Miller Electric Bobcat 225 Butt Joints, Lap Joint, Tee Joint, 16 in 30 1.6 mm Tack Welds, Or Less

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14-10. Butt Joints

1

2

1/16 in 30° (1.6 mm)

3

4

1 Tack Welds

Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld.

2 Square Groove Weld

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 oxy- acetylene or plasma cutting equip- ment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.

Create 30 degree angle of bevel on materials in V-groove welding.

4 Double V-Groove Weld

Good for materials thicker than 3/16 in (5 mm).

S-0662

14-11. Lap Joint

30°

30°

Or Less

Or Less

 

1

1

2

3

Single-Layer Fillet Weld

Multi-Layer Fillet Weld

1Electrode

2Single-Layer Fillet Weld Move electrode in circular motion.

3Multi-Layer Fillet Weld

Weld a second layer when a heavi- er fillet is needed. Remove slag be- fore making another weld pass. Weld both sides of joint for maxi- mum strength.

S-0063 / S-0064

14-12. Tee Joint

 

1

 

 

45°

 

2

Or Less

2

 

 

1

1Electrode

2Fillet Weld

Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface.

For maximum strength weld both sides of upright section.

3 Multi-Layer Deposits

Weld a second layer when a heavi- er fillet is needed. Use any of the weaving patterns shown in Section 14-9. Remove slag before making another weld pass.

3

S-0060 / S-0058-A / S-0061

OM-4434 Page 61

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Contents File Engine Drive OM-4434From Miller to You Table of Contents 10-2 10-110-3 11-1Arc 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 interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiquesLE 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 For Units With Optional Running Gear Dimensions, Weights, and Operating AnglesRobin-PoweredUnit 560 lb 254 kg DimensionsFuel Consumption Kohler-Powered Units Fuel Consumption Robin-Powered UnitsVolt-Ampere Curves For CC/AC ModeFor CC/DC Mode For CV/DC Mode Duty Cycle Generator Power CurveInstalling Welding Generator − InstallationMounting Do not use flexible mounts GroundingOil Engine Prestart Checks Robin-Powered UnitsOil Check Engine Prestart Checks Kohler-Powered Units Connecting Or Replacing the Battery Installing Exhaust PipeConnecting The Battery Connect negative − cable last Replacing The BatteryTools Needed Correct Installation Connecting to Weld Output TerminalsStop engine Work Weld Output Terminal350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft OM-4434 Place switch in Run position to operate most MIG equipment Engine Control SwitchCoarse Range Switch − Operating the Welding GeneratorInfrequently Cold Weather Engine OperationLoaded Frequently LoadedElectrode Typical Stick Welding Connections And Control SettingsBe sure to use the correct size weld cables see Section Typical MIG Welding Connections And SettingsSolid Wire Applications Fine Control, Weld Process switch Settings Self-Shielded Flux Core Wire ApplicationsSet wire feed speed between 240-270 ipm OM-4434 Typical Settings ForMaterial WorkStandard Receptacles − Operating Auxiliary EquipmentBreaker trips Optional Generator Power ReceptaclesWiring Optional 240 Volt Plug Simultaneous Weld And PowerCurrent Available in Amperes 240 ReceptacleMaintenance Label Robin-Powered Units − Maintenance ROBIN-POWERED UnitsStop engine before maintaining Routine Maintenance Robin-Powered Units100 200Stop engine and let cool Servicing Air Cleaner Robin-Powered UnitsServicing Optional Spark Arrestor Robin-Powered Units Before adding oil Close valve and valve capRunning engine Oil FillIdle Speed Adjustment Adjusting Engine Speed Robin-Powered UnitsTurn idle speed screw for fine adjustments Weld/Power Speed AdjustmentStop engine. Disconnect negative − battery cable Overload Protection Robin-Powered UnitsMaintenance Label Kohler-Powered Units − Maintenance − KOHLER-POWERED UnitsHours Nl Weld Cables ~ Slip Rings Nl Brushes OM-4434 Routine Maintenance Kohler-Powered UnitsServicing Air Cleaner Kohler−Powered Units Full Before adding oil Running engine Stop engine and let cool Oil Drain Valve2 ID x 7 in Hose Oil Filter Turn idle speed screw for fine ad- justments Adjusting Engine Speed Kohler-Powered UnitsIf a fuse opens, it usually indi Overload Protection Kohler-Powered UnitsServicing Optional Spark Arrestor Kohler-Powered Units Welding Troubleshooting − TroubleshootingGenerator Power Troubleshooting Trouble RemedyEngine Troubleshooting Control switch S2, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare PartsCircuit Diagram For Welding Generator − Electrical Diagrams228 461-A 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 Procedure Striking an Arc − Tapping Technique Electrode and Amperage Selection Chart Striking 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 Holding And Positioning Welding Gun − MIG Welding Gmaw GuidelinesSlow Normal Fast Push Perpendicular DragShort Normal Long Gun Movement During Welding 15-9 Troubleshooting − Excessive Penetration 15-7 Troubleshooting − Excessive Spatter15-8 Troubleshooting − Porosity Improper joint preparation Lack Of Penetration − shallowFusion between weld metal Base metal to move Unsteady hand Support hand on solid surface or use two handsFillet Common MIG Shielding GasesApplication Page 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