
power, the rated welding output is 140 amps.
â?7â?
How To Use Parts List
1. Refer to the drawing below.
2. Find the part on the drawing.
3. Using the item number from the drawing find the part name and description in the table.
4. Get the welder code number found on the nameplate.
5. Order the part from The Lincoln Electric Company, or from a Lincoln Field Service Shop. Be sure to give the Parts
List number, item number, part name and description, number required, the welder name, model number and code
number.
P167-A
1
18 AC-225-GLM
Dual Voltage
2
3
5
4
18
6
7
17
8
15 9
16
10
11
18
13
14 19
Item Description Item Description
1 Back Case 10 Line Switch
2 Wrap Around 11 Transformer and Base
3 Front Case 13 Work Cable
4 Warning Decal 14 Work Clamp
5 Nameplate 15 Electrode Holder
6 Range Selector Switch 16 Electrode Cable
7 Handle 17 Fan Motor and Blade
8 Output Lead Clamp 18 Undercarriage Kit
9 Input Cable (230 V Input) 19 Hand Shield (Optional)
â?8â?
Attaching Work Cable to Clamp Duty Cycle
Insert work cable through strain relief hole in work clamp The welder is rated 18% duty cycle at 60 Hz on all switch
and fasten securely with bolt and nut provided. positions. This means that the arc can be drawn for 1.8 min-
utes out of each ten minute period without any danger of
overheating. If the welder is used for more than 1.8 minutes
Electrode and Work Cable Replacement during several successive ten minute periods, it may over-
heat and damage the windings. Be sure to leave the unit
Substitution of cables with larger sizes requiring connec- âonâ? during each 10 minute period to let the fan motor run
tions to be made internally is not recommended. for adequate cooling. Overheating reduces welder life.
Connections for additional lengths or larger sizes should be
properly made externally. Lincoln Electric QD (Quick
Disconnect) connectors are available for this purpose. WARNINGâPipe Thawing
If either cable requires replacement for other reasons, they The AC-225-GLM is not recommended for thawing or
should be replaced with the appropriate Lincoln partsâ? heating of frozen pipes.
and only by qualified personnel.
Electrode Selection Guide
Welding Current Selection
See Chart on Welder and page 21.
Each position on the current selector switch is marked with
the output amperes for that setting. Turn the switch to the
current required for each application. Arc Torch (Optional Accessory)
There is a slight amount of play in each switch position. It The arc torch (see page 17) is especially suited for use on
is good practice to move the switch back and forth once these welders for brazing, welding non-ferrous metals and
within this play after switching to a new position. This wip- preheating before bending and forming.
ing action keeps the contacts free from dirt and oxides.
CAUTION: Do not turn the selector switch while welding
as this will damage the contacts.
MAINTENANCE
Routine preventative maintenance is not required. See your local Lincoln Electric Authorized Field Service Shop for
necessary repairs.
LEARNING TO WELD
The serviceability of a product or structure utilizing this type of information is and must
be the sole responsibility of the builder/user. Many variables beyond the control of The
Lincoln Electric Company affect the results obtained in applying this type of information.
These variables include, but are not limited to, welding procedure, plate chemistry and
temperature, weldment design, fabrication methods and service requirements.
The Arc-Welding Circuit
No one can learn to weld simply by reading about it. Skill
comes only with practice. The following pages will help
The operatorâs knowledge of arc welding must go beyond
the inexperienced welder to understand welding and
the arc itself. He must know how to control the arc, and this
develop his skill. For more detailed information order
requires a knowledge of the welding circuit and the equip-
a copy of âNew Lessons in Arc Weldingâ? listed on page
ment that provides the electric current used in the arc.
23.
â?9â?
Figure 1 is a diagram of the welding circuit. The circuit The âarc streamââ?? is seen in the middle of the picture. This
begins where the electrode cable is attached to the welding is the electric arc created by the electric current flowing
machine and ends where the work cable is attached to the through the space between the end of the electrode and the
welding machine. Current flows through the electrode work. The temperature of this arc is about 6000°F, which is
cable to the electrode holder, through the holder to the elec- more than enough to melt metal. The arc is very bright, as
trode and across the arc. On the work side of the arc, the well as hot, and cannot be looked at with the naked eye
current flows through base metal to the work cable and without risking painful injury. The very dark lens, specifi-
back to the welding machine. The circuit must be complete cally designed for arc welding, must be used with the hand
for the current to flow. To weld, the work clamp must be or face shield whenever viewing the arc.
tightly connected to clean base metal. Remove paint, rust,
The arc melts the base metal and actually digs into it, much
etc. as necessary to get a good connection. Connect the
as the water through a nozzle on a garden hose digs into the
work clamp as close as possible to the area you wish to
earth. The molten metal forms a molten pool or crater and
weld. Avoid allowing the welding circuit to pass through
tends to flow away from the arc. As it moves away from the
hinges, bearings, electronic components or similar devices
arc, it cools and solidifies. A slag forms on top of the weld
that can be damaged.
to protect it during cooling.
This arc-welding circuit has a voltage output of up to 79
volts which can shock.
WARNING
ELECTRIC SHOCK can kill.
Carefully review the ARC WELDING SAFETY
PRECAUTIONS at the beginning of this
manual.
FIGURE 2âThe welding arc.
The function of the covered electrode is much more than
simply to carry current to the arc. The electrode is com-
posed of a core of metal wire around which has been
extruded and baked a chemical covering. The core wire
melts in the arc and tiny droplets of molten metal shoot
across the arc into the molten pool. The electrode provides
additional filler metal for the joint to fill the groove or gap
between the two pieces of the base metal. The covering also
melts or burns in the arc. It has several functions. It makes
FIGURE 1âThe welding circuit for shielded metal arc
the arc steadier, provides a shield of smoke-like gas around
welding.
the arc to keep oxygen and nitrogen in the air away from
the molten metal, and provides a flux for the molten pool.
The electric arc is made between the work and the tip end
The flux picks up impurities and forms the protective slag.
of a small metal wire, the electrode, which is clamped in a
The principal differences between various types of elec-
holder and the holder is held by the welder. A gap is made
trodes are in their coatings. By varying the coating, it is
in the welding circuit (see Figure 1) by holding the tip of
possible to greatly alter the operating characteristics of
the electrode 1/16-1/8â? away from the work or base metal
electrodes. By understanding the differences in the various
being welded. The electric arc is established in this gap and
coatings, you will gain a better understanding of selecting
is held and moved along the joint to be welded, melting the
the best electrode for the job you have at hand. In selecting
metal as it is moved.
an electrode you should consider:
Arc welding is a manual skill requiring a steady hand, good
1. The type of deposit you want, e.g. mild steel, stainless,
physical condition, and good eyesight. The operator con-
low alloy, hardfacing.
trols the welding arc and, therefore, the quality of the weld
made . 2. The thickness of the plate you want to weld.
3. The position it must be welded in (downhand, out of
What Happens in the Arc?
position).
Figure 2 illustrates the action that takes place in the electric
4. The surface condition of the metal to be welded.
arc. It closely resembles what is actually seen during weld-
ing.
5. Your ability to handle and obtain the desired electrode.
â? 10 â?
Four simple manipulations are of prime importance. Once the arc has been established, maintaining the correct
Without complete mastery of these four, further welding is arc length becomes extremely important. The arc should be
more or less futile. With complete mastery of the four, short, approximately 1/16 to 1/8" long. As the electrode
welding will be easy. burns off the electrode must be fed to the work to maintain
correct arc length.
The easiest way to tell whether the arc has the correct
1. The Correct Welding Position
length is by listening to its sound. A nice, short arc has a
Beginners will find it easier to learn how to control the distinctive, âcracklingâ? sound, very much like eggs frying
welding arc using the two-handed technique shown below. in a pan. The incorrect, long arc has a hollow, blowing or
This requires the use of a headshield. hissing sound.
a. Hold the electrode holder in your right hand.
b. Touch your left hand to the underside of your right. 4. The Correct Welding Speed
c. Put the left elbow against your left side.
(For welding left-handed it is the opposite.) The important thing to watch while welding is the puddle
of molten metal right behind the arc. Do NOT watch the
If you are using a hand shield, hold the electrode holder in arc itself. It is the appearance of the puddle and the ridge
your right hand and the hand shield in your left. (For weld- where the molten puddle solidifies that indicate correct
ing left-handed it is the opposite.) welding speed. The ridge should be approximately 3/8"
behind the electrode.
Most beginners tend to weld too fast, resulting in a thin,
uneven, âwormyâ? looking bead. They are not watching the
molten metal.
IMPORTANT: For general welding it is not necessary to
Whenever possible, weld from left to right (if right-hand-
ed). This enables you to see clearly what you are doing. weave the arc; neither forwards and backwards nor side-
ways. Weld along at a steady pace. You will find it easier.
Hold the electrode at a slight angle as shown.
NOTE: When welding on thin plate, you will find that you
will have to increase the welding speed, whereas when
2. The Correct Way to Strike an Arc welding on heavy plate, it is necessary to go more slowly
in order to get good penetration.
Be sure the work clamp makes good electrical contact to
the work.
Lower your headshield or hold the hand shield in front of Practice
your face. Scratch the electrode slowly over the metal and
The best way of getting practice in the four skills that
you will see sparks flying. While scratching, lift the elec-
enable you to maintain:
trode 1/8" and the arc is established.
1 Correct Welding Position
NOTE: If you stop moving the electrode while scratching,
2. Correct Way To Strike An Arc
the electrode will stick.
3. Correct Arc Length
NOTE: Most beginners try to strike the arc by a fast jab- 4. Correct Welding Speed
bing motion down on the plate. Result: They either stick or
is to spend a little more time on the following exercise.
their motion is so fast that they break the arc immediately.
Use the following:
3. The Correct Arc Length
Mild Steel Plate .....................................3/16" or heavier
The arc length is the distance from the tip of the electrode
Electrode ...........................................1/8" Fleetweld 180
core wire to the base metal.
Current Setting..........................................105 Amps AC
â? 11 â?
Do the following: Of these, the Butt Weld and Fillet Weld are the two most
common welds.
1. Learn to strike the arc by scratching the electrode over
the plate. Be sure the angle of the electrode is correct. If Butt Weld
you have a headshield use both hands.
Butt Welds are the most widely used welds. Place two
2. When you can strike an arc without sticking, practice the plates side by side, leaving 1/16â? (for thin metal) to 1/8â?
correct arc length. Learn to distinguish it by its sound. (for heavy metal) space between them in order to get deep
penetration .
3. When you are sure that you can hold a short, crackling
arc, start moving. Look at the molten puddle constantly, Tack the plates at both ends, otherwise the heat will cause
and look for the ridge where the metal solidifies. the plates to move apart. (See drawing):
4. Run beads on a flat plate. Run them parallel to the top
edge (the edge farthest away from you). This gives you
practice in running straight welds, and also, it gives you
an easy way to check your progress. The 10th weld will
look considerably better than the first weld. By con-
stantly checking on your mistakes and your progress,
welding will soon be a matter of routine.
Now weld the two plates together. Weld from left to right
Common Metals (if right-handed). Point the electrode down in the crack
between the two plates, keeping the electrode slightly tilted
Most metals found around the farm or small shop are low
in the direction of travel.
carbon steel, sometimes referred to as mild steel. Typical
items made with this type of steel include most sheet metal,
plate, pipe and rolled shapes such as channels, angle irons
and âIââ?? beams. This type of steel can usually be easily
welded without special precautions. Some steel, however,
contains higher carbon. Typical applications include wear
plates, axles, connecting rods, shafts, plowshares and
scraper blades. These higher carbon steels can be welded
successfully in most cases; however, care must be taken to Watch the molten metal to be sure it distributes itself even-
follow proper procedures, including preheating the metal to ly on both edges and in between the plates.
be welded and, in some cases, carefully controlling the
temperature during and after the welding process. For fur- Penetration
ther information on identifying various types of steels and
Unless a weld penetrates close to 100%, a butt weld will be
other metals, and for proper procedures for welding them,
weaker than the material welded together.
we again suggest you purchase a copy of âNew Lessons in
Arc Weldingâ? (see page 23).
Regardless of the type of metal being welded, it is impor-
tant in order to get a quality weld that it be free of oil, paint,
rust or other contaminants.
Types of Welds In this example, the total weld is only 1/2 the thickness of
the material; thus the weld is only approximately half as
Five types of welding joints are: Butt Welds, Fillet Welds,
strong as the metal.
Lap Welds, Edge Welds and Corner Welds.
In this example, the joint has been flame beveled or ground
prior to welding so that 100% penetration could be
achieved. The weld, if properly made, is as strong or
stronger than the original metal.
â? 12 â?
downwards and make it âdrip.ââ?? Therefore a certain tech-
nique has to be followed:
Fillet Welds
When welding fillet welds, it is very important to hold the
electrode at a 45° angle between the two sides, or the metal
will not distribute itself evenly.
To make it easy to get the 45° angle, it is best to put the 1. Use 1/8" (90-105 amps) or 3/32" (60 amps) Fleetweld
electrode in the holder at a 45° angle, as shown: 180 electrode.
2. When welding, the electrode should be kept horizontal
or pointing slightly upwards. (See drawing.)
3. The arc is struck and metal deposited at the bottom of
the two pieces to be welded together.
4. Before too much molten metal is deposited, the arc is
SLOWLY moved 1/2-3/4" upwards. This takes the heat
away from the molten puddle, which solidifies. (If the
arc is not taken away soon enough, too much metal will
be deposited, and it will âdrip.ââ??)
Multiple Pass Welds
5. The upward motion of the arc is caused by a very slight
wrist motion. Most definitely, the arm must not move in
Make multiple pass horizontal fillets as shown in the
and out, as this makes the entire process very complicat-
sketch. Put the first bead in the corner with fairly high cur-
ed and difficult to learn.
rent. Hold the electrode angle needed to deposit the filler
beads as shown putting the final bead against the vertical
6. If the upward motion of the arc is done correctly with a
plate.
wrist motion, the arc will automatically become a long
arc that deposits little or no metal. (See drawing.)
7. During this entire process the ONLY thing to watch is
the molten metal. As soon as it has solidified, the arc is
SLOWLY brought back, and another few drops of metal
are deposited. DO NOT FOLLOW THE UP AND
DOWN MOVEMENT OF THE ARC WITH THE
EYES. KEEP THEM ON THE MOLTEN METAL.
8. When the arc is brought back to the now solidified pud-
dle, IT MUST BE SHORT, otherwise no metal will be
Welding in the Vertical Position deposited, the puddle will melt again, and it will âdrip.â?
Welding in the vertical position can be done either vertical- 9. It is important to realize that the entire process consists
up or vertical-down. Vertical-up is used whenever a large, of SLOW, DELIBERATE movements. There are no fast
strong weld is desired. Vertical-down is used primarily on motions.
sheet metal for fast, low penetrating welds.
Vertical-Up Welding Vertical-Down Welding
The problem, when welding vertical-up, is to put the Vertical-down welds are applied at a fast pace. These welds
molten metal where it is wanted and make it stay there. If are therefore shallow and narrow, and as such are excellent
too much molten metal is deposited, gravity will pull it for sheet metal. Do not use the vertical-down technique on
heavy metal. The welds will not be strong enough.
â? 13 â?
1. Use 1/8 or 3/32" Fleetweld 180 electrode. 2. Use 1/8 or 3/32" Fleetweld 180 electrode.
2. On thin metal, use 60-75 amps. (14 ga 75 amps â? 16 ga 3. Use low amperage. 75 amps for 1/8" electrode, 40-60
60 amps.) amps for 3/32" electrode.
3. Hold the electrode in a 30-45° angle with the tip of the 4. Move fast. Donât keep the heat on any given point too
electrode pointing upwards. long. Keep going. Whip electrode.
4. Hold a VERY SHORT arc, but do not let the electrode 5. Use lap welds whenever possible. This doubles the
touch the metal. thickness of the metal.
5. An up and down whipping motion
will help prevent burn-through on Hardfacing
very thin plate.
There are several kinds of wear. The two most often
6. Watch the molten metal carefully. encountered are:
The important thing is to continue lowering the entire arm 1. Metal to Ground Wear.
as the weld is made so the angle of the electrode does not (Plowshares, bulldozer blades, buckets, cultivator
change. Move the electrode so fast that the slag does not shares, and other metal parts moving in the soil.)
catch up with the arc. Vertical-down welding gives thin,
shallow welds. It should not be used on heavy material 2. Metal to Metal Wear.
where large welds are required. (Trunnions, shafts, rollers and idlers, crane and mine car
wheels, etc.)
Each of these types of wear demands a different kind of
Overhead Welding
hardsurfacing electrode.
Various techniques are used for overhead welding.
When applying the proper electrode, the service life of the
However, in the interest of simplicity for the inexperienced
part will in most cases be more than double. For instance,
welder the following technique will probably take care of
hardsurfacing of plowshares results in 3-5 times more
most of his needs for overhead welding:
acreage plowed.
1. Use 1/8" (90-105 amps) or 3/32" (60 amps) Fleetweld
How to Hardface the Sharp Edge (Metal to Ground
180 electrode.
Wear)
2. Put the electrode in the holder so it sticks straight out.
1. Grind the share, approximately one inch wide along the
3. Hold the electrode at an angle approximately 30° off edge, so the metal is bright.
vertical, both seen from the side and seen from the end.
2. Place the share on an incline of approximately 20-30°.
The easiest way to do this is to put one end of the share
on a brick. (See drawing.)
Most users will want to hardface the underside of the
share, but some might find that the wear is on the top
The most important thing is to hold a VERY SHORT arc. side. The important thing is to hardface the side that
(A long arc will result in falling molten metal; a short arc wears.
will make the metal stay.)
3. Use 1/8" Abrasoweldâ? electrode at 90-105 amps. Strike
If necessary â? and that is dictated by the looks of the the arc about one inch from the sharp edge.
molten puddle â? a slight back and forth motion along
4. The bead should be put on with a weaving motion, and
the seam with the electrode will help prevent âdripping.â?
it should be 1/2 to 3/4" wide. Do not let the arc blow
over the edge, as that will dull the edge. (See drawing.)
Welding Sheet Metal
Welding sheet metal presents an additional problem. The
thinness of the metal makes it very easy to burn through.
Follow these few simple rules:
1. Hold a very short arc. (This prevents burn through, since
beginners seem to hold too long an arc.)
â? 14 â?
5. Use the back-stepping method. Begin to weld 3" from 3. Build-up to size.
the heel of the share and weld to the heel. The second
4. Do not quench. This will make the deposit slightly soft-
weld will begin 6" from the heel, the third weld 9" from
er than the deposit on the idlers and rollers. That means
the heel, etc.
that the wear will primarily be on the rails, which are a
lot easier and less time-consuming and cheaper to build-
up.
NOTE: The same electrode â? BU-90 â? will give the
operator two desired hardnesses, just by a difference in
cooling rate, making it possible to put the hardest deposit
on the most expensive parts.
Backstepping greatly reduces the chances for cracking of
NOTE: The outside of the rails (the side that comes in con-
the share, and it also greatly reduces possible warpage.
tact with the ground) should be surfaced with Abrasoweld,
NOTE: The entire process is rather fast. Many beginners since this side has Metal to Ground wear.
go much to slow when hardfacing plow shares, running the
risk of burning through the thin metal.
Welding Cast Iron
Hardfacing of Idler and Roller (Metal to Metal Wear)
When welding on a piece of cold cast iron, the tremendous
A very common application of hardfacing for metal to heat from the arc will be absorbed and distributed rapidly
metal wear is the hardfacing of idlers and rollers and the into the cold mass. This heating and sudden cooling creates
rails that ride on these rollers and idlers. WHITE, BRITTLE cast iron in the fusion zone.
The reason for hardfacing these parts is primarily mone-
tary. A few dollars worth of electrode will completely build
up a roller or idler, and the hard surface will outlast sever-
al times the normal life or such rollers and idlers.
If the following procedure is followed, it is not even neces- This is the reason why welds in cast iron break. Actually,
sary to remove the grease bearing while welding. This will one piece of the broken cast iron has the entire weld on it,
save a lot of time: and the other piece has no weld on it.
1. The roller (or idler) is inserted on a piece of pipe that is
resting on two sawbucks. This enables the operator to
turn it while welding.
2. Use Jet-LHÂź BU-90 electrodes, 5/32" at 175 amps or
3/16" at 200 amps.
In order to overcome this, the welding operator has two
3. Weld across the wearing surface. Do not weld around. choices:
4. Keep the roller (or idler) cool by quenching with water, 1. He can preheat the entire casting to 500-1200°F. If the
and by stopping the welding periodically. This will pre- cast iron is hot before welding, there will be no sudden
vent shrinking of the roller (or idler) on the grease bear- chilling which creates brittle white cast iron. The entire
ing. casting will cool slowly.
5. Build-up to dimension. The weld metal deposited by 2. He can weld 1/2" at a time, and not weld at that spot
BU-90 electrode is often so smooth that machining or again until the weld is completely cool to the touch.
grinding is not necessary.
In this way no large amount of heat is put into the mass.
NOTE: The quenching of the roller (or idler) has another
Most inexperienced welders will probably use the second
purpose: It increases the hardness â? and thus the service
method, because they have no way of preheating large cast-
life â? of the deposit.
ings. Smaller castings can easily (and should) be preheated
The hardfacing of the rails is a lot easier: before welding. A forge, stove, a fire, or the Arc Torch are
all excellent means of preheating.
1. Place the rails with the side that rides on the rollers and
idlers upwards. When using the 1/2" at a time method, it is recommended
to start 1/2" away from the previous bead and weld into the
2. Use Jet-LH BU-90 electrodes. Same ampere setting as
previous bead (backstepping).
on the idlers and rollers.
â? 15 â?
After welding Cast Iron, protect the casting against fast
WARNING
cooling. Put it in a sand (or lime) box.
If sand or lime is not available, cover it with sheet metal or ELECTRIC SHOCK can kill.
any other non-flammable material that will exclude drafts When soaking electrode keep your gloves and
clothing dry. Never dip an electrode holder in
and retain heat.
water..
Cast Iron Plate Preparation
Wherever practical, the joint to be welded should be âveedâ?
Piercing Holes
out by grinding or filing to give complete penetration. This
is especially important on thick castings where maximum
1. Welder setting: Maximum
strength is required. In some instances a back-up strip may
(225 amps).
be used and plates may be gapped 1/8" or more.
2. Electrode: 1/8 or 5/32"
On sections where only a sealed joint is required and
Fleetweld 180.
strength is not important, the joint may be welded after
slightly veeing out the seam as shown. 3. Hold the electrode with a
long arc perpendicular
over the spot where the
hole is to be made.
4. When the metal is molten,
push the electrode through
the molten puddle.
5. Give the molten metal a chance to fall through the hole.
6. Circle with a long arc around the edge of the hole until
the desired diameter hole has been made.
If the electrode is pushed through too soon it will stick in
Cutting Do not exceed the Duty Cycle â? See the puddle. Be sure the metal is molten before pushing
page 9) through .
The arc welder and the electrode can be used for cutting NOTE: On heavy metal 5/16" or thicker), position the plate
steel and cast iron. Follow this procedure: to be pierced vertically, and the electrode horizontally. This
allows the molten metal to drip away freely as you are bor-
1. Use 1/8 or 5/32" Fleetweld 180 electrode.
ing through.
2. Set welder on maximum (225 amps).
3. Hold long arc on edge of metal, melting it.
4. Push the arc through the molten metal, forcing it to fall
away.
5. Raise the electrode, and start over again.
The important thing is to continue this up-and-down, saw-
ing motion, melting the metal and pushing it away.
If a lot of cutting is to be done,
soak each electrode in water for
a minute or two. It keeps them
cooler, and the electrodes last
longer.
â? 16 â?
USING THE CARBON ARC TORCH WARNING
. . . Welding Aluminum and Copper Alloys
ELECTRIC SHOCK can kill.
. . . Brazing and Soldering
The carbon arc torch rays will cause severe arc
. . . Heating, Bending and Straightening
burns to exposed skin. Therefore, a pair of
work gloves, long sleeved shirt or sleevelets,
and an apron are recommended.
Jaw Assembly
T9984
Use an arc welding headshield or hand shield with a No. 11
(2 Required)
or No. 12 lens. Oxyacetylene goggles are not sufficient eye
Complete Arc Torch
and face protection.
L2645
When adjusting the length of carbons, be sure the welder is
turned off. An arc flash while making this adjustment can
burn hands or eyes.
When laying the torch down, avoid touching the carbons to
Thumb Screw the grounded bench or work. This is best done by turning
T9078 the welder off. As an alternative, either set the torch on an
(Part of T9984)
insulated surface or lay it on its side with the leads hanging
down over the bench so the handle rests on the bench top.
DO NOT EXCEED THE OUTPUT DUTY CYCLE OF
Ground Clip THE WELDER. Exceeding this duty cycle in successive
T10379-1
10 minute periods can overheat the welder and damage the
windings. (See page 9.)
Heat Settings
Required Equipment
Recommended current settings for different material thick-
1. A Lincoln Carbon Arc Torch L-2645; Its rating is 100
nesses and carbon sizes are given in the table. Generally,
amperes.
use only enough current to cause the filler metal to flow
2. 1/4, 5/16 or 3/8â? carbons: Use only copper coated and freely on the work. Do not use currents so high that the cop-
cored carbons to avoid overheating the holder and pro- per coating burns away more than 1/2ââ?? above the arc.
vide even burning of the carbons.
Set the carbons to extend about 2â? beyond the copper jaws.
3. Any AC or DC welder: Carbons burn much faster on DC
than they do on AC. Also the carbon connected to the
positive DC output should be larger than the carbon con-
WARNING
nected to the negative DC output so both carbons
burnoff at about the same rate. Be sure the welder is turned off when making this
adjustment.
Torch Connections
Insert the straight ferrule on the end of one arc torch lead
Thickness of Approximate Current Carbon
into the standard electrode holder. Attach the spring clip on Base Metal Setting (AC) Diameter
the end of the other lead to either the work clamp or the 1/32" 30-50 amps 1/4"
welding table where the work lead is clamped. If connect- 1/16" 50-60 amps 1/4"
1/8" 70-80 amps 5/16"
ed to the table, insulate the work from the table. See draw-
1/4" 90-100 amps 3/8"
ing below.
After adjusting the welder current and setting the carbon
stickout, start the welder and you are ready to go.
â? 17 â?
Heating Heavy Parts
Heavy metal can be heated more rapidly by connecting the
work lead to the work so the arc is between the carbons and
the work as well as between the two carbons. To do this,
connect the lead carbon (the carbon which leads the direc-
tion of travel) to the electrode holder. Connect both the trail
carbon and the work cable to the work or to the welding
table. With this connection, raising the torch reduces the
2.00" amount of the arc going to the work thus reducing the heat-
ing. The arc between the carbons and work tends to pit the
surface of the work.
0.06"
Use the thumb control on the arc torch to rotate the carbons
until they touch. Start the arc by reversing the thumb con-
trol setting to spread the carbons 1/16 to 3/16" apart. As the
carbons burn away use the thumb control to maintain the Welding Aluminum Alloys With The
desired arc. When the proper arc can no longer be main- Arc Torch
tained, turn the welder off and readjust the carbon stickout.
The need to repair aluminum parts continues to grow.
A wide, soft, quiet flame gives the best results for most These repairs can be simply made with an AC welder using
jobs. When the carbon tips are too close together a small Aluminweld DC coated electrodes as a filler rod and The
flame accompanied by a hissing or crackling sound results. Carbon Arc Torch. The arc torch preheats the aluminum
plate, assuring good fusion.
The shape of a good flame is illustrated below. The flame
fans out to form a âfish tailâ? shape with inner and outer
cone. To heat a crack or a corner, position the flame as illus-
Work Preparation
trated.
Here are recommended edge preparations and types of
joints for different thicknesses of base metal. All welds
must be made in the downhand position. Round parts must
be rotated.
Heat intensity is controlled by changing the current setting,
by moving the carbons closer together or farther apart, or
by changing the distance between the flame and work.
When the work sets on a metal table, the table absorbs
some of the heat. To avoid high heat loss, the part can be set
of thin metal strips or some insulation.
Removal of Nuts and Bolts: Apply heat with the arc torch
for a few seconds and nuts can be easily turned off.
â? 18 â?
Joints If the part being brazed does not get hot enough, increase
the current or hold the torch closer to the work. Whenever
Welding Procedures possible, have the joint horizontal to secure best flow of
molten filler rod.
1. Use the recommended AC currents and carbon sizes list-
ed in the Table on page 17. A headshield is required.
Soldering
2. Use a l/8" âAluminweldâ? coated electrode as a filler rod.
The arc torch can be used to solder copper piping and other
Hold it in the left hand (for right-handed people).
copper, tinned and galvanized parts. Best results are
3. Hold the arc torch in your right hand and start the arc by obtained with overlapping pieces. Clean the surfaces to be
shorting the carbons together and adjusting them to a soldered and cover them with soldering flux to prevent oxi-
1/16" gap. dation and to speed soldering. Acid core solder produces
good results.
4. Hold the arc torch as shown here. Hold your eyes right
over the arc torch looking in between the two carbons. The best soldering can be done on the lowest current tap of
the welder. Use approximately 1/4" diameter carbon and
5. Play the arc 3" to 4" up and down the joint at the start.
make certain to bring it into firm contact with the piece to
This preheat helps to give a smoother bead and an easi-
be soldered to avoid arcing. Simply play the arc on the area
er start when the filler rod is applied.
to be soldered and feed solder into the joint as it reaches
proper temperature. After the soldering is completed, the
6. Move the torch to the beginning of the joint (right-hand-
carbon must be removed quickly to prevent arcing. Never
ed people should begin at the right and move left).
use so much heat that the solder boils.
7. Place the tip of the electrode in the arc. If the coating
melts off and flows easily into the joint, the metal is hot Heating, Bending and Straightening
enough to start welding.
Choose the carbon size and current setting depending upon
8. Let a droplet of the filler rod melt and fuse into the the thickness of the metal to be heated. Play the arc over the
joints. section to be heated until the desired temperature is
reached. For bending this is usually a dull red color on ordi-
9. Watch the molten puddle. Add more filler metal by mov-
nary mild steels.
ing the end of the rod in and out of the arc as the right
hand moves the arc torch slowly along the joint. Do not hold the carbons too close to the work. Arcing the
surface increases the tendency for the base metal to crack
Practice when the bending is done.
When you first try to weld with these procedures, you may
Carbon Arc Torch Maintenance
have a tendency to burn through. Therefore, a few minutes
practice before working on the parts to be welded is rec- The handle is held together with a screw and spring lock
ommended. Use scrap material about as thick as the part washer to give just the right friction on the electrode shafts.
you are going to weld. Practice the technique to get the feel If the handle is removed for any reason, the screw at the
of the arc. front of the handle should be turned up snugly and then
backed of 1/2 turn to give the proper friction.
Brazing
Occasionally the screws in the copper jaws will bind, so it
The techniques for brazing with an arc torch are very much will be advantageous to lubricate the threads with graphite
like the ones used for gas brazing. Only enough heat is grease and work the grease well into the threaded jaw.
needed to melt the filler metal and to raise the parts to be
brazed to the melting temperature of the filler metal â? usu-
SELECTING ELECTRODES
ally slightly over 1,000°F. A good brazed joint is assured
when the filler metal flows into the joint and adheres even-
Which electrode is best for the particular job . . . how do
ly to the surfaces. Use only enough filler metal to make a
you use it? These are important questions because the cost,
smooth joint. Use standard gas brazing rod and flux .
quality, and appearance of your work depends on proper
Heat the end of the brazing rod and dip it into the flux. The electrode selection and application. MILD STEEL ELEC-
flux will stick to the hot rod. Play the arc back and forth a TRODES may be classified into the following groups:
short distance along the seam when the right temperature is
reached. Apply flux as needed and melt off brazing rod to Out-of-Position Group (E6011)
fill the seam. Move along the seam until the job is com-
This group includes electrodes which have a snappy, deep
plete.
penetrating arc and fast freezing deposits.
â? 19 â?
These electrodes are used for general purpose all-position
fabrication and repair welding; also the best choice for pipe
welding and sheet metal butt, corner and edge welds. They
can be used for repair work when dirt, grease, plating or
paint cannot be completely cleaned from the steel.
Typically used with motions âAââ?? and âBââ?? (below) for the
first pass on vertical-up welds.
High-Deposit Group (E6027, E7024)
This group includes the heavy coated, iron powder elec-
trodes with their soft arc and fast deposit rates. These elec-
trodes have a heavy slag and produce exceptionally smooth
beads. They are generally used for production welding
where all work can be positioned for downhand welding.
Stringer beads, with drag technique, are always preferred
over weave passes with these electrodes.
High-Speed Group (E6012, E6013, E7014)
This group includes electrodes which have a moderately
forceful arc and deposit rates between those of the out-off
position and high-deposit electrodes. They are primarily
general purpose production electrodes especially for down-
hill fillets and laps or short and irregular welds that change
direction or position. Also widely used in maintenance and
recommended for sheet metal fillet and lap welds. Motion on all types of joints. It keeps the molten pool small and lets
âDââ?? (below) is generally used for vertical-up welding, but it freeze quickly so the weld metal doesnât spill down or
motions âAâ? and âBâ? are also suitable. through the joint. Keep arc short when in the crater and
longer during whip out from the crater.
Low Hydrogen Group (E7018, E7028)
Motion âBâ? is a whipping motion combined with a slight
These electrodes are generally called âlow hydrogen.â? The weave in the crater. It is used with fast-freeze electrodes as
name comes from the fact that their coating contains little the first pass on vertical fillets and V-butts.
hydrogen in either moisture or chemical form. Low hydro-
Motion âCâ? is a simple side-to-side weave used with all
gen electrodes offer these benefits: outstanding crack resis-
types of electrodes to make fill passes on vertical fillets and
tance, lowest porosity on sulphur bearing steels, and capa-
V-butts. Also sometimes used with fill-freeze and low
ble of X-ray quality deposits. Thus, they are the first choice
hydrogen electrodes to make the first pass on these joints.
when welding âproblemâ? steels. E7018 can be used in all
positions, with Motion âCâ? recommended for the first pass Motion âDâ? is a triangular weave used with fill-freeze and
on vertical-up welds. NEVER use a whipping technique or low hydrogen electrodes to make one pass vertical fillets
a long arc with these electrodes. ALWAYS fill craters by and V-butts. It results in a larger weld than Motion âCââ??.
drawing electrodes away slowly. ALWAYS keep these elec-
Motion âEâ? is a box weave used with all types of elec-
trodes dry. Electrodes not used within a few hours after a
trodes to make fill passes on vertical fillets and V-butts. It
container is opened must be stored in heat cabinets. LH-73
is similar to Motion âC,ââ?? but with a distinct pause and
is recommended with the AC-225-GLM. Normally, DC(+)
slight upward motion at each edge of the weld to assure
is preferred for these electrodes.
complete crater filling and elimination of undercut.
Motion âFâ? is a circular motion used with all types of elec-
trodes to make overhead welds. Sometimes accompanied
Motions by a slight whip after each oscillation in the crater. Always
use a series of stringer beads overhead; do not weave.
Manipulation depends on the joint. Some of the common
motions are shown above.
Motion âGâ? is a simple side-to-side weave used with all
electrodes on wide fillets or butts in the flat position.
Motion âAâ? is a straight whipping motion used with fast-
freeze electrodes to make stringer beads in all positions and
â? 20 â?
NOTE: The AC-225-GLM is an AC welder. DC electrodes have been included in the chart below for added information.
ELECTRODE IDENTIFICATION AND OPERATION DATA
Electrode
Conforms to Test Polarity Sizes and Current Ranges (Amps.)
Coating Requirements of Electrode (+) = âReverseâ?
Color AWS Class Brand Name 5/64" Size 3/32" Size 1/8" Size 5/32" Size 3/16" Size 7/32" Size 1/4" Size 5/16" Size
(â?) = âStraightâ?
MILD STEEL
Brick Red E6010 Fleetweld 5P DC(+) 40-75 75-130 90-175 140-225 200-275 220-325 240-400
DC(â?) 80-135 110-180 155-250 225-295 245-325
Tan E6012 Fleetweld 7
AC 90-150 120-200 170-275 250-325 275-360
AC 50-85 75-120 90-160 120-200 150-260 190-300
Gray E6011 Fleetweld 35
DC(+) 40-75 70-110 80-145 110-180 135-235 170-270
AC 80-130 120-160
Red Brown E6011 Fleetweld 35LS
DC(±) 70-120 110-150
AC 50-80 75-105 110-150 160-200 205-260
Gray Tan E6013 Fleetweld 37
DC(±) 45-75 70-95 100-135 145-180 190-235
AC 110-160 150-225 200-280 260-340 280-425
Gray Brown E7014 Fleetweld 47
DC(â?) 100-145 135-200 185-235 235-305 260-380
AC 100-150 150-200 200-260
Gray* E6013 Fleetweld 57
DC(â?) 90-135 135-180 180-235
AC 40-90 60-120 115-150
Brown E6011 Fleetweld 180
DC(±) 40-80 55-110 105-135
AC 65-120 115-175 180-240 240-300 300-380 340-440
Gray E7024 JetweldÂź 1
DC(±) 60-110 100-160 160-215 220-280 270-340 320-400
AC 190-240 250-300 300-380 350-450
Red Brown E6027 Jetweld 2
DC(±) 175-215 230-270 270-340 315-405
AC 65-120 115-175 180-240 240-315 300-380 350-450 380-600
Gray* E7024 Jetweld 3(1)
DC(±) 60-110 100-160 160-215 215-285 270-340 315-405 360-600
DC(+) 70-100 90-150 120-190 170-280 210-330 290-430 375-500
Gray E7018 Jetweld LH-70
AC 80-120 110-170 135-225 200-300 260-380 325-440 400-530
E7018 AC 70-90 95-135 140-200
Gray* Jetweld LH-73
(white numbers) DC(+) 65-85 90-125 130-185
DC(+) 70-110 95-160 120-190 180-270 250-330 300-400
White E7018 Jetweld LH-75
AC 80-110 100-170 135-225 210-290 270-370 325-420
7018 DC(+) 85-110 110-160 130-200 180-270 250-330 300-400
Gray JET-LH 78
(white numbers) AC 120-170 140-230 210-290 270-370 325-420
AC 180-270 240-330 275-410 360-520
Gray Brown E7028 Jetweld LH-3800
DC(+) 170-240 210-300 260-380
LOW ALLOY, HIGH TENSILE STEEL
5/16" Jetweld 3 does not conform to any AWS/ASME classification.
(1)
Pink E7010-A1 Shield ArcÂź 85 DC(+) 50-90 75-130 90-175 140-225
Pink* E7010-A1 Shield-Arc 85P DC(+) 140-225
Tan E7010-G Shield Arc HYP DC(+) 75-130 90-185 140-225 160-250
Gray E8010-G Shield-Arc 70+ DC(+) 75-130 90-185 140-225
DC(+) 90-150 120-180 180-270 250-350
Gray Brown E8018-C1 Jet-LHÂź 8018 C1
AC 110-160 140-200 200-300 300-400
DC(+) 110-150 130-190 180-270 250-330 300-400
Gray Brown E8018-C3 Jet-LH 8018 C3
AC 120-170 140-225 210-290 270-370 325-420
DC(+) 110-150 130-190 180-270
Gray E8018-B2 Jetweld LH-90
AC 120-170 140-225 210-290
DC(+) 70-100 85-155 120-195 160-280 190-310 230-360
Gray E11018-M Jetweld LH-110M
AC 80-110 100-170 135-225 200-310 240-350 290-410
STAINLESS STEEL
Pale Green E308-15 StainweldÂź 308-15 DC(+) 30-70 50-100 75-130 95-165 150-225
Gray E308-16 Stainweld 308-16 DC(+); AC 20-45 30-60 55-95 80-135 115-185 200-275
Gray E308L-16 Stainweld 308L-16 DC(+); AC 30-65 55-100 80-140 115-190
Gray E309-16 Stainweld 309-16 DC(+); AC 30-60 55-95 80-135 115-185 200-275
Gray E310-16 Stainweld 310-16 DC(+); AC 30-65 55-100 80-140 120-185 200-275
Gray E316L-16 Stainweld 316L-16 DC(+); AC 30-65 55-100 80-140 115-190
Pale Green E347-15 Stainweld 347-15 DC(+) 30-70 50-100 75-130 95-165
Gray E347-16 Stainweld 347-16 DC(+); AC 30-60 55-95 80-135 115-185
ALUMINUM
White AluminweldÂź DC(+) 20-55 45-125 60-170 85-235
1/8" Size 5/32" Size 3/16" Size 1/4" Size
CAST IRON
Light Tan ESt FerroweldÂź DC(+); AC 80-100
DC(±) 60-110 100-135
Black ENiCl SoftweldÂź
AC 65-120 110-150
HARDFACING
DC(±) 40-150 75-200 110-250 150-375
Black Abrasoweld
AC 50-165 80-220 120-275 165-410
Black Faceweld 1 DC(+); AC 60-150
Âź
Black Faceweld 12 DC(+); AC 60-150
DC(±) 145-210 180-280 230-360
Dark Gray Jet-LH BU-90
AC 155-225 200-290 255-375
DC(±) 120-180 160-260 200-350
Dark Gray MangjetÂź
AC 135-230 165-285 220-385
DC(+) 110-275 150-400
Dark Gray WearweldÂź
AC 125-275 200-400
Means registered Trademark of The Lincoln Electric Company.
Âź
The electrodes under the shaded portions of this chart will operate on
the AC-225-GLM Arc Welder. Be careful of abusing the duty cycle with
* Has identification dot on coating.
large electrodes which will overheat and damage the machine.
â? 21 â?
â? 22 â?
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects, such
since 1933, the Procedure Handbook is considered by many to as distortion; and supplemental information on arc welding
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questions and answers are suggested for each
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A must for all welders, supervisors, engineers and
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tity discount prices which include shipping by
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Need Welding Training?
The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
How To Read Shop Drawings
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The book contains the latest information and application
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187 pages with more than 100 illustrations. Size 8-1/2â? x 11â? Lincoln Welding School
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(ED-80) New Lessons in Arc Welding $5.00 L
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â? 23 â?
â? 24 â?
â? 25 â?
q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q ProtĂ©jase los ojos, los oĂdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del ĂĄrea de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vĂȘte- q Gardez Ă lâĂ©cart de tout matĂ©riel q ProtĂ©gez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des piĂšces sous tension.
q Isolez-vous du travail et de la terre.
German q BerĂŒhren Sie keine stromfĂŒhrenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamåveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENĂĂO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURERâS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYERâS SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHĂTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piraciĂłn. mentaciĂłn de poder de la mĂĄquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilaciĂłn o
aspiraciĂłn para gases.
q DĂ©branchez le courant avant lâentre- French
q NâopĂ©rez pas avec les panneaux
q Gardez la tĂȘte Ă lâĂ©cart des fumĂ©es.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour Îter les fumées des zones
de travail.
q Strom vor Wartungsarbeiten German
q Anlage nie ohne SchutzgehÀuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie fĂŒr gute Be- und
EntlĂŒftung des Arbeitsplatzes!
Portuguese
q NĂŁo opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENĂĂO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratĂłria.
q Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUĂĂES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRĂTICAS DE SEGURANĂA DO EMPREGADOR.
LIMITED WARRANTY
STATEMENT OF LIMITED WARRANTY CONDITIONS OF WARRANTY
The Lincoln Electric Company (Lincoln) warrants to the end TO OBTAIN WARRANTY COVERAGE:
user (purchaser) of all new welding and cutting equipment,
The purchaser must contact Lincoln or Lincolnâs Authorized
electrode and flux (collectively called the âGoodsâ?) that it will
Service Facility about any defect claimed under Lincolnâs
be free of defects in workmanship and material.
warranty.
This warranty is void if Lincoln or its Authorized Service
Facility finds that the equipment has been subjected to Determination of warranty on welding and cutting equipment
improper installation, improper care or abnormal opera-
will be made by Lincoln or Lincolnâs Authorized Service
tions.
Facility.
WARRANTY PERIOD (1) (2) (3)
Lincoln will assume both the parts and labor expense of WARRANTY REPAIR:
correcting defects during the full warranty period. All war-
If Lincoln or Lincolnâs Authorized Service Facility confirms
ranty periods date from the date of purchase to the original
the existence of a defect covered by this warranty, the defect
end user and are as follows:
will be corrected by repair or replacement at Lincolnâs
7 Years option.
â? Main power rectifiers on all non-inverter low frequency (50
and 60 Hz) type welders.
At Lincolnâs request, the purchaser must return, to Lincoln or
3 Years its Authorized Service Facility, any âGoodsâ? claimed defec-
â? All Lincoln welding machines, wirefeeders and plasma tive under Lincolnâs warranty.
cutting machines unless listed below.
FREIGHT COSTS:
2 Years
The purchaser is responsible for shipment to and from the
â? Power Arc 5000
Ranger 10, Ranger 10-LX Lincoln Authorized Service Facility.
Weldanpower 125, Weldanpower 150
WARRANTY LIMITATIONS
1 Year
â? AC-100 Lincoln will not accept responsibility or liability for repairs
Invertec V100-S, Invertec V130-S, Invertec V200-T made outside of a Lincoln Authorized Service Facility.
Power Arc 4000
Pro-Cut 20
Lincolnâs liability under this warranty shall not exceed the
cost of correcting the defect of the Lincoln product.
â? All water coolers (internal or external models)
â? All stick electrode, welding wire and flux. Lincoln will not be liable for incidental or consequential dam-
ages (such as loss of business, etc.) caused by the defect
â? Arc welding and cutting robots and robotic controllers
or the time involved to correct the defect.
â? All Environmental Systems equipment, including portable
units, central units, gun and cable assemblies and acces- This written warranty is the only express warranty provided
sories. (Does not include consumable items listed under
by Lincoln with respect to its products. Warranties implied
30 day warranty.)
by law such as the warranty of merchantability are limited to
â? All welding and cutting accessories including gun and the duration of this limited warranty for the equipment
cable assemblies, TIG and plasma torches, spool guns, involved.
wire feed modules, undercarriages, field installed options
that are sold separately, unattached options, welding sup-
This warranty gives the purchaser specific legal rights. The
plies, standard accessory sets, replacement parts, and
purchaser may also have other rights which vary from state
Magnum products. (Does not include expendable parts
listed under 30 day warranty) to state.
30 Days
Equipment manufactured for the Lincoln Electric Company is subject to the
(1)
â? All consumable items that may be used with the environ-
mental systems described above. This includes hoses, fil- warranty period of the original manufacturer.
ters, belts and hose adapters.
All engines and engine accessories are warranted by the engine or engine
(2)
accessory manufacturer and are not covered by this warranty.
â? Expendable Parts - Lincoln is not responsible for the
replacement of any expendable part that is required due
SAE400 WELD Nâ? AIR compressor is warranted by the compressor manu-
(3)
to normal wear.
facturer and not covered by this warranty.
Dec, â?97
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
â? Sales and Service through Subsidiaries and Distributors Worldwide â?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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