Troubleshooting − Burn-Through | Miller Electric 185 DX guide

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.

OM-4415 Page 50

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Miller Electric 185 manual Troubleshooting − Burn-Through, Troubleshooting − Waviness Of Bead, Troubleshooting − Distortion

Contents

Description OM-4415Processes File Engine Drive From Miller to You Table of Contents Page Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burns ARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Fire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injury EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peut Proposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF Weld, Power, And Engine Specifications − SpecificationsSymbol Definitions − Definitions Duty Cycle Dimensions, Weights, And Operating AnglesDimensions 100% Duty Cycle at 100 Amperes CC/DC Volt-Ampere Curves Standard Model Honda EngineDX Model Kohler Engine Auxiliary Power Standard Model Honda Engine Auxiliary Power DX Model Kohler EngineFuel Consumption Curves Generator Power Curves Power Output Standard Model Honda EnginePower Output DX Model Kohler Engine Movement − InstallationInstalling Welding Generator Hazards 13 mm Full Gasoline Grounding Generator When Supplying Building SystemsEngine Prestart Checks − Standard Model Fuel Valve Open valve Connect negative − cable last Engine Prestart Checks − DX Model+ − Tools Needed 1/2 Selecting Weld Cable Sizes Connecting To Weld Output TerminalsStop engine before connecting to weld output terminals 150 ft 200 ft 250 ft OM-4415 − Operating the Welding Generator Controls Standard Models See Section To Start Turn Engine switch to OffDescription Of Controls Standard Models See Section To Stop Controls DX Models See Section Description Of Controls DX Models See Section Generator Power Panel Receptacles − Operating Auxiliary Equipment − Maintenance Routine Maintenance Stop engine Servicing Air CleanerPrecleaner Paper Element Standard Model Shown Idle Speed Adjustment Adjusting Engine Speed Honda-Powered UnitsWeld/Power Speed Adjustment Stop Engine Close Adjusting Engine Speed Kohler−Powered Units Stop engine. Close fuel valveTools Needed Generator Power − TroubleshootingTroubleshooting Welding Engine − Parts List Recommended Spare PartsRecommended Spare Parts − Electrical Diagrams Circuit Diagram For Standard Models Circuit Diagram for DX Models − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require? 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 / Volts = Starting Amperage Typical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Cord Lengths for 240 Volt Loads Stick Welding Procedure − 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 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