Miller Electric Bobcat 225 manual

Bobcat 225 Processes Description ™ Non-Critical TIG (GT A W) W elding Stick (SMAW ) Welding MIG (GMAW) Welding Flux Cored (FCA W ) W elding Engine Driven Welding Generator OM-4434 218 653J 2007 − 11 Visit our website at www.MillerWelds.com File: Engine Drive[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

T ABLE OF CONTENTS 8-5. Changing Engine Oil, Oil Filter , and Fuel Filter (Robin-Powered Units) 36 . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Adjusting Engine Speed (Robin-Powered Units) 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Overload Protection (Robin-Powered Units) 38 . . . . . . . [...]

OM-4434 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or [...]

OM-4434 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation is [...]

OM-4434 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to cha[...]

OM-4434 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS.  [...]

OM-4434 Page 5 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  The user is responsible for having a qualified electrician promptly corre[...]

OM-4434 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des ble[...]

OM-4434 Page 7 Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation.  Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas to[...]

OM-4434 Page 8  Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et N FPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affe c l’ouïe.  Porter des protections approuvés pour les or e les si le niveau sonore [...]

OM-4434 Page 9  Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser dan[...]

OM-4434 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d’a rrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager l e moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e pas [...]

OM-4434 Page 1 1 2-6. P r oposition californienne 65 A vertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de [...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator’s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Engine Choke Check V alve Clearance Do not switch whil[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 13 4-2. Dimensions, W eights, and Operating Angles Dimensions A Height 33-1/2 in (851 mm) (T o T op Of Exhaust) A B C Width 20 in (508 mm) C ! D d il l i ld Depth 45-3/8 in (1 153 mm) D ! Do not exceed tilt angles or engine could be dama g ed or unit could ti p . A 20 in ([...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 14 4-4. Fuel Consumption (Robin-Powered Units) 220 571 On a typical job using 1/8 in 7018 electrodes (125 amps, 20% duty cycle), expect about 20 hours of op- eration. W elding at 150 amps at 40% duty cycle uses approximately 3/4 gal- lon per hour , or about 16 hours of ope[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 15 4-6. V olt-Ampere Curves 166 024-A / 166 025-A / 166 026-A The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. A. For CC/AC Mode B. For CC/[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 16 4-7. Generator Power Curve 200 294 The generator power curve shows the generator power in amperes available at the receptacles. Continuous W elding 4-8. Duty Cycle 1 19 454-A Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 17 SECTION 5 − INST ALLA TION install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712 ! Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. ! Always securely fasten weld- ing generator on[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 18 5-2. Engine Prestart Checks (Robin-Powered Units) 803 848-C / 217 015-A Full Full Gasoline Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.  Follow run-in procedure in en- gine manual. NOTICE − This unit ha[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 19 5-3. Engine Prestart Checks (Kohler-Powered Units) 803 847-C / 217 015-A Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.  Follow run-in procedure in en- gine manual. NOTICE − This unit has a low oil pressu[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 20 5-4. Installing Exhaust Pipe 803 847 / Ref 801 681 / Ref. 228 199-A ! Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust outlet. ! Point exhaust pipe in desired di- rection but always away f[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 21 ! Stop engine. 1 W ork Weld Output T erminal 2 Electrode W eld Output T erminal Connect work cable to W ork terminal. Connect electrode holder cable or electrode weld cable to Electrode ter- minal for Stick and MIG welding. Connect torch cable to Electrode ter- minal fo[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 22 5-7. Selecting W eld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W elding Amperes 10 − 60% Duty Cycle 60 ?[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 23 Notes[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 24 SECTION 6 − OPERA TING THE WELDING GENERA TOR 4 1 3 6 6-1. Front Panel Controls Ref. 228 199-A 1 Engine Control Switch Use switch to start engine, select speed, and stop engine. In Run/Idle position, engine runs a t idle speed at no load, and weld/power speed under lo[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 25 6-2. Cold Weather Engine Operation Ref. 216 170 1 Engine Control Switch Carburetor Icing Carburetor icing causes the unit to drop below the normal idle speed and then stall. This condition occurs when the temperature is near freezing and the rela- tive humidity is high.[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 26 ELECTRODE DC* AC POSITION PENETRA TION USAGE MIN. PREP , ROUGH HIGH SP ATTER GENERAL SMOOTH, EASY , F AST LOW HYDROGEN, STRONG SMOOTH, EASY , F ASTER CAST IRON ST AINLESS DEEP DEEP LOW MED LOW LOW LOW LOW ALL ALL ALL ALL ALL FLA T HORIZ FILLET ALL ALL EP EP EP ,EN EP ,E[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 27 6-4. T ypical MIG Welding Connections And Settings A. Solid Wire Applications 803 847-C / 802 766 / 228 199-A ! Stop engine.  This section provides general guide- lines and may not suit all ap- plications.  The control panel shows the typical settings for welding [...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 28 B. Self-Shielded Flux Core Wire Applications 803 847-C / 802 766 / 228 199-A ! Stop engine.  This section provides general guidelines and may not suit all applications.  Th e control panel sho ws the typi - cal settings for welding with .045 (71T -1 1) self-shield[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 29 6-5. T ypical MIG Connections And Settings Using Weld Control And Spoolgun 802 847-C / 228 199-A  This section provides general guide- lines and may not suit all applications. 1 W eld Control 2 Spoolgun 3 Optional Contactor (Recommended) 4 Reed Switch 5 W eld Cable ([...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 30 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. Standard Receptacles 803 847-C / Ref. 228 199-A ! If unit does not have GFCI re- ceptacles, use GFCI-protected extension cord.  Generator power decreases as weld current increases. Set Fine Control R1 at 10 for full [...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 31 ! If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord.  Generator power decreases as weld current in creases. S et Fine Control R1 at 10 for full genera- tor power. Combined output of all recepta cles limite d to 10 kV A/kW rating of the gen[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 32 7-3. Simultaneous W eld And Power W eld Current in Amperes T otal Power in Watts 120 V Full kV A Receptacle Amperes 240 V Full kV A Receptacle Amperes 250 2200 18 9 180 3500 29 14 125 5200 43 21 90 8000 66 33 0 10,000 Robin Engine 10,500 Kohler Engine 84 Robin Engine 88[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 33 SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS) 8-1. Maintenance Label (Robin-Powered Units)[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 34 8-2. Routine Maintenance (Robin-Powered Units) ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = C[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 35 ! Stop engine. NOTICE − Do not run engine with- ou t air cleaner or with dirty element. 1 Precleaner Was h precleaner with soap and wa- ter solution. Allow precleaner to air dry completely . Spread 1 tablespoon SAE 30 oil evenly into precleaner . Squeeze out excess oi[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 36 8-5. Changing Engine Oil, Oil Filter , and Fuel Filter (Robin-Powered Units) 803 848-C / 802 921-A / S-0842 ! Stop engine and let cool. 1 Oil Drain V alve 2 1/2 ID x 7 in Hose 3 Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. ! Close valv[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 37 8-6. Adjusting Engine Speed (Robin-Powered Units) 803 848-C / 802 457 After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. Remove rear panel and air cleaner to access idle speed[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 38 8-7. Overload Protection (Robin-Powered Units) 803 848-C ! Stop engine. Disconnect negative ( − ) battery cable. 1 Fuse F1 (See Section 1 1 -1) F1 protects the weld excitation winding from overload. If F1 opens, weld output stops or is low . 2 Fuse F2 (See Section 1 1[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 39 SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 9-1. Maintenance Label (Kohler-Powered Units)[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 40 9-2. Routine Maintenance (Kohler-Powered Units) ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = [...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 41 ! Stop engine. NOTICE − Do not run engine with- ou t air cleaner or with dirty element. 1 Precleaner Was h precleaner with soap and wa- ter solution. Allow precleaner to air dry completely . Spread 1 tablespoon SAE 30 oil evenly into precleaner . Squeeze out excess oi[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 42 9-4. Changing Engine Oil, Oil Filter , and Fuel Filter (Kohler-Powered Units) 803 847-C / S-0842 ! Stop engine and let cool. 1 Oil Drain V alve 2 1/2 ID x 7 in Hose 3 Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. ! Close valve and valve[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 43 9-5. Adjusting Engine Speed (Kohler-Powered Units) 803 849 / 801 209-A After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. Turn Fine Control to 10. Remove rear panel and air cl[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 44 9-6. Overload Protection (Kohler-Powered Units) 803 847-C ! Stop engine. Disconnect negative ( − ) battery cable. 1 Fuse F1 (See Section 1 1 -1) F1 protects the weld excitation winding from overload. If F1 opens, weld output stops or is low . 2 Fuse F2 (See Section 1 [...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 45 SECTION 10 − TROUBLESHOOTING 10-1. Welding T roubleshooting T rouble Remedy Low or no weld output; generator pow- er output okay at ac receptacles. Check control settings. Check weld connections. Check fuse F1, and replace if open (see Section 8-7 or 9-6). Have Factor[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 46 T rouble Remedy No generator power or weld output. Be sure all equipment is disconnected from receptacles when starting unit. Check fuses F1 and F2, and replace if open (see Section 8-7 or 9-6). Check plug PLG6 connection. Have Factory Authorized Service Agent check bru[...]

 A complete Parts List is available at www .MillerW elds.com OM-4434 Page 47 T rouble Remedy Battery Discharges between uses. Clean battery , terminals, and posts with baking soda and water solution; rinse with clear water . Periodically recharge battery (approximately every 3 months). Replace battery . Check voltage regulator and connections ac[...]

OM-4434 Page 48 SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For Welding Generator[...]

OM-4434 Page 49 228 461-A[...]

OM-4434 Page 50 SECTION 13 − GENERA TOR POWER GUIDELINES  The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 13-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Pro[...]

OM-4434 Page 51 13-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Us e ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. A[...]

OM-4434 Page 52 13-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Sta rting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285[...]

OM-4434 Page 53 13-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in [...]

OM-4434 Page 54 13-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not li[...]

OM-4434 Page 55 13-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this equip[...]

OM-4434 Page 56 13-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840 4[...]

OM-4434 Page 57 SECTION 14 − STICK WELDING (SMA W) GUIDELINES 14-1. Stick Welding Procedure stick 2007 − 04 − ST-151 593 1 W orkpiece Make sure workpiece is clean be- fore welding. 2 W ork Clamp 3 Electrode A small diameter electrode requires less current than a large one. Fol- low electrode manufacturer’ s instructions when setting weld am[...]

OM-4434 Page 58 14-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELECTR[...]

OM-4434 Page 59 14-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of Work Angle Sid e V iew of Electrode Angle End V iew of Work Angle S ide View of Electrode Angle 10 ° -30 ° 14-6. Poor W eld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crate[...]

OM-4434 Page 60 14-8. Conditions That Affect W eld Bead Shape  W el d bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. S-0061 ELECTRODE ANGLE ARC LENGTH TRA V EL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle 14-9. Elec[...]

OM-4434 Page 61 14-10. Butt Joints S-0662 1 T ack Welds Prevent ed ge s o f j oint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. 2 Square Groove W el d Good for materials up to 3/16 in (5 mm) thick. 3 Single V -Groove Weld Good for materials 3/16 − 3/4 in (5-19 mm) thick. Cut bevel with ox[...]

OM-4434 Page 62 14-13. W eld T est S-0057-B 1 V ise 2 W eld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 14-14. T roubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets i n weld metal. Possi[...]

OM-4434 Page 63 14-16. T roubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in prop[...]

OM-4434 Page 64 14-19. T roubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 14-20. T roubleshooting − W avine[...]

OM-4434 Page 65 SECTION 15 − MIG WELDING (GMA W) GUIDELINES 15-1. T ypical MIG Process Connections Using A V oltage-Sensing Wire Feeder ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce wor k c la mp a s close to the weld as possible. V oltage sensing wire feeders are used [...]

OM-4434 Page 66 15-3. Conditions That Affect W eld Bead Shape  Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS (STICK[...]

OM-4434 Page 67 15-4. Gun Movement During Welding  Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however , for wide groove weld joints or bridging acros s gaps, a weave bead or multiple stringer beads works better . 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Alon[...]

OM-4434 Page 68 15-7. T roubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use [...]

OM-4434 Page 69 15-10. T roubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintainin[...]

OM-4434 Page 70 15-13. T roubleshooting − W aviness Of Bead W aviness O f Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support han[...]

OM-4434 Page 71 15-15. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Gas Spray Arc Steel Short Circuiting Steel Spray Arc S[...]

Notes[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wo rks Comp any 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − USA USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 920-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters − U[...]