Miller Millermatic 141 Owner's Manual
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Miller Millermatic 141 Owner's Manual

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Millermatic 141
OM-264423C
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
R
File: MIG (GMAW)
2018−10

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Summary of Contents for Miller Millermatic 141

  • Page 1 OM-264423C 2018−10 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic 141 For product information, File: MIG (GMAW) 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 ....... . . 1-1.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 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 Indicates special instructions.
  • Page 6 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 8: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2018−01_fre 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 10 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 12: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.
  • Page 13 Notes OM-264423 Page 9...

  • Page 14: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.

  • Page 15: Section 4 − Specifications

    A complete Parts List is available on-line at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output.

  • Page 16: Duty Cycle And Overheating

    A complete Parts List is available on-line at www.MillerWelds.com 4-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens and output stops. Wait fifteen minutes for unit to cool.

  • Page 17: Section 5 − Installation

    A complete Parts List is available on-line at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Do not move or operate unit where it could tip. Movement Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 18: Connecting 120 Volt Input Power

    A complete Parts List is available on-line at www.MillerWelds.com 5-2. Connecting 120 Volt Input Power Installation must meet all National and Local Codes − have only qualified persons make this installation. Special installation may be required where gasoline or volatile liquids are present −...

  • Page 19: Electrical Service Guide

    A complete Parts List is available on-line at www.MillerWelds.com 5-3. Electrical Service Guide Elec Serv 2014−01 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.

  • Page 20: Installing Work Clamp

    A complete Parts List is available on-line at www.MillerWelds.com 5-5. Installing Work Clamp Tighten connection hardware with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and ex- cessive heating of the work clamp.

  • Page 21: Process/Polarity Table

    A complete Parts List is available on-line at www.MillerWelds.com 5-7. Process/Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output ing gas put terminal terminal...

  • Page 22: Installing Welding Gun Or Spool Gun

    A complete Parts List is available on-line at www.MillerWelds.com 5-9. Installing Welding Gun Or Spool Gun Drive Assembly Gun Trigger Plug Gun Trigger Receptacle Route gun trigger plug through front panel. Insert plug into receptacle, and tighten threaded collar. Gun Securing Knob Gun End Loosen knob.

  • Page 23: Changing Drive Roll Or Wire Inlet Guide

    A complete Parts List is available on-line at www.MillerWelds.com 5-10. Changing Drive Roll Or Wire Inlet Guide Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place.

  • Page 24: Installing Wire Spool And Adjusting Hub Tension

    A complete Parts List is available on-line at www.MillerWelds.com 5-11. Installing Wire Spool And Adjusting Hub Tension Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Installing 8 in. (203 mm) Wire Spool Adapter and retaining ring When a slight force is...

  • Page 25: Threading Welding Wire

    A complete Parts List is available on-line at www.MillerWelds.com 5-12. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling.

  • Page 26: Installing Gas Supply

    A complete Parts List is available on-line at www.MillerWelds.com 5-13. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, other stationary support so cylinder cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter with CO shielding gas.

  • Page 27: Removing Mig Gun After Installation To Replace With A Spool Gun

    A complete Parts List is available on-line at www.MillerWelds.com 5-14. Removing MIG Gun After Installation To Replace With A Spool Gun Open Pressure Assembly Cut Off End Of Wire Turn Off Power Knob Hold wire tightly to keep it from unraveling. Loosen Knob, Disconnect Gun Trigger Rewind Wire Onto Spool, Fasten Plug, And Remove Gun From Unit...

  • Page 28: Section 6 − Operation

    A complete Parts List is available on-line at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Manual Setup ** See weld parameter chart for Auto-Set instructions. ** Multiple passes required for solid wire Rear View 274600-A / 267833-A Voltage/Material Thickness Control Wire Speed/Wire Diameter Control Over Temperature Light If unit overheats, light turns on and output Turn control clockwise inside white scale...

  • Page 29: Using Auto-Set

    A complete Parts List is available on-line at www.MillerWelds.com 6-2. Using Auto-Set ** See weld parameter chart for Auto-Set instructions. ** Multiple passes required for solid wire 274600-A Wire Speed/Wire Diameter Control Auto-Set Light Voltage/Material Thickness Control Adjust the Voltage/Material Thickness To turn Auto-Set on, turn the Wire Speed/ control knob to the desired steel material The Auto-Set light illuminates indicating...

  • Page 30: Weld Parameter Chart

    A complete Parts List is available on-line at www.MillerWelds.com 6-4. Weld Parameter Chart 267 700-C OM-264423 Page 26...

  • Page 31: Weld Parameters

    A complete Parts List is available on-line at www.MillerWelds.com 6-5. Weld Parameters Ref. 267 700-C OM-264423 Page 27...

  • Page 32: Section 7 − Maintenance &Troubleshooting

    A complete Parts List is available on-line at www.MillerWelds.com SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months...

  • Page 33: Troubleshooting Table

    A complete Parts List is available on-line at www.MillerWelds.com 7-4. Troubleshooting Table Trouble Remedy Secure power cord plug in receptacle (see Section 5-2). No weld output; wire does not feed; fan does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1).

  • Page 34: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-264423 Page 30...
  • Page 35 263 745-B OM-264423 Page 31...

  • Page 36: Section 9 − Gmaw Welding (Mig) Guidelines

    SECTION 9 − GMAW WELDING (MIG) GUIDELINES 9-1. Typical GMAW (MIG) Process Connections Weld 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. Regulator/ Flowmeter Wire Feeder/...
  • Page 37 9-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trig- ger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned cor- rectly on seam.
  • Page 38 9-5. Gun Movement During Welding Normally, a single stringer bead is satisfactory 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. Stringer Bead − Steady Movement Along Seam Weave Bead −...
  • Page 39 9-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.
  • Page 40 9-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.
  • Page 41 9-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand.
  • Page 42 9-16. Common GMAW (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 developed over the years. The most commonly used shielding gases are listed in the following table. Application Short Short...
  • Page 43 9-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. Wire feed motor operates, but wire does not feed. Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match wire size and type if necessary.

  • Page 44: Section 10 − Parts List

    SECTION 10 − PARTS LIST A complete Parts List is available on-line at www.MillerWelds.com 10-1. Recommended Spare Parts Item Part Description Quantity ..... 246372 NOZZLE, slip type .500 orf flush .
  • Page 45 Notes...
  • Page 46 Notes...
  • Page 47 Effective January 1, 2018 (Equipment with a serial number preface of MJ or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 48 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2018 Miller Electric Mfg. LLC 2018−01...

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