Troubleshooting − Burn-Through | Miller Electric 145 DXR, 145

13-19. Troubleshooting − 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.

13-20. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes	Corrective Actions

Unsteady hand.	Use two hands. Practice technique.

13-21. Troubleshooting − Distortion

			Distortion − contraction of weld met-
			al during welding that forces base
			metal to move.
		Base metal moves
		Base metal moves
		in the direction of
		in the direction of
		the weld bead.

Possible Causes			Corrective Actions

Excessive heat input.			Use restraint (clamp) to hold base metal in position.

			Make tack welds along joint before starting welding operation.

			Select lower amperage for electrode.

			Increase travel speed.

			Weld in small segments and allow cooling between welds.

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Contents

OM-4417210 403F ProcessesDescription File Engine Drive From Miller to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burns Fumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Welding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injury Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference − Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peut Principales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF − Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − Definitions Dimensions Dimensions, Weights, And Operating AnglesVolt-Ampere Curves Fuel Consumption Generator Power Curve Duty Cycle100% Duty Cycle at 80 Amperes CC/DC Minutes Welding − Installation Installing Welding GeneratorMovement Hazards Engine Prestart Checks − Standard Model Grounding Generator When Supplying Building SystemsOil Connecting The Battery DX Models Only Engine Prestart Checks − DX Model Connecting To Weld Output Terminals Selecting Weld Cable Sizes45 m 60 m 70 m 90 m 105 m 120 m 10 − Put terminals − Operating the Welding Generator Controls Standard Models See Section Stop engine and add oil if light goes on see Section Description Of Controls Standard Models See SectionTo Start Controls DX Models See Section Description Of Controls DX Models See Section − Operating Auxiliary Equipment Generator Power Panel ReceptaclesAC Receptacle RC1 − Maintenance Routine Maintenance Servicing Air Cleaner Precleaner Paper ElementStop engine Standard Model Shown Adjusting Engine Speed Standard Models Only Stop Engine CloseValve Tools Needed Weld/Power Speed Adjustment Adjusting Engine Speed DX Models OnlyIdle Speed Adjustment − Troubleshooting TroubleshootingGenerator Power Welding Engine Recommended Spare Parts − Parts ListRecommended Spare Parts − Electrical Diagrams Circuit Diagram For Standard Models Circuit Diagram for DX Models Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require? Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt LoadsCurrent Load Watts Amperes Cord Lengths for 240 Volt Loads Stick Welding Procedure − Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work Angle Conditions That Affect Weld Bead Shape Electrode Movement During Welding Butt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack Welds Troubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Your distributor also gives ServiceSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s