Stick Welding Smaw Guidelines | Miller Electric 145 DX specification

SECTION 12 − STICK WELDING (SMAW) GUIDELINES

12-1. Stick Welding Procedure

Y Weld current starts when electrode touches work- piece.

1 7

YWeld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

1 Workpiece

Make sure workpiece is clean be- fore welding.

2Work Clamp

3Electrode

A small diameter electrode requires less current than a large one. Fol- low electrode manufacturer’s instructions when setting weld am- perage (see Section 12-2).

4Insulated Electrode Holder

5Electrode Holder Position

6Arc 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 mak- ing another weld pass.

Tools Needed:

stick 12/96 − ST-151 593

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Miller Electric 145 DX manual Stick Welding Smaw Guidelines, Stick Welding Procedure

145 DX specifications

Miller Electric has established itself as a leading name in the welding industry, and the Miller Electric 145 DX and 145 are notable additions to its lineup of innovative welding machines. Designed to offer versatility and efficiency, these units cater to both novice welders and seasoned professionals seeking reliable equipment for various welding applications.

One of the key features of the Miller Electric 145 DX and 145 is their advanced welding technology. Both models utilize inverter technology, which allows for a compact design while delivering exceptional power. This inverter design not only increases efficiency but also reduces energy consumption, making it an environmentally friendly choice. The lightweight nature of these units makes them highly portable, allowing users to easily transport them to job sites or move them around the workshop.

The Miller Electric 145 DX model incorporates a digital interface that simplifies set-up and operation. This user-friendly digital display shows critical parameters such as voltage and amperage, helping the operator make quick adjustments on-the-fly for optimal results. The advanced Auto-Set feature adjusts the machine settings automatically based on the material thickness and type, significantly reducing the learning curve for inexperienced welders.

Both the 145 DX and 145 models can handle a variety of welding processes, including MIG and TIG welding. This versatility makes them suitable for a wide range of applications, from automotive repair and fabrication to metal sculpture and DIY projects. The machines are capable of welding aluminum, stainless steel, and mild steel with ease, providing excellent penetration and bead appearance.

Another noteworthy characteristic of the Miller Electric 145 series is their reliability and durability. Designed with robust components that can withstand challenging working environments, these machines are built to last. The thermal overload protection feature ensures the units do not overheat, safeguarding the internal components and ensuring a longer operational life.

In summary, the Miller Electric 145 DX and 145 stand out in the welding equipment market due to their advanced inverter technology, user-friendly digital interfaces, versatile capabilities, and durability. They are ideal choices for anyone looking to elevate their welding experience, delivering consistent and reliable performance across a variety of projects.

Contents

Description OM-4417210 403CProcesses File Engine Drive From Miller to You Table of Contents Page Symbol Usage Arc Welding Hazards Engine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interference UN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïe LE Surchauffement peut endom- mager le moteur électrique ’AIR Comprimé peut provoquer des blessures’EMPLOI Excessif peut LES Étincelles Volantes risquent de provoquer des blessures Pour les moteurs diesel LE Soudage À L’ARC risque de provoquer des interférencesPour les moteurs à essence Boulevard, Rexdale, Ontario, Canada M9W 1R3 téléphone Weld, Power, And Engine Specifications − SpecificationsSymbol Definitions − Definitions Dimensions, Weights, And Operating Angles DimensionsVolt-Ampere Curves Fuel Consumption Generator Power Curve Duty Cycle100% Duty Cycle at 80 Amperes CC/DC − Installation Installing Welding GeneratorGrounding Generator To Truck Or Trailer Frame 13 mm Full Gasoline Grounding Generator When Supplying Building SystemsEngine Prestart Checks − Standard Model Fuel Valve Open valve + − Connecting The Battery DX Models OnlyEngine Prestart Checks − DX Model Tools Needed 1/2 150 ft 200 ft 250 ft Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Material Thickness Reference Chart − Operating the Welding Generator Controls Standard Models See Section Description Of Controls Standard Models See Section Stop engine and add oil if light goes on see SectionTo Start Controls DX Models See Section Description Of Controls DX Models See Section Generator Power Panel Receptacles − Operating Auxiliary EquipmentAC Receptacle RC1 − Maintenance Routine Maintenance Servicing Air Cleaner Stop engineStandard Model Shown Adjusting Engine Speed Standard Models Only Stop engine. Close fuel valveTools Needed Adjusting Engine Speed DX Models Only Weld/Power Speed AdjustmentIdle Speed Adjustment Generator Power − TroubleshootingTroubleshooting Welding Engine − Electrical Diagrams Circuit Diagram For Standard Models Circuit Diagram for DX Models − Generator Power Guidelines Selecting Equipment Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = Watts Industrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Single-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes Stick Welding Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Positioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics 10-30 9090 End View of Work Angle Conditions That Affect Weld Bead Shape Electrode Movement During Welding Tee Joint Butt JointsLap Joint 16 in 30 1.6 mm Tack Welds Weld Test Troubleshooting − PorosityTroubleshooting − Excessive Spatter Possible Causes Corrective Actions Troubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion − Parts List Main Assembly Standard Model Dia Part Description Quantity Mkgs Main Assembly DX Model 4546 51 41 Main Assembly OM-4417 Service Your distributor also givesSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s