Miller Bobcat 265X Owner's Manual
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Miller Bobcat 265X Owner's Manual

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Bobcat
OWNER'S MANUAL
OM-291417E
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Engine Driven Welder/Generator
265X
™
2023-11

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  • Page 1 OM-291417E 2023-11 Processes Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Engine Driven Welder/Generator Bobcat 265X ™ OWNER’S MANUAL For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING..............1 Symbol Usage .
  • Page 4 TABLE OF CONTENTS Fault Indicator ..................... 44 Troubleshooting .

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 Accidental contact of electrode to metal objects can cause sparks, ex- FLYING METAL OR DIRT can injure plosion, overheating, or fire. Check and be sure the area is safe be- eyes. fore doing any welding. � Welding, chipping, wire brushing, and grinding �...

  • Page 7: Engine Hazards

    � Install cylinders in an upright position by securing to a stationary � Turn face away from valve outlet when opening cylinder valve. Do support or cylinder rack to prevent falling or tipping. not stand in front of or behind the regulator when opening the valve.

  • Page 8: Compressed Air Hazards

    1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
  • Page 9 � Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.

  • Page 10: California Proposition 65 Warnings

    � If notified by the FCC about interference, stop using the equipment � Be sure all equipment in the welding area is electromagnetically at once. compatible. � Have the installation regularly checked and maintained. � To reduce possible interference, keep weld cables as short as �...

  • Page 11: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 � Ne pas toucher aux portes-électrodes qui sont raccordés à deux bien ventilé, et en portant un respirateur à alimentation d’air. Les machines à souder en même temps, car cela entraîne la présence revêtements et tous les métaux renfermant ces éléments peuvent d’une tension de circuit-ouvert double.

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    � Ne pas souder là où l’air ambiant pourrait contenir des poussières, � Les porteurs d’implants médicaux doivent consulter leur médecin gaz ou émanations inflammables (vapeur d’essence, par et le fabricant du dispositif avant de s’approcher de la zone où se exemple).

  • Page 14: Dangers Liés À L'air Comprimé

    � Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- inflammables. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. � Tenir à distance les produits inflammables de l’échappement. LA VAPEUR ET LE LIQUIDE DE Les PIÈCES MOBILES peuvent REFROIDISSEMENT CHAUD peuvent...

  • Page 15: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    L’AIR COMPRIMÉ risque de Les PIÈCES MOBILES peuvent provoquer des blessures ou même la causer des blessures. mort. � S’abstenir de toucher des parties mobiles telles � Avant d’intervenir sur le circuit d’air comprimé, que des ventilateurs, courroies et rotors. couper l’alimentation électrique, verrouiller etéti- �...
  • Page 16 � Utiliser uniquement des équipements adéquats pour un fonction- � Régler les commandes de charge de batterie sur la position d’arrêt nement avec une alimentation de 50/60 ou de 60 Hz. avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.

  • Page 17: Proposition Californienne 65 Avertissements

    � Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...
  • Page 18 les porteurs d’implants médicaux doivent être prises: par exemple, 5. Connecter la pince sur la pièce aussi près que possible de la des restrictions d’accès pour les passants ou une évaluation indivi- soudure. duelle des risques pour les soudeurs. Tous les soudeurs doivent ap- 6.

  • Page 19: Section 3 - Definitions

    � Complete Parts List is available at www.MillerWelds.com SECTION 3 – DEFINITIONS Become trained and read the instructions before working on the Become trained and read the instructions before working on the machine or heating. machine or heating. 3-1. Additional Safety Symbol Definitions Safe85 2012 06 Safe85 2012 06 �...
  • Page 20 � Complete Parts List is available at www.MillerWelds.com Shielded Metal Arc Welding Hertz Welding (SMAW) Gas Metal Arc Single Phase Single Phase Welding (GMAW) Alternator Flux Cored Arc Welding (FCAW) OM-291417 Page 16...

  • Page 21: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 22: Base Unit Dimensions, Weights, And Operating Angles

    � Complete Parts List is available at www.MillerWelds.com 4-6. Base Unit Dimensions, Weights, And Operating Angles Dimensions External Dimensions Height (With Exhaust) 31.16 in. (791 mm) Do not exceed tilt angles or engine could Width 20.13 in. (511 mm) be damaged or unit could tip. Depth 37.06 in.

  • Page 23: Dimensions For Units With Optional Running Gear

    � Complete Parts List is available at www.MillerWelds.com 4-7. Dimensions For Units With Optional Running Gear Dimensions Height To Top Of Exhaust Pipe: 41.46 in. (105.31 cm) Height To Top Of Handle: 40.18 in. (102.06 cm) Width With Ca- ble Holders: 40.62 in.

  • Page 24: Volt-Ampere Curves

    � Complete Parts List is available at www.MillerWelds.com 4-9. Volt-Ampere Curves The volt-ampere curve shows the minimum STICK and maximum voltage and amperage output (CC Mode) capabilities of the welding generator. Curves of all other settings fall between the curves shown.

  • Page 25: Fuel Consumption

    � Complete Parts List is available at www.MillerWelds.com 4-10. Fuel Consumption The curves show typical fuel use under auxil- Auxiliary Fuel Consumption iary and weld loads. 7.57 2.00 Aux Power 5.67 1.50 3.78 1.00 Run No-Load 1.89 0.50 Idle 0.00 2000 4000 6000...

  • Page 26: Section 5 - Installation

    � Complete Parts List is available at www.MillerWelds.com 1-1. Installing Welder/Generator SECTION 5 – INSTALLATION 1-1. Installing Welder/Generator 5-1. Installing Welder/Generator Complete Parts List available at www.MillerWelds.com Do not move or operate unit where Movement it could tip. Do not lift unit from end. Do not weld on base.

  • Page 27: Grounding Generator To Truck Or Trailer Frame

    � Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 3 Metal Vehicle Frame Always ground generator frame to some running gear insulate the vehicle frame to prevent electric welding generator from the vehicle shock and static electricity hazards.

  • Page 28: Installing Exhaust Pipe

    � Complete Parts List is available at www.MillerWelds.com 5-4. Installing Exhaust Pipe Stop engine and let cool. Engine backfire can cause severe burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust outlet. Do not point exhaust pipe toward LP fuel tank (if equipped).

  • Page 29: Engine Prestart Checks

    � Complete Parts List is available at www.MillerWelds.com 5-5. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with synthetic blend 10W-30 engine oil. � Follow run-in procedure in engine manual.

  • Page 30: Connecting Or Replacing The Battery

    � Complete Parts List is available at www.MillerWelds.com 5-6. Connecting Or Replacing The Battery Connect negative (-) battery cable last. Battery is most easily accessed through the side door. Connect battery, negative cable last. Close access door. � Do not allow the battery cables to touch opposing terminals.

  • Page 31: Weld Output Terminals

    � Complete Parts List is available at www.MillerWelds.com 5-7. Weld Output Terminals Stop engine. Turn off power before connecting to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. RUN/IDLE 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal START Connect electrode or torch cable to positive terminal for Direct Current Electrode Positive...

  • Page 32: Selecting Cable Sizes

    � Complete Parts List is available at www.MillerWelds.com 5-9. Selecting Cable Sizes* NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 33: Section 6 - Operation

    � Complete Parts List is available at www.MillerWelds.com SECTION 6 – OPERATION 6-1. Dial Front Panel Controls 20 21 22 STICK CHOKE NO GAS RUN/IDLE ELECTRODE SIZE START 2 Engine Hour Meter/Fuel Gauge/Idle 3 Weld Process Selector Switch 1 Engine Control Switch Control Use switch to select type of weld output.

  • Page 34: Fuel/Hour Gauge Descriptions

    7018 (1/8 in.) Electrode: � Set weld process selector switch to STICK position. � Adjust welding output between 90 and 135 amps. � Miller recommends Hobart filler metals. 3/4 in. ps head wrench crescent wrench nutdriver chippinghammer OM-291417 Page 30...

  • Page 35: Typical Mig Welding Connections And Settings

    � Complete Parts List is available at www.MillerWelds.com 6-4. Typical MIG Welding Connections and Settings A. Solid Wire Applications Stop engine. � This section provides general guide- 20 21 22 STICK lines and may not suit all applications. CHOKE NO GAS 1 Work Clamp RUN/IDLE ELECTRODE...
  • Page 36 � Set wire feed speed between 105– 195 IPM. � Do a test weld. To increase arc length, increase voltage. To shorten arc length reduce voltage or increase wire feed speed. � Miller recommends Hobart filler metals. 3/4 in. ps head wrench crescent wrench nutdriver chippinghammer...

  • Page 37: Cold Weather Engine Operation

    � Complete Parts List is available at www.MillerWelds.com 6-5. Cold Weather Engine Operation 1 Run Position – For cold starts and en- Breather Icing air off. This increases engine temperature gine warm up during operation in both idle and high speed. Oil breather/pulse line icing occurs in severe 2 Run/Idle Position –...

  • Page 38: Section 7 - Operating Auxiliary Equipment

    � Complete Parts List is available at www.MillerWelds.com SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles Duplex receptacles supply 120 V 60 Hz sin- 6 Supplementary Protector CB3 Use GFCI protection when operating gle-phase power at weld/power speed. Max- auxiliary equipment.

  • Page 39: Gfci Receptacle Information, Resetting, And Testing

    � Complete Parts List is available at www.MillerWelds.com 7-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 40: Simultaneous Weld And Power

    � Complete Parts List is available at www.MillerWelds.com 7-3. Simultaneous Weld And Power Weld Current in Amperes Total Power in Watts 120 V Full kVA (4 Wire) Recep- 240 V Full kVA Receptacle tacle Amperes Amperes 1600 4600 Complete Parts List available at www.MillerWelds.com 6300 7300 9500...

  • Page 41: Wiring Instructions For 240 Volt, Single-Phase Plug (Nema 6-50P)

    � Complete Parts List is available at www.MillerWelds.com 7-5. Wiring Instructions For 240 Volt, Single-Phase Plug (NEMA 6-50P) The plug can be wired for a 240 V, 2-wire load. 1 Plug Wired for 240 V, 2-Wire Load 2 Load 1 (Brass)Terminal 3 Load 2 (Brass) Terminal 4 Ground (Green) Terminal Current Available in Amperes...

  • Page 42: Section 8 - Maintenance And Troubleshooting

    � Complete Parts List is available at www.MillerWelds.com SECTION 8 – MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Stop engine before maintaining. � See Engine Manual and Maintenance Label for important start-up, service, and storage information. Service Engine more often if used in severe conditions.

  • Page 43: Maintenance Label

    � Complete Parts List is available at www.MillerWelds.com 8-2. Maintenance Label OM-291417 Page 39...

  • Page 44: Servicing Air Cleaner

    � Complete Parts List is available at www.MillerWelds.com 8-3. Servicing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty. 1 Precleaner Wash precleaner with soap and water solu- tion.

  • Page 45: Overload Protection

    � Complete Parts List is available at www.MillerWelds.com 8-4. Overload Protection tools/ Stop engine. Disconnect negative (-) battery cable. 1 Fuse F6 F6 protects the engine wiring system from ear plugs electrodewrench helmet weldshield faceshield overload. If F6 opens, engine will not crank. Replace any open fuses.

  • Page 46: Changing Engine Oil, Oil Filter, And Fuel Filter

    � Complete Parts List is available at www.MillerWelds.com 8-5. Changing Engine Oil, Oil Filter, And Fuel Filter tools Stop engine and let cool. 1 Oil Drain Valve Change engine oil and filter according to en- gine owner’s manual. NOTICE – Close valve and valve cap before rubbergloves weldgloves earmuffs...

  • Page 47: Adjusting Engine Speed

    � Complete Parts List is available at www.MillerWelds.com 8-6. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: Start engine and run until warm. Open top and side access doors. Idle Speed Adjustment Move Engine Control switch to Run/Idle position.

  • Page 48: Servicing Optional Spark Arrestor

    � Complete Parts List is available at www.MillerWelds.com 8-7. Servicing Optional Spark Arrestor tools/ Stop engine and let cool. 1 Spark Arrestor Screen allen_wrench allen_set flathead philips head wrench cresce Clean and inspect screen. Replace spark ar- restor if screen wires are broken or missing. tools/ 1/4 in.

  • Page 49: Troubleshooting

    � Complete Parts List is available at www.MillerWelds.com 8-9. Troubleshooting A. Welding Troubleshooting Trouble Remedy Low or no weld output; generator Check control settings. power output okay at AC receptacles. Check weld connections. Have Factory Authorized Service Agent check brushes and slip rings. No weld output or generator power Be sure all equipment is disconnected from receptacles when starting unit.
  • Page 50 � Complete Parts List is available at www.MillerWelds.com C. Engine Troubleshooting Trouble Remedy Engine will not crank. Check fuse F6, and replace if open (see Section 8-4). Check battery voltage. Check battery connections and tighten if necessary. Check plug PLG5 and plug PLG8 connections. Have Factory Authorized Service Agent check Engine Control switch S2.

  • Page 51: Section 9 - Parts List

    � Complete Parts List is available at www.MillerWelds.com SECTION 9 – PARTS LIST 9-1. Recommended Spare Parts Recommended Spare Parts Dia. Mkgs. Part No. Description Quantity 283588 Electric Fuel Pump (High Altitude) 280236 Receptacle, GFCI 15/20A 215621 Fuse, 30 Amp Ato Type (Kohler CH730) 276379 Switch, Oil Pressure (Kohler CH730) 292928...

  • Page 52: Section 10 - Electrical Diagrams

    SECTION 10 – ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram OM-291417 Page 48...
  • Page 53 289542C OM-291417 Page 49...

  • Page 54: Section 11 - Generator Power Guidelines

    SECTION 11 – GENERATOR POWER GUIDELINES � The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 11-1. Selecting Equipment 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...

  • Page 55: How Much Power Does Equipment Require

    11-3. How Much Power Does Equipment Require? 1 Resistive Load A light bulb is a resistive load and requires a constant amount of power. VOLTS 115 2 Non-Resistive Load AMPS 50/60 Equipment with a motor is a non-resistive load and requires approximately six times more power while starting the motor than when running (see Section 11-7).

  • Page 56: Approximate Power Requirements For Farm/Shop Equipment

    11-5. Approximate Power Requirements For Farm/Shop Equipment Farm/Shop Equipment Rating Starting Watts Running Watts Stock Tank De-Icer 1000 1000 Grain Cleaner 1/4 HP 1650 Portable Conveyor 1/2 HP 3400 1000 Grain Elevator 3/4 HP 4400 1400 Milk Cooler 2900 1100 Milker (Vacuum Pump) 2 HP 10,500...

  • Page 57: Approximate Power Requirements For Contractor Equipment

    11-6. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw...

  • Page 58: Power Required To Start Motor

    11-7. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.

  • Page 59: Typical Connections To Standby Power

    11-9. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) applicable codes...
  • Page 60 B. Cord Lengths For 240 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current (Amperes) Load (Watts)

  • Page 61: Section 12 - Stick Welding (Smaw) Guidelines

    SECTION 12 – STICK WELDING (SMAW) GUIDELINES tools/ 12-1. Stick Welding Procedure wrench crescent wrench allen_set flathead philips head wrench crescent wrench Weld current starts when electrode Tools Needed: touches workpiece. Weld current can damage elec- tronic parts in vehicles. Discon- nect both battery cables before welding on a vehicle.
  • Page 62 12-2. Electrode And Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 FLAT SMOOTH, EASY, 7024 EP,EN 6013...
  • Page 63 12-4. Positioning Electrode Holder 1 End View Of Work Angle Groove Welds 2 Side View Of Electrode Angle After learning to start and hold an arc, prac- tice running beads of weld metal on flat 10 -30 10 -30 plates using a full electrode. Hold the electrode nearly perpendicular to the work, although tilting it ahead (in the di- rection of travel) will be helpful.
  • Page 64 12-7. Conditions That Affect Weld Bead Shape Electrode Angle � Weld bead shape is affected by elec- trode angle, arc length, travel speed, and thickness of base metal. 1 Angle Too Small 2 Correct Angle 3 Drag 4 Angle Too Large 5 Too Short 6 Normal Arc Length...
  • Page 65 12-9. Welding Lap Joints 1-1. Welding Lap Joints 1 Electrode 2 Single-Layer Fillet Weld 1-1. Welding Lap Joints Move electrode in circular motion. 3 Multi-Layer Fillet Weld Weld a second layer when a heavier fillet is needed. Remove slag before making anoth- er weld pass.
  • Page 66 12-11. Welding T-Joints 1-3. Welding T-Joints 1/16 in. (1.6 mm) 1 Electrode 2 Fillet 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. 1-3.
  • Page 67 12-13. Troubleshooting Porosity - small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.
  • Page 68 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. Waviness Of Bead - weld metal that is not parallel and does not cover joint formed by base metal.

  • Page 69: Section 13 - Gmaw Welding (Mig) Guidelines When Using A Voltage-Sensing Feeder

    SECTION 1 GMAW WELDING (MIG) GUIDELINES WHEN SECTION 13 – GMAW WELDING (MIG) GUIDELINES WHEN USING A VOLTAGE-SENSING FEEDER USING A VOLTAGE-SENSING FEEDER 13-1. Typical GMAW (MIG) Process Connections Using A Voltage-Sensing Wire Feeder Weld current can damage elec- tronic parts in vehicles. Discon- nect both battery cables before welding on a vehicle.
  • Page 70 13-2. Holding And Positioning Welding Gun � Welding wire is energized when gun trigger is pressed. Before lowering hel- met and pressing trigger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is posi- tioned correctly on seam.
  • Page 71 13-3. Conditions That Affect Weld Bead Shape Gun Angles and Weld Bead Profiles � Weld bead shape depends on gun an- 5-15° gle, direction of travel, contact to work distance (stickout), travel speed, thick- ness of base metal, wire feed speed (weld current), and voltage.
  • Page 72 13-4. Gun Movement During Welding � Normally, a single stringer bead is sat- isfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 1 Stringer Bead - Steady Forward Move- ment Along Weld Joint 2 Weave Bead - Side To Side Movement Along Weld Joint...
  • Page 73 13-8. Troubleshooting – Porosity Porosity - small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc. Remove spatter from gun nozzle.
  • Page 74 Maintain proper work and travel angles. 13-12. Troubleshooting – Burn-Through Burn-Through - a hole caused by excessive penetration. Possible Causes Corrective Actions Excessive heat input. Select lower voltage and reduce wire feed speed. Increase and/or maintain steady travel speed. 13-13. Troubleshooting – Waviness Of Bead Waviness Of Bead - weld metal that is not parallel and does not cover joint formed by base metal.
  • Page 75 13-15. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been devel- oped over the years. The most commonly used shielding gases are listed in the following table. Application Short Cir- Short Cir-...
  • Page 76 13-16. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates, but wire does not Too little pressure on drive rolls. Increase pressure setting on drive rolls. feed. Incorrect drive rolls. Check size stamped on drive rolls, replace to match wire size and type if necessary.
  • Page 77 Notes...
  • Page 78 Notes...
  • Page 79 Effective January 1, 2023 (Equipment with a serial number preface of ND or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. LIMITED WARRANTY - Subject to the terms and...
  • Page 80 Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © 2023 Miller Electric Mfg. LLC 2023-11...

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