9
SLAG REMOVAL
Wear ANSI
approved safety
glasses (ANSI Standard Z87.1) and
protective clothing when removing
slag. Hot, flying debris can cause
personal injury to anyone in the area.
After completing the weld, wait for the
welded sections to cool. A protective
coating called slag now covers the weld
bead which prevents contaminants in
the air from reacting with the molten
metal. Once the weld cools to the point
that it is no longer glowing red, the
slag can be removed. Removal is done
with a chipping hammer. Lightly tap
the slag with the hammer and break it
loose from the weld bead. The final
clean-up is done with a wire brush.
When making multiple weld passes,
remove the slag before each pass.
WELDING POSITIONS
Four basic welding positions can be used;
flat, horizontal, vertical, and overhead.
Welding in the flat position is easier than
any of the others because welding speed
can be increased, the molten metal has
!
WARNING
Figure 9 - Multiple Weld Passes
Welding Guidelines (Continued)
Welder/Generator
less tendency to run, better penetration
can be achieved, and the work is less
fatiguing.
Other positions require different
techniques such as a weaving pass,
circular pass, and jogging. A higher skill
level is required to complete these welds.
All work should be performed in the
flat position if possible. For specific
applications, consult an arc welding
handbook.
WELD PASSES
Sometimes more then one pass is
necessary to fill the joint. The root pass
is first, followed by filler passes and the
cover pass (See Figures 8 & 9). If the
Figure 8 - Weld Passes
Cover
Filler
Root
pieces are thick, it may be necessary to
bevel the edges that are joined at a 60º
angle. Remember to remove the slag
before each pass.
No output voltage
Low output voltage
with no load
High output voltage
with no load
1. Engine speed is too slow
2. Open, shorted, or incorrect wiring
3. Faulty capacitor
4. Open or shorted field windings
5. Open diodes
6. Front panel switch set incorrectly
7. Circuit breaker tripped
1. Engine speed is too slow
2. Open diodes
3. Faulty capacitor
4. Open or shorted field windings
5. Voltage setting on front panel incorrect
1. Faulty capacitor
2. Engine speed is too fast
3. Voltage setting on front panel incorrect
1. Adjust engine speed
✽
2. Referring to the wiring diagram, clean and
reconnect all wiring
✽
3. Replace capacitor
✽
4. Test winding resistance, replace field
winding if necessary
✽
5. Test diodes, replace if necessary
✽
6. Set front panel switch to generator
7. Reset circuit breaker
1. Adjust engine speed
✽
2. Test diodes, replace if necessary
✽
3. Replace capacitor
✽
4. Test winding resistance, replace field
winding if necessary
✽
5. Adjust setting on front panel
1. Replace capacitor
✽
2. Adjust engine speed
✽
3. Adjust setting on front panel
Troubleshooting Chart - Generator
Symptom
Possible Cause(s)
Corrective Action
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