Miller Electric Welder Operations Instructions

ProcessesStick (SMAW) Welding155 095 E2013−07Guidelines ForShielded Metal ArcWelding (SMAW)Visit our website atwww.MillerWelds.com

155 095 Page 83-3. Striking An Arc − Scratch Start Technique! Welding current starts assoon as electrode touches theworkpiece.. The scratch-start tec

155 095 Page 93-5. Positioning Electrode HolderS-066090° 90°10°- 30°45°45°End View Of Work Angle Side View Of Electrode AngleEnd View Of Work Angle Si

155 095 Page 103-6. Electrode Movement During Welding. A single stringer bead is satisfac-tory for most narrow groove weldjoints; however, for wide g

155 095 Page 113-7. Conditions That Affect Weld Bead Shape. Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness

155 095 Page 123-8. Poor Weld Bead Characteristics1 Large Spatter Deposits2 Rough, Uneven Bead3 Slight Crater DuringWelding4 Bad Overlap5 Poor Penetra

155 095 Page 133-10. Typical Weld Joints804 248Vertical Position WeldsOverhead Position WeldsFlat Position Welds Horizontal Position WeldsTee JointGro

155 095 Page 143-11. Welding Groove (Butt) JointsTypes Of Groove (Butt) Joint Welds1 Tack WeldsPrevent butt joint distortion by tack weldingthe materi

155 095 Page 153-12. Welding Tee Joints1 Electrode2 Fillet WeldKeep arc short and move at definiterate of speed. Hold electrode asshown to provide fu

155 095 Page 163-14. Welding Horizontal Beads And Groove (Butt) Joints. When welding horizontally,gravity may distort the mol-ten metal.. This techn

155 095 Page 173-15. Welding Vertical Beads And Groove (Butt) Joints. When welding vertically,gravity may distort the mol-ten metal.. This technique

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1...1-1. Symbol Usage 1...

155 095 Page 183-16. Welding Vertical Tee Joints And Lap Joints. When welding vertically,gravity may distort the mol-ten metal.. This technique is n

155 095 Page 193-17. Welding Overhead Groove (Butt) Joints And Tee Joints. When welding overhead,gravity may distort the mol-ten metal.. This techni

155 095 Page 203-18. Weld Test1 Vise2 Weld Joint3 HammerStrike the weld joint in the directionshown. A good weld bends over butdoes not break.If the w

155 095 Page 214-2. Excessive SpatterExcessive Spatter − scattering ofmolten metal particles that cool tosolid form near weld bead.Possible Causes Cor

155 095 Page 224-5. Excessive PenetrationGood PenetrationExcessive Penetration − weld metalmelting through base metal andhanging underneath weld.Exces

Notes16 Gauge (.063 in.)22 Gauge (.031 in.)24 Gauge (.025 in.)20 Gauge (.037 in.)18 Gauge (.050 in.)14 Gauge (.078 in.)1/8 in. (.125 in.)3/16 in. (.18

NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

NotesOver 80,000 trainedsince 1930!400 Trade Square East, Troy, Ohio 453731-800-332-9448 www.welding.orgStart Your ProfessionalWelding Career Now!

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2013 Miller Electric Mfg. Co. 2013−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer

155 095 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom 2011−107Protect yourself and others from injury — read, follow, and save these imp

155 095 Page 2Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.FUMES AND GASES can be hazardous.D Keep

155 095 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

155 095 Page 41-4. California Proposition 65 WarningsWelding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of

155 095 Page 5SECTION 2 − PRINCIPLES OF SHIELDED METAL ARCWELDING (SMAW)Shielded Metal Arc Welding (SMAW) or Stick welding is a process which melts an

155 095 Page 6SECTION 3 − SHIELDED METAL ARC WELDING (SMAW)PROCEDURE3-1. Typical Stick Welding Set-Up! Welding current starts as soon aselectrode touc

155 095 Page 73-2. Electrode And Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321/43/3