ESAB MILLERMATIC 35S Troubleshooting instruction

Brand: ESAB

Model: MILLERMATIC 35S

Category: Welding System

Type: Troubleshooting instruction

This manual is also suitable for

Competitive Adaptor Package

INSTRUCTIONS for

F-12-844-B

December, 1995

The adaptor packages were made available so that

the MT-200 or MT-400 torch can be used with Miller

wire feeder models listed above.

REQUIRED EQUIPMENT (See Fig. 1)

1. MT-200 or MT-400 Torch.

2. Power Cable Connection - Cable Splice (81F80)

or Cable Connector (81F25) is required if adapt-

ing an MT torch to a 50 Series or Swingarc (single

or dual) wire feeder. Selection depends on na-

ture of application or preference.

CONTENTS OF ADAPTOR PACKAGES (See

Fig. 1)

One each of the following items are supplied with

the Complete Competitive Adaptor Package, P/N

600308 (MT-200, -400).

Description.............................................. Part No.

MT-200/-400 Wire Feeder Connector .......2075212

Torch Retaining Pin ..................................2075221

Switch Lead with Miller W. F. Plug ..............999181

Gas Hose Assembly, 36-in........................ 999182*

Nipple, Gas Hose ........................................ 11N22

Nut, Gas Hose............................................136Z08

Snap Busing

Adaptor Outlet Guide Kit.............................600337

Includes:

Adaptor Outlet Guide............................... 999180**

Liner (0.070", 0.035", &

0.045" Wire.................................................690515

Liner (0.100" I.D.) - 0.045", 0.052" &

1/16 Wire....................................................690514

Liner (0.140" I.D.) - 5/64", 3/32", &

7/64" Wire...................................................993844

*Includes Connector (2075366) and two hose clamps (98W43).

**Includes No. 8-32 x 1/8" setscrew and 5/64" hex key.

Note that each package includes components simi-

lar to Wire Feeder Connector Assembly (P/N

2075379) which as noted in the torch booklets (F-

COMPETITIVE ADAPTOR PACKAGE

P/N 600308 (MT-200 AND MT-400)

For Connecting the MT-/Type Torch

To Miller's 50 Series, Millermatic 35*, 35S* or 200,

Mig-Mate 150, Swingarc-Single or Dual

F-12-844-B

12-778 and F-12-768) is a required accessory of an

MT Torch. Therefore, you do not need to order a

Wire Feeder Connector Assembly for use with this

kit.

INSTALLATION

Before installing the adaptor package, make sure

that all input power to the wire feeder is

deenergized (OFF).

1. The liners supplied with the kit are recommended

for use with the following hard and cored wire

sizes:

P/N 690515 - 0.030", 0.035", and 0.045" wires

P/N 690514 - 0.045", 0.052", and 1/16" wires

P/N 993844 - 5/64", 3/32", and 7/64" wires

Cut a 3-3/4-in. long piece from the liner that you

intend to use with a pair of sharp wire cutters.

Remove burrs and sharp edges from each end

of the 3-3/4-in. long liner.

2. Insert the liner into the adaptor outlet guide (P/N

999180) as shown in Fig. 1. Tighten setscrew in

the adaptor to lock the liner in place. Do NOT

overtighten.

3. Connect adaptor outlet guide to the W.F. Con-

nector wrench tight, and then plug it into the out-

let of the wire feeder.

4. Connect gas hose (P/N 999182) to the W.F. Con-

nector.

5. With the exception of the Millermatic 35, 35S and

200, cut the gas hose to the desired length and

install gas hose nipple and nut (P/N 11N22 and

136Z08) using the supplied hose clamp (P/N

98W43) to secure the nipple to hose.

On the Millermatic 35, 35S, and 200, connect

the gas hose as follows (refer to Fig. 2):

Be sure this information reaches the operator.

You can get extra copies through your supplier.

F-12-844-B 12/95 2C Printed in U.S.A.

a. Remove right side panel and disconnect the

gas hose from the gas solenoid valve located

on the lower part of the rear panel.

b. Drill a 7/16-in. dia. hole at a convenient loca-

tion on the upper right hand corner of the front

panel, and then install the supplied snap bush-

ing to the hole.

c. Insert the unfitted end of the gas hose through

the hole of the bushing and then install gas

nipple and nut to the hose securing the nipple

to hose with the supplied hose clamp.

d. Connect the gas hose to the solenoid valve.

Tighten firmly with a wrench.

e. Install right side panel back onto the

Millermatic.

6. Power on the Millermatic 35, 35S, and 200 wire

feeder is supplied through the feed roll acces-

sory support. Therefore, the power cable on the

W.F. Connector should be cut off (at the end of

the steel band) and insulated with several layers

of electrical tape.

If using a 50 series or Swing-Arc wire feeder,

connect the W.F. Connector power cable to cable

from power source by using a cable splice

(81F80) or cable connector (81F25). (See

Fig. 1)

7. Insert the inlet end of the torch fully into the W.F.

Connector and lock it in place with the retaining

pin or lock screw.

8. Connect the torch switch lead (P/N 999181) to

the torch and the wire feeder.

9. Refer to the MT touch booklet (Form F-12-778 -

MT-200 or F-12-768 - MT-400) for additional in-

stallation information and to the manufacturer's

wire feeder booklet for operating details.

Fig. 1 - Connecting Adaptor Package Components and Required Equipment to MT Torch.

ADAPTOR OUTLET

GUIDE - 999180

RETAINING PIN - 2075221 (MT-200/-400)

WIRE FEED

CONNECTOR

2075212 (MT-200/-400)

MT TORCH

LINER

(Cut to length)

WIRE FEEDER

BLOCK

CONNECTOR

81F25

SPLICE

81F80

CLAMP

98W43

(Supplied w/999182)

NUT - 136Z08

NIPPLE - 11N22

GAS HOSE -

999182

SWITCH LEAD

w/PLUG -

999181

REQUIRED

•

POWER CABLE CONNECTION

•Required for Miller's 50 Series and Swingarc.

On Millermatic 35, 35S and 200 Wire Feeders,

cut off power cable from W.F. Connector and insulate.

DRILL 7/16" DIA. HOLE

INSTALL SNAP BUSHING

GAS SOLENOID VALVE

GAS HOSE - 999182

Fig. 2 - Connecting Gas Hose to Millermatic 35, 35S,

and 200 Wire Feeder

ESAB MILLERMATIC 35S Troubleshooting instruction

Brand: ESAB

Model: MILLERMATIC 35S

Category: Welding System

Type: Troubleshooting instruction

This manual is also suitable for

Competitive Adaptor Package

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ESAB MILLERMATIC 35S Troubleshooting instruction

This manual is also suitable for

ESAB MILLERMATIC 35S Troubleshooting instruction

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