Page 1
AC-235
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Specications and availability of optional
features may have changed.
WELDING POWER SOURCE
by
IM556
May, 2004
Contents Page
Safety Precautions ...............................................................................................2
Installation and Operating Instructions
for AC-235 ...................................................................................................7
Includes safety, installation, operating instructions
and parts lists.
Learning to Weld ...............................................................................................11
Using the Carbon Arc Torch..............................................................................18
Includes for heating metal, welding aluminum or
brazing with an arc torch.
Selecting Electrodes ..........................................................................................23
Brief descriptions of the types and operating
data for all Lincoln electrodes.
Welding Books and Teaching Aids ...................................................................25
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• Sales and Service through Subsidiaries and Distributors Worldwide •
• World's Leader in Welding and Cutting Products •
Copyright © 2004 Lincoln Global Inc.
Page 2
SAFETY
WARNING
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 purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” 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.
ELECTRIC SHOCK can kill.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
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,
kneeling or Iying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
1.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
1.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
2.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
3.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
ARC RAYS can burn.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
FUMES AND GASES
can be dangerous.
3.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
vapors
to
Apr. ‘93
3.e. Also see item 7b.
– 2 –
Page 3
SAFETY
WELDING SPARKS can
cause fire or explosion.
4.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
4.f.
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.
Always wear safety glasses with side shields when in a
welding area.
4.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
4.h. Also see item 7c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
5.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
– 3 –
Mar. ‘93
Page 4
SAFETY
FOR ENGINE
powered equipment.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
7.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been
eliminated.
____________________________________________________
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
ELECTRIC AND MAGNETIC
FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
8d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
8.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
8.d.5. Do not work next to welding power source.
____________________________________________________
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
– 4 –
Mar. ‘93
Page 5
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue ou
les vétements mouillés. Porter des gants secs et sans trous
pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un échauf-
fement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage, câbles
de grue, ou autres circuits. Cela peut provoquer des risques
d’incendie ou d’echauffement des chaines et des câbles jusqu’à
ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui pro-
duit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou quand
on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au soudage
à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons
sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une bonne
mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher
à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
– 5 –
Mar. ‘93
Page 6
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product •••
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.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
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.
– 6 –
Page 7
OPERATING INSTRUCTIONS
WARNING
•Have an electrician install and service this equipment.
•Turn the input power off at the fuse box before working on equipment.
•Do not touch electrically hot parts.
Input Power and Grounding Connections
Before starting the installation, check with the power company to be sure your power supply is adequate for the voltage, amperes, phase and frequency specified on the welder
nameplate. Also, be sure the planned installation will meet
the United States National Electrical Code and local code
requirements. This welder may be operated from a single
phase line or from one phase of a two or three phase line.
CONNECT TO A SYSTEM GROUNDING
WIRE. SEE THE UNITED STATES
NATIONAL ELECTRICAL CODE
AND/OR LOCAL CODES FOR OTHER
DETAILS AND MEANS FOR PROPER
GROUNDING.
CONNECT TO HOT WIRES OF
A THREE-WIRE, SINGLE
PHASE SYSTEM OR TO ONE
}
PHASE OF A TWO OR THREE
PHASE SYSTEM.
Attaching Electrode Cable to Holder
WARNING
All models designed to operate on less than 250 volt input
lines are shipped with the input cable connected to the
welder.
Place the welder so there is free circulation of air in through
the louvers in the back and sides of the case and out of the
bottom on all four sides. Mount a NEMA Type 6-50R
receptacle in a suitable location. Be sure it can be reached
by the plug on the input cable attached to the welder.
WARNING
These installation instructions apply to the input wiring
and overload protection installed to supply one AC-235
and comply with the United States National Electrical
Code as it applies to electric welders. Other equipment
should not be connected to this supply without consulting the input power requirements for that equipment,
the United States National Electrical Code, and all local
codes.
Using the following instructions, have a qualified electrician connect this receptacle (NEMA 6-50R Type) to the
power lines at the fuse box. Three #10 or larger copper
wires are required if conduit is used. For long cable runs
over 100', #8 or larger wire in conduit will be needed to
prevent excessive voltage drops. Fuse the two hot lines
with 50 ampere super lag type fuses as shown in the following diagram. The center contact in the receptacle is for
the grounding connection. A green wire in the input cable
connects this contact to the frame of the welder. This
insures proper grounding of the welder frame when the
welder plug is inserted into the receptacle. If a separate disconnect switch is used, it should have two poles for the two
hot lines and both should be fused for 50 amperes.
Before attaching the electrode cable to the electrode
holder or the work cable to clamp, be certain the welder
is turned off or the input power is disconnected.
1. Loosen locking screw and slide handle off holder. Place
handle over electrode cable.
2. Remove insulation from electrode cable 1” ± 1/16”
(25.4mm ± 1.6mm) from end.
3. Back out cable connecting screw until end is flush with
inside surface of jaw body.
4. Remove cable connecting clamp from holder jaws. Place
clamp over bare end of electrode cable and insert into
holder with clamp centered against connecting screw.
5. Tighten cable connecting screw securely against clamp.
– 7 –
Page 8
6. Slide handle into position and secure by turning the locking screw in until it is tight. The threaded end of the
screw will then pass against the inside of the handle and
the head of the screw will be completely inside the handle.
Important Safety Note: Make sure insulation is secure and
that screws are tight and cannot be touched. If screw can
be touched, DO NOT USE HOLDER, contact your distributor.
Attaching Work Cable to Clamp
Insert work cable through strain relief hole in work clamp
and fasten securely with bolt and nut provided.
Duty Cycle
The AC-235 is rated for 20% duty cycle on all switch positions except maximum (235 amps). At 235 amps the duty
cycle is 18%. A 20% duty cycle means that the arc can be
drawn for 2 minutes out of each ten minute period. An 18%
duty cycle means that the arc can be drawn for 1.8 minutes
out of each ten minute period. If the welding time is longer
than this for several successive ten minute periods, the
windings may overheat and be damaged. Be sure to leave
the unit “on” for each 10 minute period to let the fan motor
run for adequate cooling. Overheating reduces welder life.
Electrode Selection Guide
See Chart on Welder and at the end of this manual
Arc Torch (Optional Accessory)
The arc torch (see page 18) is especially suited for use on
these welders for brazing, welding non-ferrous metals and
preheating before bending and forming.
Electrode and Work Cable Replacement
Substitution of cables with larger sizes requiring connections to be made internally is not recommended.
Connections for additional lengths or larger sizes should be
properly made externally. Lincoln Electric QD (Quick
Disconnect) connectors are available for this purpose.
If either cable requires replacement for other reasons, they
should be replaced with the appropriate Lincoln parts—
and only by qualified personnel.
Welding Current Selection
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.
There is a slight amount of play in each switch position. It
is good practice to move the switch back and forth once
within this play after switching to a new position. This wiping action keeps the contacts free from dirt and oxides.
MAINTENANCE
Routine preventative maintenance is not required. See your
local Lincoln Electric Authorized Field Service Shop for
necessary repairs.
CAUTION
Do not turn the selector switch while welding as this will
damage the contacts.
– 8 –
Page 9
NOTES
–9 –
Page 10
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.
Parts List P-275 (AC-235)
10
2
11
1
4
3
7
5
6
12
16
Item Description
1A Fan Motor
1B Fan Blade
2 Case
3 Nameplate
4 Warning Decal
5 Selector Switch
6 Switch Handle
7 Output Lead Clamp
8 Line Switch
10 Lower Back Panel
11 Upper Back Panel
ACCESSORIES
12 Electrode Cable
13 Electrode Holder
14 Work Cable
15 Head Shield
15A Welding Gloves
13
15
14
21
15A
17
18
19
Item Description
16 Work Clamp
17 Wheel
18 Washer
19 Axle
20 Front Foot
21 Push Nut
22 Input Cable
8
22
20
OPTIONAL UNDERCARRIAGE KIT INCLUDES:
INPUT CABLE
– 10 –
Page 11
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.
No one can learn to weld simply by reading about it. Skill
comes only with practice. The following pages will help
the inexperienced welder to understand welding and
develop his skill. For more detailed information order
a copy of “New Lessons in Arc Welding” listed on page
25.
The Arc-Welding Circuit
The operator’s knowledge of arc welding must go beyond
the arc itself. He must know how to control the arc, and this
requires a knowledge of the welding circuit and the equipment that provides the electric current used in the arc.
Figure 1 is a diagram of the welding circuit. The circuit
begins where the electrode cable is attached to the welding
machine and ends where the work cable is attached to the
welding machine. Current flows through the electrode
cable to the electrode holder, through the holder to the electrode and across the arc. On the work side of the arc, the
current flows through base metal to the work cable and
back to the welding machine. The circuit must be complete
for the current to flow. To weld, the work clamp must be
tightly connected to clean base metal. Remove paint, rust,
etc. as necessary to get a good connection. Connect the
work clamp as close as possible to the area you wish to
weld. Avoid allowing the welding circuit to pass through
hinges, bearings, electronic components or similar devices
that can be damaged.
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 1—The welding circuit for shielded metal arc
welding.
The electric arc is made between the work and the tip end
of a small metal wire, the electrode, which is clamped in a
holder and the holder is held by the welder. A gap is made
in the welding circuit (see Figure 1) by holding the tip of
the electrode 1/16-1/8” away from the work or base metal
being welded. The electric arc is established in this gap and
is held and moved along the joint to be welded, melting the
metal as it is moved.
Arc welding is a manual skill requiring a steady hand, good
physical condition, and good eyesight. The operator controls the welding arc and, therefore, the quality of the weld
made .
What Happens in the Arc?
Figure 2 illustrates the action that takes place in the electric
arc. It closely resembles what is actually seen during welding.
The “arc stream’’ is seen in the middle of the picture. This
is the electric arc created by the electric current flowing
through the space between the end of the electrode and the
work. The temperature of this arc is about 6000°F.
(3315°C), which is more than enough to melt metal. The
arc is very bright, as well as hot, and cannot be looked at
with the naked eye without risking painful injury. The very
dark lens, specifically designed for arc welding, must be
used with the hand or face shield whenever viewing the arc.
The arc melts the base metal and actually digs into it, much
as the water through a nozzle on a garden hose digs into the
earth. The molten metal forms a molten pool or crater and
tends to flow away from the arc. As it moves away from the
arc, it cools and solidifies. A slag forms on top of the weld
to protect it during cooling.
–11 –
Page 12
FIGURE 2—The welding arc.
The function of the covered electrode is much more than
simply to carry current to the arc. The electrode is composed 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
the arc steadier, provides a shield of smoke-like gas around
the arc to keep oxygen and nitrogen in the air away from
the molten metal, and provides a flux for the molten pool.
The flux picks up impurities and forms the protective slag.
The principal differences between various types of electrodes are in their coatings. By varying the coating, it is
possible to greatly alter the operating characteristics of
electrodes. By understanding the differences in the various
coatings, you will gain a better understanding of selecting
the best electrode for the job you have at hand. In selecting
an electrode you should consider:
If you are using a hand shield, hold the electrode holder in
your right hand and the hand shield in your left. (For welding left-handed it is the opposite.)
Whenever possible, weld from left to right (if right-handed). This enables you to see clearly what you are doing.
Hold the electrode at a slight angle as shown.
2. The Correct Way to Strike an Arc
Be sure the work clamp makes good electrical contact to
the work.
Lower your headshield or hold the hand shield in front of
your face. Scratch the electrode slowly over the metal and
you will see sparks flying. While scratching, lift the electrode 1/8" (3.2mm) and the arc is established.
NOTE: If you stop moving the electrode while scratching,
the electrode will stick.
1. The type of deposit you want, e.g. mild steel, stainless,
low alloy, hardfacing.
2. The thickness of the plate you want to weld.
3. The position it must be welded in (downhand, out of
position).
4. The surface condition of the metal to be welded.
5. Your ability to handle and obtain the desired electrode.
Four simple manipulations are of prime importance.
Without complete mastery of these four, further welding is
more or less futile. With complete mastery of the four,
welding will be easy.
1. The Correct Welding Position
Beginners will find it easier to learn how to control the
welding arc using the two-handed technique shown below.
This requires the use of a headshield.
a. Hold the electrode holder in your right hand.
b. Touch your left hand to the underside of your right.
c. Put the left elbow against your left side.
(For welding left-handed it is the opposite.)
NOTE: Most beginners try to strike the arc by a fast jabbing motion down on the plate. Result: They either stick or
their motion is so fast that they break the arc immediately.
3. The Correct Arc Length
The arc length is the distance from the tip of the electrode
core wire to the base metal.
Once the arc has been established, maintaining the correct
arc length becomes extremely important. The arc should be
short, approximately 1/16 to 1/8" (1.6 to 3.2mm) long. As
the electrode 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
length is by listening to its sound. A nice, short arc has a
distinctive, “crackling” sound, very much like eggs frying
in a pan. The incorrect, long arc has a hollow, blowing or
hissing sound.
– 12 –
Page 13
4. The Correct Welding Speed
The important thing to watch while welding is the puddle
of molten metal right behind the arc. Do NOT watch the
arc itself. It is the appearance of the puddle and the ridge
where the molten puddle solidifies that indicate correct
welding speed. The ridge should be approximately 3/8"
(9.5mm) behind the electrode.
Most beginners tend to weld too fast, resulting in a thin,
uneven, “wormy” looking bead. They are not watching the
molten metal.
IMPORTANT: For general welding it is not necessary to
weave the arc; neither forwards and backwards nor sideways. Weld along at a steady pace. You will find it easier.
NOTE: When welding on thin plate, you will find that you
will have to increase the welding speed, whereas when
welding on heavy plate, it is necessary to go more slowly
in order to get good penetration.
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 constantly checking on your mistakes and your progress,
welding will soon be a matter of routine.
Common Metals
Most metals found around the farm or small shop are low
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 “I’’ 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
follow proper procedures, including preheating the metal to
be welded and, in some cases, carefully controlling the
temperature during and after the welding process. For further information on identifying various types of steels and
other metals, and for proper procedures for welding them,
we again suggest you purchase a copy of “New Lessons in
Arc Welding” (see page 25).
Practice
The best way of getting practice in the four skills that
enable you to maintain:
1 Correct Welding Position
2. Correct Way To Strike An Arc
3. Correct Arc Length
4. Correct Welding Speed
is to spend a little more time on the following exercise.
Use the following:
Mild Steel Plate ......................3/16" (4.8mm) or heavier
Electrode ............................1/8" (3.2mm) Fleetweld 180
Current Setting..........................................105 Amps AC
Do the following:
1. Learn to strike the arc by scratching the electrode over
the plate. Be sure the angle of the electrode is correct. If
you have a headshield use both hands.
2. When you can strike an arc without sticking, practice the
correct arc length. Learn to distinguish it by its sound.
3. When you are sure that you can hold a short, crackling
arc, start moving. Look at the molten puddle constantly,
and look for the ridge where the metal solidifies.
Regardless of the type of metal being welded, it is important in order to get a quality weld that it be free of oil, paint,
rust or other contaminants.
Types of Welds
Five types of welding joints are: Butt Welds, Fillet Welds,
Lap Welds, Edge Welds and Corner Welds.
Of these, the Butt Weld and Fillet Weld are the two most
common welds.
Butt Weld
Butt Welds are the most widely used welds. Place two
plates side by side, leaving 1/16” (1.6mm) (for thin metal)
to 1/8” (3.2mm) (for heavy metal) space between them in
order to get deep penetration .
– 13 –
Page 14
Tack the plates at both ends, otherwise the heat will cause
the plates to move apart. (See drawing):
Now weld the two plates together. Weld from left to right
(if right-handed). Point the electrode down in the crack
between the two plates, keeping the electrode slightly tilted
in the direction of travel.
Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates.
Penetration
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
electrode in the holder at a 45° angle, as shown:
Unless a weld penetrates close to 100%, a butt weld will be
weaker than the material welded together.
(12.7 mm)
In this example, the total weld is only 1/2 (12.7mm)the
thickness of the material; thus the weld is only approximately half as strong as the metal.
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.
Multiple Pass Welds
Make multiple pass horizontal fillets as shown in the
sketch. Put the first bead in the corner with fairly high current. Hold the electrode angle needed to deposit the filler
beads as shown putting the final bead against the vertical
plate.
Welding in the Vertical Position
Welding in the vertical position can be done either verticalup or vertical-down. Vertical-up is used whenever a large,
strong weld is desired. Vertical-down is used primarily on
sheet metal for fast, low penetrating welds.
Vertical-Up Welding
The problem, when welding vertical-up, is to put the
molten metal where it is wanted and make it stay there. If
too much molten metal is deposited, gravity will pull it
downwards and make it “drip.’’ Therefore a certain tech-
– 14 –
Page 15
nique has to be followed:
1. Use 1/8" (3.2mm) at 90-105 amps or 3/32" (2.4mm) at
60 amps Fleetweld® 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" (12.7-19mm) 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 “drip.’’)
5. The upward motion of the arc is caused by a very slight
wrist motion. Most definitely, the arm must not move in
and out, as this makes the entire process very complicated and difficult to learn.
6. If the upward motion of the arc is done correctly with a
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.
1. Use 1/8 (3.2mm) or 3/32" (2.4mm) Fleetweld 180 electrode.
2. On thin metal, use 60-75 amps. (14 ga 75 amps — 16 ga
60 amps.)
3. Hold the electrode in a 30-45° angle with the tip of the
electrode pointing upwards.
4. Hold a VERY SHORT arc, but do not let the electrode
touch the metal.
5. An up and down whipping motion
will help prevent burn-through on
very thin plate.
6. Watch the molten metal carefully.
The important thing is to continue lowering the entire arm
as the weld is made so the angle of the electrode does not
change. Move the electrode so fast that the slag does not
catch up with the arc. Vertical-down welding gives thin,
shallow welds. It should not be used on heavy material
where large welds are required.
Overhead Welding
Various techniques are used for overhead welding.
However, in the interest of simplicity for the inexperienced
welder the following technique will probably take care of
most of his needs for overhead welding:
1. Use 1/8" (3.2mm) at 90-105 amps or 3/32" (2.4mm) at
60 amps Fleetweld 180 electrode.
2. Put the electrode in the holder so it sticks straight out.
3. Hold the electrode at an angle approximately 30° off
vertical, both seen from the side and seen from the end.
8. When the arc is brought back to the now solidified puddle, IT MUST BE SHORT, otherwise no metal will be
deposited, the puddle will melt again, and it will “drip.”
9. It is important to realize that the entire process consists
of SLOW, DELIBERATE movements. There are no fast
motions.
Vertical-Down Welding
Vertical-down welds are applied at a fast pace. These welds
are therefore shallow and narrow, and as such are excellent
for sheet metal. Do not use the vertical-down technique on
heavy metal. The welds will not be strong enough.
The most important thing is to hold a VERY SHORT arc.
(A long arc will result in falling molten metal; a short arc
will make the metal stay.)
If necessary — and that is dictated by the looks of the
molten puddle — a slight back and forth motion along
the seam with the electrode will help prevent “dripping.”
–15 –
Page 16
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.)
2. Use 1/8” (3.2mm) or 3/32" (2.4mm) Fleetweld 180 electrode.
3. Use low amperage. 75 amps for 1/8" (3.2mm) electrode,
40-60 amps for 3/32" (2.4mm) electrode.
4. Move fast. Don’t keep the heat on any given point too
long. Keep going. Whip electrode.
5. Use lap welds whenever possible. This doubles the
thickness of the metal.
Hardfacing
There are several kinds of wear. The two most often
encountered are:
1. Metal to Ground Wear.
(Plowshares, bulldozer blades, buckets, cultivator
shares, and other metal parts moving in the soil.)
2. Metal to Metal Wear.
(Trunnions, shafts, rollers and idlers, crane and mine car
wheels, etc.)
Each of these types of wear demands a different kind of
hardsurfacing electrode.
When applying the proper electrode, the service life of the
part will in most cases be more than double. For instance,
hardsurfacing of plowshares results in 3-5 times more
acreage plowed.
How to Hardface the Sharp Edge (Metal to Ground
Wear)
1. Grind the share, approximately one inch (25mm) wide
along the edge, so the metal is bright.
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
side. The important thing is to hardface the side that
wears.
3. Use 1/8" (3.2mm) Abrasoweld™ electrode at 90-105 amps.
Strike the arc about one inch (25mm) from the sharp edge.
4. The bead should be put on with a weaving motion, and
it should be 1/2 to 3/4" (12.7 to 19mm) wide. Do not let
the arc blow over the edge, as that will dull the edge.
(See drawing.)
(12.7 to 19 mm)
5. Use the back-stepping method. Begin to weld 3"
(75mm) from the heel of the share and weld to the heel.
The second weld will begin 6" (150mm) from the heel,
the third weld 9" (225mm) from the heel, etc.
Backstepping greatly reduces the chances for cracking of
the share, and it also greatly reduces possible warpage.
NOTE: The entire process is rather fast. Many beginners
go much to slow when hardfacing plow shares, running the
risk of burning through the thin metal.
Hardfacing of Idler and Roller (Metal to Metal Wear)
A very common application of hardfacing for metal to
metal wear is the hardfacing of idlers and rollers and the
rails that ride on these rollers and idlers.
The reason for hardfacing these parts is primarily monetary. A few dollars worth of electrode will completely build
up a roller or idler, and the hard surface will outlast several times the normal life or such rollers and idlers.
If the following procedure is followed, it is not even necessary to remove the grease bearing while welding. This will
save a lot of time:
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-LH
®
BU-90 electrodes, 5/32" (4.0mm) at 175
amps or 3/16" (4.8mm) at 200 amps.
3. Weld across the wearing surface. Do not weld around.
4. Keep the roller (or idler) cool by quenching with water,
and by stopping the welding periodically. This will prevent shrinking of the roller (or idler) on the grease bearing.
5. Build-up to dimension. The weld metal deposited by
BU-90 electrode is often so smooth that machining or
grinding is not necessary.
– 16 –
Page 17
NOTE: The quenching of the roller (or idler) has another
purpose: It increases the hardness — and thus the service
life — of the deposit.
The hardfacing of the rails is a lot easier:
1. Place the rails with the side that rides on the rollers and
idlers upwards.
2. Use Jet-LH BU-90 electrodes. Same ampere setting as
on the idlers and rollers.
3. Build-up to size.
4. Do not quench. This will make the deposit slightly softer than the deposit on the idlers and rollers. That means
that the wear will primarily be on the rails, which are a
lot easier and less time-consuming and cheaper to buildup.
In this way no large amount of heat is put into the mass.
Most inexperienced welders will probably use the second
method, because they have no way of preheating large castings. Smaller castings can easily (and should) be preheated
before welding. A forge, stove, a fire, or the Arc Torch are
all excellent means of preheating.
When using the 1/2" (12.7mm) at a time method, it is recommended to start 1/2" (12.7mm) away from the previous
bead and weld into the previous bead (backstepping).
After welding Cast Iron, protect the casting against fast
cooling. Put it in a sand (or lime) box.
If sand or lime is not available, cover it with sheet metal or
any other non-flammable material that will exclude drafts
and retain heat.
NOTE: The same electrode — BU-90 — 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.
NOTE: The outside of the rails (the side that comes in contact with the ground) should be surfaced with Abrasoweld,
since this side has Metal to Ground wear.
Welding Cast Iron
When welding on a piece of cold cast iron, the tremendous
heat from the arc will be absorbed and distributed rapidly
into the cold mass. This heating and sudden cooling creates
WHITE, BRITTLE cast iron in the fusion zone.
This is the reason why welds in cast iron break. Actually,
one piece of the broken cast iron has the entire weld on it,
and the other piece has no weld on it.
Cast Iron Plate Preparation
Wherever practical, the joint to be welded should be “veed”
out by grinding or filing to give complete penetration. This
is especially important on thick castings where maximum
strength is required. In some instances a back-up strip may
be used and plates may be gapped 1/8" (3.2mm) or more.
On sections where only a sealed joint is required and
strength is not important, the joint may be welded after
slightly veeing out the seam as shown.
Cutting Do not exceed the Duty Cycle — See
page 8)
In order to overcome this, the welding operator has two
choices:
1. He can preheat the entire casting to 500-1200°F. (260649°C). If the cast iron is hot before welding, there will
be no sudden chilling which creates brittle white cast
iron. The entire casting will cool slowly.
2. He can weld 1/2" (12.7mm) at a time, and not weld at that spot
again until the weld is completely cool to the touch.
The arc welder and the electrode can be used for cutting
steel and cast iron. Follow this procedure:
1. Use 1/8:” (3.2mm) or 5/32" (4.0mm) Fleetweld 180 electrode.
2. Set welder on maximum (235 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, sawing motion, melting the metal and pushing it away.
–17 –
Page 18
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.
USING THE CARBON ARC TORCH
. . . Welding Aluminum and Copper Alloys
. . . Brazing and Soldering
. . . Heating, Bending and Straightening
WARNING
ELECTRIC SHOCK can kill.
When soaking electrode keep your gloves and
clothing dry. Never dip an electrode holder in
water..
Piercing Holes
1. Welder setting: Maximum
(235 amps).
2. Electrode: 1/8” (3.2mm) or
5/32" (4.0mm) Fleetweld 180.
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
the puddle. Be sure the metal is molten before pushing
through .
NOTE: On heavy metal (5/16" (7.9mm) or thicker), position the plate to be pierced vertically, and the electrode horizontally. This allows the molten metal to drip away freely
as you are boring through.
Use 235
amperes
Jaw Assembly
T9984
(2 Required)
Complete Arc Torch
K1876-1
Thumb Screw
T9078
(Part of T9984)
Ground Clip
T10379-1
Required Equipment
1. A Lincoln Carbon Arc Torch L-2645; Its rating is 100
amperes.
2. 1/4, 5/16 or 3/8” (6.4, 7.9, or 9.5mm) carbons: Use only
copper coated and cored carbons to avoid overheating
the holder and provide even burning of the carbons.
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 connected to the negative DC output so both carbons
burnoff at about the same rate.
Torch Connections
Insert the straight ferrule on the end of one arc torch lead
into the standard electrode holder. Attach the spring clip on
the end of the other lead to either the work clamp or the
welding table where the work lead is clamped. If connected to the table, insulate the work from the table. See drawing below.
CAUTION: INSULATION IS REQUIRED
IN THESE TWO AREAS.
– 18 –
Page 19
WARNING
ARC RAYS can burn.
The carbon arc torch rays will cause severe
arc burns to exposed skin. Therefore, a pair of
work gloves, long sleeved shirt or sleevelets,
and an apron are recommended.
Use an arc welding headshield or hand shield with a No. 11
or No. 12 lens. Oxyacetylene goggles are not sufficient eye
and face protection.
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
the grounded bench or work. This is best done by turning
the welder off. As an alternative, either set the torch on an
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
THE WELDER. Exceeding this duty cycle in successive
10 minute periods can overheat the welder and damage the
windings. (See page 8.)
Heat Settings
Recommended current settings for different material thicknesses and carbon sizes are given in the table. Generally, use
only enough current to cause the filler metal to flow freely on
the work. Do not use currents so high that the copper coating
burns away more than 1/2’’ (12.7mm) above the arc.
2.00"
0.06"
Use the thumb control on the arc torch to rotate the carbons until
they touch. Start the arc by reversing the thumb control setting
to spread the carbons 1/16 to 3/16" (1.6 to 4.8mm) apart. As the
carbons burn away use the thumb control to maintain the
desired arc. When the proper arc can no longer be maintained,
turn the welder off and readjust the carbon stickout.
A wide, soft, quiet flame gives the best results for most
jobs. When the carbon tips are too close together a small
flame accompanied by a hissing or crackling sound results.
The shape of a good flame is illustrated below. The flame
fans out to form a “fish tail” shape with inner and outer
cone. To heat a crack or a corner, position the flame as illustrated.
Set the carbons to extend about 2” (50mm) beyond the copper jaws.
WARNING
Be sure the welder is turned off when making this
adjustment.
Thickness of Approximate Current Carbon
Base Metal Setting (AC) Diameter
1/32"(0.8) 30-50 amps 1/4"(6.4)
1/16"(1.6) 50-60 amps 1/4"(6.4)
1/8"(3.2) 70-80 amps 5/16"(7.9)
1/4"(6.4) 90-100 amps 3/8"(9.5)
After adjusting the welder current and setting the carbon
stickout, start the welder and you are ready to go.
– 19 –
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
on 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.
Page 20
Heating Heavy Parts
Welding Procedures
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 direction 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
amount of the arc going to the work thus reducing the heating. The arc between the carbons and work tends to pit the
surface of the work.
Welding Aluminum Alloys With The
Arc Torch
The need to repair aluminum parts continues to grow.
These repairs can be simply made with an AC welder using
Aluminweld DC coated electrodes as a filler rod and The
Carbon Arc Torch. The arc torch preheats the aluminum
plate, assuring good fusion.
1. Use the recommended AC currents and carbon sizes listed in the Table on page 19. A headshield is required.
2. Use a l/8" (3.2mm) ‘Aluminweld’ coated electrode as a
filler rod. Hold it in the left hand (for right-handed people).
3. Hold the arc torch in your right hand and start the arc by
shorting the carbons together and adjusting them to a
1/16" (1.6mm) gap.
4. Hold the arc torch as shown here. Hold your eyes right
over the arc torch looking in between the two carbons.
5. Play the arc 3" to 4" (75 to 100mm) up and down the
joint at the start. This preheat helps to give a smoother
bead and an easier start when the filler rod is applied.
6. Move the torch to the beginning of the joint (right-handed people should begin at the right and move left).
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
enough to start welding.
8. Let a droplet of the filler rod melt and fuse into the
joints.
9. Watch the molten puddle. Add more filler metal by moving the end of the rod in and out of the arc as the right
hand moves the arc torch slowly along the joint.
Work Preparation
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.
Practice
When you first try to weld with these procedures, you may
have a tendency to burn through. Therefore, a few minutes
practice before working on the parts to be welded is recommended. Use scrap material about as thick as the part
you are going to weld. Practice the technique to get the feel
of the arc.
Brazing
The techniques for brazing with an arc torch are very much
like the ones used for gas brazing. Only enough heat is needed to melt the filler metal and to raise the parts to be brazed
to the melting temperature of the filler metal — usually
slightly over 1,000°F. (538°C). A good brazed joint is
assured when the filler metal flows into the joint and adheres
evenly to the surfaces. Use only enough filler metal to make
a smooth joint. Use standard gas brazing rod and flux .
Heat the end of the brazing rod and dip it into the flux. The
flux will stick to the hot rod. Play the arc back and forth a
short distance along the seam when the right temperature is
reached. Apply flux as needed and melt off brazing rod to
fill the seam. Move along the seam until the job is complete.
–20 –
Page 21
If the part being brazed does not get hot enough, increase
the current or hold the torch closer to the work. Whenever
possible, have the joint horizontal to secure best flow of
molten filler rod.
Soldering
The arc torch can be used to solder copper piping and other
copper, tinned and galvanized parts. Best results are
obtained with overlapping pieces. Clean the surfaces to be
soldered and cover them with soldering flux to prevent oxidation and to speed soldering. Acid core solder produces
good results.
The best soldering can be done on the lowest current tap of
the welder. Use approximately 1/4" (6.4mm) diameter carbon and make certain to bring it into firm contact with the
piece to be soldered to avoid arcing. Simply play the arc on
the area to be soldered and feed solder into the joint as it
reaches proper temperature. After the soldering is completed, the carbon must be removed quickly to prevent arcing.
Never use so much heat that the solder boils.
Heating, Bending and Straightening
Choose the carbon size and current setting depending upon
the thickness of the metal to be heated. Play the arc over the
section to be heated until the desired temperature is
reached. For bending this is usually a dull red color on ordinary mild steels.
Do not hold the carbons too close to the work. Arcing the
surface increases the tendency for the base metal to crack
when the bending is done.
Carbon Arc Torch Maintenance
The handle is held together with a screw and spring lock
washer to give just the right friction on the electrode shafts.
If the handle is removed for any reason, the screw at the
front of the handle should be turned up snugly and then
backed off 1/2 turn to give the proper friction.
Occasionally the screws in the copper jaws will bind, so it
will be advantageous to lubricate the threads with graphite
grease and work the grease well into the threaded jaw.
SELECTING ELECTRODES
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 “A’’ and “B’’ (below) for the
first pass on vertical-up welds.
High-Deposit Group (E6027, E7024)
This group includes the heavy coated, iron powder electrodes with their soft arc and fast deposit rates. These electrodes 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 downhill 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
“D’’ (below) is generally used for vertical-up welding, but
motions “A” and “B” are also suitable.
Low Hydrogen Group (E7018, E7028)
These electrodes are generally called “low hydrogen.” The
name comes from the fact that their coating contains little
hydrogen in either moisture or chemical form. Low hydrogen electrodes offer these benefits: outstanding crack resistance, lowest porosity on sulphur bearing steels, and capable of X-ray quality deposits. Thus, they are the first choice
when welding “problem” steels. E7018 can be used in all
positions, with Motion “C” recommended for the first pass
on vertical-up welds. NEVER use a whipping technique or
a long arc with these electrodes. ALWAYS fill craters by
drawing electrodes away slowly. ALWAYS keep these electrodes dry. Electrodes not used within a few hours after a
container is opened must be stored in heat cabinets. LH-73
is recommended with the AC-235. Normally, DC(+) is preferred for these electrodes.
Which electrode is best for the particular job . . . how do
you use it? These are important questions because the cost,
quality, and appearance of your work depends on proper
electrode selection and application. MILD STEEL ELECTRODES may be classified into the following groups:
Out-of-Position Group (E6011)
This group includes electrodes which have a snappy, deep
penetrating arc and fast freezing deposits.
– 21 –
Page 22
Motions
Manipulation depends on the joint. Some of the common
motions are shown above.
Motion “A” is a straight whipping motion used with fastfreeze electrodes to make stringer beads in all positions and
on all types of joints. It keeps the molten pool small and lets
it freeze quickly so the weld metal doesn’t spill down or
through the joint. Keep arc short when in the crater and
longer during whip out from the crater.
Motion “B” is a whipping motion combined with a slight
weave in the crater. It is used with fast-freeze electrodes as
the first pass on vertical fillets and V-butts.
Motion “C” is a simple side-to-side weave used with all
types of electrodes to make fill passes on vertical fillets and
V-butts. Also sometimes used with fill-freeze and low
hydrogen electrodes to make the first pass on these joints.
Motion “D” is a triangular weave used with fill-freeze and
low hydrogen electrodes to make one pass vertical fillets
and V-butts. It results in a larger weld than Motion “C’’.
Motion “E” is a box weave used with all types of electrodes to make fill passes on vertical fillets and V-butts. It
is similar to Motion “C,’’ but with a distinct pause and
slight upward motion at each edge of the weld to assure
complete crater filling and elimination of undercut.
Motion “F” is a circular motion used with all types of electrodes to make overhead welds. Sometimes accompanied
by a slight whip after each oscillation in the crater. Always
use a series of stringer beads overhead; do not weave.
Motion “G” is a simple side-to-side weave used with all
electrodes on wide fillets or butts in the flat position.
– 22 –
Page 23
NOTE: The AC-235 is an AC welder. DC electrodes have been included in the chart below for referance only.
ELECTRODE IDENTIFICATION AND OPERATION DATA
Coating Requirements of Electrode
Color AWS Class Brand Name
Conforms to Test Polarity Sizes and Current Ranges (Amps.)
Brick Red E6010 Fleetweld 5P DC(+) 40-75 75-130 90-175 140-225 200-275 220-325 240-400
Tan E6012 Fleetweld 7
Gray E6011 Fleetweld 35
Red Brown E6011 Fleetweld 35LS
Gray Tan E6013 Fleetweld 37
Gray Brown E7014 Fleetweld 47
Gray* E6013 Fleetweld 57
Brown E6011 Fleetweld 180
®
Gray E7024 Jetweld
1
Red Brown E6027 Jetweld 2
Gray* E7024 Jetweld 3
(1)
Gray E7018 Jetweld LH-70
Gray*
E7018
(white numbers) DC(+) 65-85 90-125 130-185
Jetweld LH-73
White E7018 Jetweld LH-75
Gray
7018
(white numbers) AC 120-170 140-230 210-290 270-370 325-420
JET-LH 78
Gray Brown E7028 Jetweld LH-3800
(1)
5/16" Jetweld 3 does not conform to any AWS/ASME classification.
Pink E7010-A1 Shield Arc®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
Gray Brown E8018-C1 Jet-LH
®
8018 C1
Gray Brown E8018-C3 Jet-LH 8018 C3
Gray E8018-B2 Jetweld LH-90
Gray E11018-M Jetweld LH-110M
Pale Green E308-15 Stainweld®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
White Aluminweld
Light Tan ESt Ferroweld
Black ENiCl Softweld
®
®
®
Black Wearshield ABR
Black Faceweld
Black Faceweld 12 DC(+); AC 60-150
®
1 DC(+); AC 60-150
Dark Gray Jet-LH BU-90
Dark Gray Mangjet
Dark Gray Wearweld
®
®
Electrode
(+) = “Reverse”
(–) = “Straight”
5/64" Size 3/32" Size 1/8" Size 5/32" Size 3/16" Size 7/32" Size 1/4" Size 5/16" Size
MILD STEEL
DC(–) 80-135 110-180 155-250 225-295 245-325
AC 90-150 120-200 170-275 250-325 275-360
AC 50-85 75-120 90-160 120-200 150-260 190-300
DC(+) 40-75 70-110 80-145 110-180 135-235 170-270
AC 80-130 120-160
DC(±) 70-120 110-150
AC 50-80 75-105 110-150 160-200 205-260
DC(±) 45-75 70-95 100-135 145-180 190-235
AC 110-160 150-225 200-280 260-340 280-425
DC(–) 100-145 135-200 185-235 235-305 260-380
AC 100-150 150-200 200-260
DC(–) 90-135 135-180 180-235
AC 40-90 60-120 115-150
DC(±) 40-80 55-110 105-135
AC 65-120 115-175 180-240 240-300 300-380 340-440
DC(±) 60-110 100-160 160-215 220-280 270-340 320-400
AC 190-240 250-300 300-380 350-450
DC(±) 175-215 230-270 270-340 315-405
AC 65-120 115-175 180-240 240-315 300-380 350-450 380-600
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
AC 80-120 110-170 135-225 200-300 260-380 325-440 400-530
AC 70-90 95-135 140-200
DC(+) 70-110 95-160 120-190 180-270 250-330 300-400
AC 80-110 100-170 135-225 210-290 270-370 325-420
DC(+) 85-110 110-160 130-200 180-270 250-330 300-400
AC 180-270 240-330 275-410 360-520
DC(+) 170-240 210-300 260-380
LOW ALLOY, HIGH TENSILE STEEL
DC(+) 90-150 120-180 180-270 250-350
AC 110-160 140-200 200-300 300-400
DC(+) 110-150 130-190 180-270 250-330 300-400
AC 120-170 140-225 210-290 270-370 325-420
DC(+) 110-150 130-190 180-270
AC 120-170 140-225 210-290
DC(+) 70-100 85-155 120-195 160-280 190-310 230-360
AC 80-110 100-170 135-225 200-310 240-350 290-410
STAINLESS STEEL
ALUMINUM
DC(+) 20-55 45-125 60-170 85-235
1/8" Size 5/32" Size 3/16" Size 1/4" Size
CAST IRON
DC(+); AC 80-100
DC(±) 60-110 100-135
AC 65-120 110-150
HARDFACING
DC(±) 40-150 75-200 110-250 150-375
AC 50-165 80-220 120-275 165-410
DC(±) 145-210 180-280 230-360
AC 155-225 200-290 255-375
DC(±) 120-180 160-260 200-350
AC 135-230 165-285 220-385
DC(+) 110-275 150-400
AC 125-275 200-400
®
Means registered Trademark of The Lincoln Electric Company.
* Has identification dot on coating.
The electrodes under the shaded portions of this chart will operate on
the AC-235 Arc Welder. However, the size and current used must be
within the capacity of the welder.
– 23–
Page 24
– 24 –
Page 25
Page 26
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S 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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Page 27
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Não toque as partes elétricas nuas.
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
Page 28
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
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