Millermatic 135 110v Problem!

by Curtis
(Crane, Mo.)

I have recently begun to have trouble with my welder, and I cannot figure it out. I'm hoping someone on here can point me in the right direction. I have a Millermatic 135, 110v, that I purchased new 10 years ago, I have good power supply, clean wire and good ground. While welding it has begun to sputter and run out of wire and lose the arc. Normally you just turn up your wire speed and its fixed, but it is not helping this time. I am welding 14 gauge tube, in various joint configurations, the metal is clean and oil free. I attempted to adjust the speed and voltage today while in use, and it did not seem to help any. I normally run around 35 on wire speed, and the same on voltage, welded miles of things that way, but now its not working. My feed roller is good, wire is feeding smooth, it just runs out of arc more or less. Any suggestions would be greatly appreciated.

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Nov 25, 2013
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Fixed
by: Curtis

Anon, thanks for the suggestion. I had actually replaced my liner before the problem became worse. And in the end I believe it was the root of my problem. The clamp inside the housing that holds the end of the liner/gun assembly had actually came loose on me, every time I pulled the trigger it moved farther and farther out, causing it to lose ground and spark simultaneously. I moved the assembly back into place and retightened the knob, works like a champ now!

Nov 25, 2013
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Miller magic problem
by: Anonymous

Replace your liner. A lot of welding shops replace the liners after 50 pounds of wire went through it.

Dec 04, 2011
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Thanks!
by: curtis

Welding rod, I had inspected my tip numerous times but had not replaced it yet. I put a new one in and it is significantly better now. I guess I learned my lesson about maintenance! Anonymous, I would not have ever suspected the like.er, that's great advice. I had put a new liner in recently, but had used it many hours since then. I will be keeping an eye on it from now one. Thanks for the great advice, I knew it would be something simply stupid, and stupidly simple!

Nov 26, 2011
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millermatic problem
by: Welding Rod

You seem to know what you are doing, so I am almost embarassed to ask if you checked your tip and nozzle for spatter.

A problem I find re-occuring is the wing nut tensioner on the spool sometimes tightens itself up and interferes with smooth feed.

If you are welding steel and the nut is loosened too much the resulting slack sometimes causes an erratic arc.

Nov 25, 2011
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acting short?
by: Anonymous

Hello there. I have the very same model and its age also. It has been flawless !!!!!!!!!!!!!!!! The only trouble I ever had was after being in many tight and awkward positions was that the very inside of the liner has gotten a "groove". It actually cut a groove in it. This momentarily caused the same thing you have going on. Every time I used it I had the similar problem. I took mine to the place I bought it and only paid a small fee to have the entire liner replaced! Since then its been Rolls Royce wonderful. I hope this helps. Put all your settings back. Make the phone call to your local dealer. If you have any problems call the main office.

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