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March

1995

Effective

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OM-121

KF851

986A

163

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OM-121

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11/89

Section

SECTION

SECTiON

SECTION

No.

-

1

SAFETY

1-1.

1-2.
1-3.

1

-4.

Introduction

General

Arc

Standards

2-INTRODUCTION

2-1.

2-2.

2-3.

2-4.

2-5.

3-1.

3-2.
3-3.

Volt-Ampere

Duty

General

Receiving-Handling

Description

3

INSTALLATION

Location
Weld

Electrical

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Booklet

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Information

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TABLE

FOR

Index

Curves

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Connections

Connections

OF

OPERATION

Safety

CONTENTS

ARC

OF

WELDING

POWER

Page

SOURCE

No.

1

1

4

5

6

7

7
7

7

8
8

9

SECTION

SECTION

SECTION

SECTION

4-1.
4-2.

4-3.

4-4.

5-1.
5-2.

6-1.

6-2.

6-3.

6-4.

6-5.

6-6.

4-

OPERATOR

Power
Electrode
Heat

Amperage

5-

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ELECTRICAL

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Scale

OF

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Arc

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DIAGRAMS

Control

(SMAW)

10

10

10

11

11

11

12

12

12
12

13

14

Diagram

7-1.

Circuit

Diagram

15

Section

No.

Page

No.

SECTION

SECTION

8-

8-1.
8-2.
8-3.

8-4.

8-5.

8-6.

8-7.

9-

Figure

Figure
Figure
Figure

PRINCIPLES

General

Striking

The

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METAL

And

ARC

Overhead

WELDING

15

16
17

17

18

20

22

24

26

27

28

SECTION

1-1.

INTRODUCTION

We

learn

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OM-121

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DEFACE

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OM-121

986

Page

2

Empties:

mark

MI;

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keep

promptly.

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other

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statement

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OM-121

986

Page

3

1-3.

ARC

WELDING

Comply

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careless

high

bright

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OM-121

986

Page

4

electrically

tally.

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OM-121

986

Page

8

C.

Weld

tIon

4-2)

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WARNING:

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IMPORTANT:

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OM-121

986

Page

9

The

wall

location

cle

with

cable

power

or

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receptacle

a

by

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grounding

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OPERATOR

Figure

CONTROLS

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3-2.

Conductor

Input

RANGE

ELECTRODE

:

Connections

RECEPTACLES

4-1.

POWER

POWER

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the

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amperage

age

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OM-121

986

Page

10

4-4.

AMPERAGE

An

indicator

selected

age

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by

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when

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-

1

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Power

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insert

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OM-121

986

Page

11

SECTION

MAINTENANCE

6-

&

TROUBLESHOOTING

IMPORTANT:

this

unit

for
maintained
when

necessary.

FAN

unit

draft

should

labels.

MOTOR

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cautionary

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ings

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6-2.

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months

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adequate

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the

oilingofbearings

Warranty

in

of

dirt

components.

CLEANING

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live

touch

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6-4.

OM-121

986

touch

down

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fuses

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turn.

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10.

secure

dle.

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ing

the

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IMPORTANT:

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to

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turn

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cranking

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1/4

and

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situation

vibration

the

is

assumed

it

Section

to

ing

with

the

was

working

the

to

welding

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following

remedies
this

welding

this

Use
while

performing

trouble

dures,

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the

tion,

strictly

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3

of

function

properly,

process.

chart

for

some

power

in

chart

is

not

remedied

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nearest

manufacturers

followed.

the

unit

this

manual,

of

controls,

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of

the

source.

conjunction

toubleshooting

after

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was

properly

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that

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to

troubles

with

installed

the

operator

welding

trouble

diagnose

that

the

may

procedures.

performing

Authorized

of

cases

recommendations

Service

equipment

OM-121

is

power

is

not

and

develop

circuit

these

should

986

accord

familiar

source

related

provide

in

diagram

If

the

proce

Station

malt

unc

be

13

Page

Table

6-1.

Troubleshooting

Chart

fan

current.

run;

start;

does

weld

erratic

PROBABLE

line

switch

welding

or

damp

motor

wrong

fuse.

FM

Open

POWER

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receptacle.

CAUSE

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connections.

electrodes.

ELECTRODE

Check

Replace

line

Si.

fuses

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fit

properly

into

receptacles.

different

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freely,

The

ELECTRODE

vide

better

both

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electrodes.

FM

leads.

replace

arc

ELECTRODE

REMEDY

and

replace

connections.

WORK

the

If

FM.

starting

okay

LOW

for

and

receptacle

receptacles.

if

Make

and

fan

some

open.

sure

plugs

ELECTRODE

motor

turns

will

electrodes.

pro

OM-121

986

Page

14

SECTION

~w

POWER
A~4D

Gpo.

PLUG

CORD

7

ELECTRICAL

DIAGRAMS

TI

GENERAL

8-1

Shielded
machine

one

piece

nected

the

trolled,

the
trode

metal
electrodes

to

of

(0.10-0.14)
applied

arc

transfers

In

welding,

tial.

voltage

arc

practical

current,

quires

tion,

marked

Metal

depends

of

side

the

of

steel

to

an

electrode

the

metal

and

is

will

moved

be

deposit

arc

used

produce

steel

strong,

wire,

percentage

a

special

and

at

the

across

ordertoutilize

some

The

power

and

current.

less

the

and

measure

measured

current

scale

off

for

length

SECTION

Arc

welding

upon

secondary

the

and

electrode,

touches

the

from

deposited

the

along

uniform

a

in

welding

sound

usually

called

coating

time

same

the

arc.

these

a

the

of

than

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various

of

welding

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electrode

the

in

amperes.

front

means

in

on

the



8

PRINCIPLES

with

transformer

a

the

fundamental

welding

other

arc

an

steel.

the

on

circuitisattached

of

side

will

be

lithe

electrode

the

steel.

arc

steelatthe

calledabead.

layer

are

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welds.

of

which

protects

principles

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sinceitcontains

mild

carbon.

assists

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in

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the

circuitisdetermined

arc

voltage

diameter.

heat

or

power

a

large

the

of

current

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one.

welding

values.

small

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DIagram

that

fact

circuit

the

established

is

properly

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pass

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correct

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speed,

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this

in

creating

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power

governed

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is

terms

electrode

simplify

machine

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OF

welding

when

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when

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through

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elec

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of

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metal

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WORK

7-1.

SHIELDED

to

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the

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is

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size

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available.

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HIGH

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METAL

exact

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on

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Table

Requirements

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5/64
3/32

1/8

5/32

3/16

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a

part

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have

8-1.

Mild

ARC

required

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to

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thickness.

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lower

a

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8-1.

Flat

WELDING

for

a

job

and

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be

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current

sections.

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recommendation

Requirements

Electrodes

For

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Mi

20

40

65

90

120

Position

depends

the

position

sufficient

be

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manufacturers

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upon

of

weld

for

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to

weld

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given

used

on

charts

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50

80
125
160

180

the

on

thin

a

OM-121

986

Page

15

While

it

is

always

shown

as

tion,

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in

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reduce

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in

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a

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in

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overhead

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value

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used

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posi

8-4,

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Figure

8-2.

STRIKING

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the

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to

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fundamental

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OM-121

986

Figure

16

Page

8-5.

Electrode

Insertion

Figure

8-8.

To15

Base

Metal

Electrode

I

Electrode

Position

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slag

is

quite

layers

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melted

not

fastatravel

too

TEE

other

tee

preparation,
Typical

8-15

bottom

Figure

weld

was

and

1/4

AND

basic

When

root).

proceed

double

will

available,

the

vise.

will

holding

weld

V

be

thickness.Onthe

may

practice

pieces

metal

burns.

welded

Hammer

8-14.

bend

the

looks

groove

necessary

be

necessary

butt

Where

this

should

of

piece

side

root

A

over,

cause.

spongy)

too

long

Is

good

perhaps

manipulated

from

likely

calls

on

bevel

in.

Vise

and

and

electrode

the

to

happen

for

breaking

is

still

and

the

speed

mm)

(6.4

LAP

type

lap

8-14.

JOINTS

of

joints.

other

FIgure

welded

Figure

thorough

cause

weld,

tee

8-16

skill

has

and

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to

butt

to

deposit

heavier

fill

to

weldsitis

elaborate

be

observed

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the

in

direction

a

of

the

weld

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the

there

it

is

an

arc.

arc

done

sInce

weld

weld,

will

weld

are

porous.

was

may

be

metal,

with

it

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the

incorrectly

coating

I

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a

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will

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it

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found

evident.

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quite

insufficient

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76

to

(51

-I

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the

fillet

For

this

than

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lap

joints

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in.

type

respectively.

been

acquired

to

then

joints.

the

wisetocheck

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a

plates,

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groove

or

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with

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a

In

handlIng

heat

and

a

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joint

mm)

absorbed

can

just

than

the

in

break

not

breaks,

number

large

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there

are

short

too

thus

be

to

made

between

that

the

means

to

likely

heat.

is

weld,

of

welding,

above

tends

manner

examine

is

permitting

trapped.

be

used

edges,

are

pictured

on

also

layer

corn

the

equip

cause

the

to

under

of

prob

bits

of

the

or

in

sev

lay

original

that

is

found

for

no

is

nec

in

OM-121

986

Page

18

ARC

RATE

SHORT

450

OF

Or

AND

SPEED-NO

Lees

MOVED

AT

DEFINITE

OSCILLATION

Figure

8-15.

Tee

Joint

Figure

Circular

Weave

Figure

8-18.

Tee

8-17.

Joint

Multi-Layer

Fillet

Deposits

Square

Sox

Weld



Tee

Joint

Weave

Considering

the

that

method

The

method

be

not

To

depositasingle

shown

corner

mately

be

deposited

heavier

a

cated
shown

the

position

of

electrode

satisfactory.

in

Figure

and

a

equal.

fillet

in

Figure

in

Figure

Figure

tee

of

holding

8-17.

fillet,

For

maximum

each

on

is

needed,

8-18,

8-19.

8-16.

Lap

it

first,

joint

the

of

pieces

manipulation

electrode

the

fillet

pass

the

weld,

will

This

sideofwhich

strength

sideofthe

deposit

using

any

Joint

will

be

requires

than

hold

provide

upright

second

a

of

the

seen

immediately

forabutt

for

butt

the

electrode

fusion

will

be

weld

fillet

a

section.

layer

weaving

different

a

weld.

welds

into

approxi

should

When

as

patterns

will

as

the

indi

Figure

The

type,

therefore

the

pass

the

joint,

lap

the

application

weld.

details.

8-19.

Tee

while

fillet,

requires

For

Figure

JoInt

involving

has

metal

still

another

are

given

two

a

pass

300

8-20.

Lap

Fillet

Weld

the

same

distributed

technique.

in

Figure

weld,

Or

Lose

Joint

Weave

fundamental

differently

8-20,

Figure

Fillet

Weld

OM-121

The

for

8-21

Patterns

weld

details

a

single

provides

986

Page

and

of

19

To

progress

move

zontal

the

weld

with

plates

beads

this

into

practice

vertical

are

given

it

is

necessary

position.

in

The

Figure

details

8-24.

now

of

to

hori

Figure

8-6.

AND

The

importance

possible,

the

weld

ever,

on

parts

horizontally,

the

at

difficult

skill.

Asisthe

start

practicing

positions.

tions,

and

(tee

One

of

positions

molted

therefore,

making
degrees

mastered

tently,

Again

beads

Figure

8-21.

WELDING

OVERHEAD

cannot

is

better,

occasions

in

a

position

vertically

beginning

very

will

and

of

case

Then

practice

the

may

lap

joints)

first

is

that

metal

to

must

horizontal

shown

as

that

so

practice

with

begin

vertically

8-23.)

Multi-Layer

VERTICALLY,

of

welding

be

stressed

the

operation

will

anse

in

which

and

that

require

welding

first

by

facts

running

as

proficiency

be

continued

in

these

be

to

the

force

drip

(fall)

be

acquired

weld

beads

in

Figure

uniform

on

welding

an

easy

on

plates

Deposit

in

the

flat

too

strongly.

easier

whenitis

welds

overhead,

welding

constant

in

the

flat

weld

is

gained

on

positions.

noted

when

of

gravity

down.

to

overcome

on

8-22.

beads

can

vertically

operation

set

at

Joint

Lay

HORIZONTALLY,

and

must

on

and

The

faster.

be

in

these

whenever

deposited

be

positions

to

itisbest

the

fillet

position,

necessary

must

it

in

these

practice

position,

beads

butt

welding

tends

to

cause

The

technique

this.

When

be

such

45

inclined

this
made

be

may

as

degrees.

To

Left

plates

Right

quality

How

work

to

realized

develop

various

opera

welds

in

these

the

used,

Start

45

at

has

been

consis

started.

running

(See

of

to

by

is

______________

Figure

Welding

upward

vertically

or

generally

therefore,

A

ticed.

trated

Since

weld
cal

_______

Figure

pass

deposit.

ers

method

in

single

beads

and

horizontal

i~gure

8-26

vertical

Two

are

given

Figure

90

8-24.

starting

conceded

weld

beads

8-25.

weld

must

90



8-25.

provides

butt

methods

in

Figure

(

Tilt

LDirection



HorIzontal

Vertical

be

may

from

the

that

in

for

making

beads

be

practiced

positions.

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Weave

in.

1/2

1Wide

Weave

information

weld

the

or

of

depositing

8-27.

Vertical

Direction

15

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Plate

performed

top

working

this

weave

of

are

on

Of

TowardJj~

Of

~

Weld

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either

and

welding

upward

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limited

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should

manner

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(13

Pattern

c.~-~

mm)~t~~



first

pass

the

Vertical

suitable

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subsequent

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by

down.

is

easier

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value,

in

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~

mm)

(13



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for

a

multiple



welding

it

and

be

prac

is

illus

weaving

the

verti

in.

single

layer

lay

is

Figure

OM-121

Figure

8-23.

986

Page

8-22.

Horizontal

Inclined

Vertical

20

Weld

Weld

Plate

Beads

Beads



InclIned



Plate

Arrows

Up

Figure

Of

Return

8-26.

Show

Electrode

Crater

To

Single

Lifting

And

Pass

Vertical

Butt

Weld

Shorten

arrowheads

when

of

at

weld



8-29.

Figure

at

arc

MultI-Layer

Butt

Deposit

Weld

Horizontal

Figure

The

Figure

shown

ing

strip.

without

should

tack

welded

details

8-28

the

at

its

great

centered

be

and

sides

at

slight

down
before

over

Hesitate

with

up

motion

r1

crossing

H

4th

Layer.~

8-27.

Multi-Layer

Butt

for

hotizontal

and

Figure

footofthe

use

difficulty.

the

to

8-29.

weld.

permits

In

the

on

plates

Deposit

Weld

welds

Note

This

is

securing

the

use,

backing

the

on

reverse

cc

U

-~

are

that

a

known

sound

a

beveled

strip

I

.1

Vertical

shown

of

strip

the

as

root

plate

and

side.

metal

edges

the

back

pass

strip

Fillet

WeldVertical

tee

and

When

and

lap

tee

joints

For

weave

Multi-Layer

welds

in

Figure

the

layers

in

Figure

8-30.

same

on

8-31.

on

8-30.

method

both

on

8-31.

similar

r

Figure

For

fillet

shown

weld,

first

layer

sequent

shown

somewhat

a

Show~avingf~

Motion

in

is

~

Figure

joints

lap

depositing

would

be

tee

joints.

two

means

additional

be

may

U

Deposit

Tee

Joint

the

technique

a

muRilayerfiliet

used

to

For

layers

seen

I.

Shows

Weaving

deposit

depositing

used

are

on

lap

in

Figure

~

~9



Tee

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is

the

sub~

and

are

joints

8-32.

7_7

fin

1o~

Figure

8-28.

Root

Direction

Of

Weldlng.~

15

lilt

Direction

travel

of

Pass

,

In

FIgure

8-32.

Multi-Layer

Deposit



OM-121

Lap

Joint

986

Page

21

Welding

master.

weld

beads,

making

head

of

welding

weaving

used;

The

in

trated

the

first

be

may

ing

the

should
beads

Figure

and

Figure

deposited

single

overhead

on

8-38.

for

that

8-37.

employed

in

the

Again

the

fillet

welds.

is

necessary,

technique

Figure

of

pass

layer

be

employed.

a

Note

reason

Again

for

welding

overhead

proceed

position

through

making

the

For

8-35;

8-33

the

for

this

Figure

multilayer

shown

as

fillets

position

the

or

the

The

muitilayer

that

single

the

use

the

technique

lap

of

butt

electrode

will

pattern

overhead

covers

welds.

in

Figure

first

layer

technique

sequence

fillet

weld

beads

same

joints.

is

the

final

the

steps

welds

and

position

helpful.

prove

in

single

Figure

welds

butt

pass

8-34

Subsequent

8-36.

of

multiple

in

for

is

recommended

are

technique

fillet

welds

for

problem

of

making

finally

For

the

of

over

When

may
is

illus

welds

beads

deposit

fillets

Figure

8-37

depositing

provided

shown

may

be

be

to

or

in

in

in

Figure

8-36.

Multi-Layer

Butt

Deposit

Weld



Overhead

Figure

Figure

Figure

8-33.

8-34.

8-35.

Direction

Of

Electrode

Weave

Overhead

900

Welding

I

15

PositionOverhead

Butt



Overhead

Weld

Pattern



Root

Weld

Weld

Pass

Figure

FIgure

8-7.

CONCLUSION

It

be

may

to

the

part

welding.

ing

end.

some

tent

least

qualified

Personal

operator

Therefore,

facility

supervision.

secure

welding

Overhead

8-37.

Single

(13

mm)I

T~

8-38.

MultI-Layer

appreciated

beginner

is

for

the

that

all

instruction

the

best

effort

an

instruction

In

any

benefit

operator.

Tee

Weld

Pass

1/2

(13mm)

~

Tee

the

Deposit

Joint

no

printed

skill

necessary

an

experienced

by

should

and

for

accomplishing

be

practice

the

beginner

means

event

of

criticismoffinished

Joint

In.



Overhead

instruction

for

successful

made

to

under

should

welds



can

weld

secure

compe

im

this

by

at

a

OM-121

986

Page

22

NOTES

OM-121

986

Page

23

SECTION

It)

8-

PARTS

LIST

cJ

U

I,

/

/

/

/

/

/

---~

c~1



//

//

I

//

//

//

I

/

/

OM-121

986

Page

Ret.

ST-052

395-F

24

Item

No.

Dia.

Mkgs.

Part

No.

Figure

8-1.

Main

Description

Assembly

Quantity

...4

...8

10

11

12

...13....FM..

14

15

...17....T1..

18

19

*Recommended
BE

SURE

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039

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605

601

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800
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668

787

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511

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103

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297

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Parts.

MODEL

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RECEPTACLE

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sti

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stl

NUT,

SWITCH,

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BLANK,

SECTION,

snap-in

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BLADE,

fan

MOTOR,

WRAPPER

handle

PIN,
HANDLE,

TRANSFORMER

CLAMP,

nyt

NAMEPLATE,

jack

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flat

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slflkg

lock

hex

jam

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in

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230V

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control

control

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current

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plug

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REPLACEMENT

units)

PARTS.

3

1

1

2

1
1
1
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1

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1
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1
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1

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OM-121

986

Page

25

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

..4...SEC.

...6...PRI..
...6...PRI..

10

11

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522

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8

REPLACEMENT

PARTS.

SA-052

396-E

OM-121

986

Page

26

Item

No.

Part

No.

Description

Quantity

1

2

3

4

5
6

7

8
9

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13
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PARTS.

OM-121

986

Page

27