SECTION
8-
WELDING
METHODS
&
TROUBLESHOOTING
mcd5.~
9192
a
WARNING
ELECTRIC
SHOCK
can
kill.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Do
not
touch
live
electrical
parts.
Keep
all
panels
and
covers
securely
in
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDSs)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
Allow
work
and
equipment
to
cool
before
handling
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
8-1.
Shielded
Metal
Arc
Welding
(SMAW)
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts
such
as
fans,
belts,
and
rotors.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
touching
welded
metal.
Wear
protective
gloves
and
clothing.
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
opera
tions.
WELDING
CURRENT
can
damage
elec
tronic
parts
in
vehicles.
Disconnect
both
battery
cables
before
welding
on
a
vehicle.
Place
work
clamp
as
close
to
the
weld
as
possible.
See
Safety
Rules
at
beginning
of
manual
for
basic
welding
safety
information.
N
OTE
~
Welding
current
starts
as
soon
as
electrode
touches
the
workpiece.
1
Workpiece
Make
sure
workpiece
is
clean
be
fore
welding.
2
Work
Clamp
Place
as
close
to
the
weld
as
possi
ble.
3
Electrode
A
small
diameter
electrode
re
quires
less
current
than
a
large
one.
Follow
recommendations
of
electrode
manufacturer
when
set
ting
weld
amperage
(see
Figure
8-2).
4
Insulated
Electrode
Holder
5
Electrode
Holder
Position
6
Arc
Length
Arc
length
is
the
distance
from
the
electrode
to
the
workpiece.
A
short
arc
with
correct
amperage
will
give
a
sharp,
crackling
sound.
7
Slag
Use
a
chipping
hammer
and
wire
~
brush
to
remove
slag.
Remove
slag
and
check
weld
bead
before
making
another
weld
pass.
ST-151
593
4
4
2
7
Tools
Needed:
Figure
8-1.
Shielded
Metal
Arc
Welding
(SMAW)
Procedure
OM-160
518
Page
20