Miller Electric 185 DX Troubleshooting − Incomplete Fusion, Troubleshooting − Lack Of Penetration

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13-16. Troubleshooting − Incomplete Fusion

			Incomplete Fusion − failure of weld metal to fuse completely with
			base metal or a preceeding weld bead.




	Possible Causes		Corrective Actions

Insufficient heat input.			Increase amperage. Select larger electrode and increase amperage.

Improper welding technique.			Place stringer bead in proper location(s) at joint during welding.

			Adjust work angle or widen groove to access bottom during welding.

			Momentarily hold arc on groove side walls when using weaving technique.

			Keep arc on leading edge of weld puddle.

Workpiece dirty.			Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
			welding.

13-17. Troubleshooting − Lack Of Penetration

				Lack Of Penetration − shallow fusion between weld metal and
				base metal.

Lack of Penetration			Good Penetration

Possible Causes				Corrective Actions

Improper joint preparation.				Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique.				Keep arc on leading edge of weld puddle.

Insufficient heat input.				Increase amperage. Select larger electrode and increase amperage.

				Reduce travel speed.

13-18. Troubleshooting − Excessive Penetration

				Excessive Penetration − weld metal melting through base metal and
				hanging underneath weld.

Excessive Penetration			Good Penetration

Possible Causes				Corrective Actions

Excessive heat input.				Select lower amperage. Use smaller electrode.

				Increase and/or maintain steady travel speed.

OM-4415 Page 49

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Contents Processes OM-4415Description File Engine DriveFrom Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionCompressed Air Hazards Engine HazardsHOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité Symbol Definitions − SpecificationsWeld, Power, And Engine Specifications − DefinitionsDimensions Dimensions, Weights, And Operating AnglesDuty Cycle 100% Duty Cycle at 100 Amperes CC/DCDX Model Kohler Engine Volt-Ampere CurvesStandard Model Honda Engine Fuel Consumption Curves Auxiliary Power Standard Model Honda EngineAuxiliary Power DX Model Kohler Engine Power Output DX Model Kohler Engine Generator Power CurvesPower Output Standard Model Honda Engine Installing Welding Generator − InstallationMovement HazardsEngine Prestart Checks − Standard Model Grounding Generator When Supplying Building Systems13 mm Full Gasoline Fuel Valve Open valve+ − Engine Prestart Checks − DX ModelConnect negative − cable last Tools Needed 1/2Stop engine before connecting to weld output terminals Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 150 ft 200 ft 250 ftOM-4415 Controls Standard Models See Section − Operating the Welding GeneratorDescription Of Controls Standard Models See Section Turn Engine switch to OffTo Start To StopControls DX Models See Section Description Of Controls DX Models See Section − Operating Auxiliary Equipment Generator Power Panel ReceptaclesRoutine Maintenance − MaintenancePrecleaner Paper Element Servicing Air CleanerStop engine Standard Model ShownWeld/Power Speed Adjustment Adjusting Engine Speed Honda-Powered UnitsIdle Speed Adjustment Stop Engine CloseTools Needed Adjusting Engine Speed Kohler−Powered UnitsStop engine. Close fuel valve Troubleshooting − TroubleshootingGenerator Power WeldingEngine Recommended Spare Parts − Parts ListRecommended Spare Parts Circuit Diagram For Standard Models − Electrical DiagramsCircuit Diagram for DX Models Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment How Much Power Does Equipment Require? Grounding When Supplying Building SystemsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Cord Lengths for 120 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCurrent Load Watts Amperes Cord Lengths for 240 Volt Loads− Stick Welding Smaw Guidelines Stick Welding ProcedureStriking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleElectrode Movement During Welding Conditions That Affect Weld Bead ShapeLap Joint Butt JointsTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Support ServiceYour distributor also gives Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s