Lincoln Electric SVM103-C service manual Welding Cast Iron, Cast Iron Plate Preparation

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Section TOC

Master TOC

B-19

 

OPERATION

B-19

 

 

 

 

4. The bead should be put on with a weaving motion,

 

and it should be 1/2-3/4” (12.7-19.0mm) wide. Do

When breaking

not let the arc blow over the edge, as that will dull

the weld stays on

the edge. (See drawing below.)

 

one piece

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Work Table

Strike Arc

 

Here

Sharp Edge

Brick

 

 

 

Plow Share

 

1/2-3/4" width

 

(12-20mm)

 

 

Positioning of Share

Weaving Motion

To overcome this, the welding operator has two choices:

1.Preheat the entire casting to 500-1200°F (260- 649°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.

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5.Use the back-stepping method. Begin to weld 3” (76mm) from the heel of the share and weld to the heel. The second weld will begin 6” (152mm) from the heel, the third weld 9” (229mm) from the heel, etc.

B

A

C

D

E First weld from A to B; then

 

 

3"

 

 

 

 

 

 

from C to A; then from D to C;

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

then from E to D; and so on.

(75mm)

 

 

 

 

 

 

 

 

 

BACKSTEPPING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Backstepping greatly reduces the chances for crack- ing of the share, and it also greatly reduces warping.

NOTE: The entire process is rather fast. Many beginners go much too slowly when hardfacing plow- shares, running the risk of burning through the thin metal.

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. (See drawing below.)

2.Weld 1/2” (12.7mm) at a time, and do not weld at that spot again until the weld is cool.

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 pre- heating large castings. Smaller castings can easily (and should) be preheated before welding. A forge, stove, 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. This is called backstepping.

After welding Cast Iron, protect the casting against fast cooling. Put it in a container of warm, dry sand or lime.

If sand or lime is not available, cover it with sheet metal or any other non-flammable material that will diminish drafts and retain heat.

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hot

White brittle

cold

cold

cast iron

Cast Iron Plate Preparation

 

 

 

 

 

Wherever practical, the joint to be welded should be

This is the reason why welds in cast iron break.

“veed” out by grinding or filing to give complete pene-

tration as shown in figures (a), (b) and (c) below. This is

Actually, one piece of the broken cast iron has the

especially important on thick castings where maximum

entire weld on it and the other piece has no weld on it.

strength is required. In some instances a back-up

(See drawing below.)

 

 

 

POWER-ARC 4000

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Contents Safety Depends on You POWER-ARCCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications POWER-ARC InstallationStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Cert. Kool Bore Spark Arrester125 amp Electrical Output ConnectionsWelding Cable Connections Cable Size forPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesMachine Grounding Circuit Breakers Premises WiringThese Devices Without POWER-ARC Table of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsWelding Capability Operational Features and ControlsDesign Features Advantages Recommended ApplicationsGENERATOR/WELDER Controls Controls and Settings20 AMP, 120 Volt Duplex Receptacle Gasoline Engine ControlsStarting the Engine Engine OperationBefore Starting the Engine For a HOT Engine General Information To USE the Generator AS AN Auxiliary Power SupplyGenerator Operation Suggested Power Applications Running Watts Start-up Watts Table B.1 Generator Power ApplicationsWelding Operation Table B.2 Welding APPLICATIONS/ELECTRODE Selection Guide Welding GuidelinesOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Butt Welds PracticeUse the following Do the followingPenetration Fillet WeldsVertical-Down Welding Vertical-Up WeldingWelding Sheet Metal Overhead WeldingHardfacing To Reduce Wear Cast Iron Plate Preparation Welding Cast IronLow Hydrogen Group Stable-Arc E7018 High-Speed Group AWS E6013Out-of-Position Group AWS E6011 Table of Contents Accessories Section Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Table of Contents Maintenance Section Engine Adjustments MaintenanceRoutine and Periodic Maintenance Engine MaintenanceFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule Do not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure D.6. Major Component Locations Table of Contents Theory of Operation Section ENGINE, EXCITATION, Rotor and Stator Theory of OperationFigure E.3 Field Excitation and Auxiliary Power Rotor Field Feedback and Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent ProtectionTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairOutput Problems TroubleshootingVice Facility Or contact your local LincolnElectric Authorized Field Ser Local Lincoln Electric Authorized Field Service FacilityTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Materials Needed This procedure takes approximately 15 minutes to performRotor Voltage Test Test DescriptionRotor Voltage Test Test ProcedureRotor Resistance Test This procedure takes approximately 25 minutes to performRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE This procedure takes approximately 20 minutes to perform Engine Throttle Adjustment TestOscilloscope Method Strobe-tach MethodFrequency Counter Method Wing NUT High Speed Stop Screw High Idle no Load Scope SettingsNormal Open Circuit Weld Voltage Waveform Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 125 Amps AT 23 VAC Typical Weld Output WaveformMachine Loaded Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal This procedure takes approximately 35 minutes to perform Capacitor AND/OR Diode Bridge Removal and ReplacementFigure F.8 Location and Discharging the Field Capacitor Procedure Capacitor Removal and REPLACE- MentFigure F.8A Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementInstructions STATOR/ROTOR Removal and ReplacementThis procedure takes approximately 3 hours to perform STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputReturn to Section TOC Table of Contents Diagrams Section Wiring Diagram Power ARC DiagramsDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form
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