Miller matic 35 heat control

[klyde]

I have the Miller matic that says use wire feed 50 and heat control 3 for
0.062 steel. When I ust that setting it immediately blows a hole thru the metal. I have to reduce the heat control down to 1 to keep from blowing holes thru and even then I seem to be getting more penetration than I want. Trouble shooting section doesn't list this kind of problem. Any ideas?

Klyde

 

[shenion]

What size and type of wire?

 

[klyde]

Wire size is 0.035. Type unk but it is copper coated? Large spool.

 

[shenion]

You would probably need to lower the wire speed on 0.035 down to where it would be just "popping" for it to work.

If a low wire speed does not work, try 0.030" or 0.025".

The Miller setting probably assume a production setup where you would be moving the torch as fast as possible.

 

[klyde]

Thanks for the fast response. I have found the wire to be corroded a bit so I've taken off pretty much a couple of layers. In the process I disconnected the reel, removed the drive tension and tried to pull the wire out of the gun. It required significan pulling so I'm suspecting the liner needs replacing. So far my TIG welder is looking better and better. But I can't stand having a tool that I don't know how to use it to at least a basic level. I'm also having trouble locating a partsl manual for the Tweco model 4 Mig Gun that I have. Any hints??

Thanks
Klyde

 

[shenion]

For Tweco info go to the Thermadyne site (Thermadyne owns Tweco.)

I have a #4 Tweco gun, probably 30+ years old and still works great. looks a little beat up though. I did replace the liner. I picked up a smaller Tweco gun as the #4 is huge

Tweco stuff cab be expensive as many suppliers charge full list. Places like WeldingDepot.com sell Parweld parts that are good and reasonably priced. Check your local gas supplier though, mine actually has decent prices on Tweco if they are in a good mood . I picked up 4 liners for my #4 off ebay for something like $15; someone was closing out old stock. One was for 0.080 (2mm) wire, doubt I'll ever have a use for that one.

Running rusty wire will plug up the liner. What brand wire? I find Lincoln and Hobart do not rust even in my garage that has flooded several times. You can try blowing out the liner with a compressor (remove gun and electrode tip and plow air through center of machine connection end.

A long gun may take considerable force especially if the line is coiled tight.

 

[klyde]

Tweco #4 gun

Trying to remove and replace the liner. So far have been unable to find all the set screws locking it in. The gun is attached to a MillerMatic 35 and has some boxes attached near the welder that don't show up in any of the Miller or Tweco literature. I'm sure that somewhere there is some instructions on how to adapt the Tweco to the Miller. Tweco tech support wasn't much help. My TIG system is looking much better.

 

[klyde]

Tweco #4 gun

My Millermatic 35 has a Tweco model no. 4 Mig gun. The brochures say this is a 400 amp gun and the Millermatic 35 is a 160amp welder. Seems to be a mis-match here. Is there a better, lighter gun that can be used instead? To date I'm not impressed with the Tweco service I've found.

 

[klyde]

Continuing Saga of the Miller Matic 35 vs Tweco No. 4 Mig Gun

I got the new conduit and am having trouble installing the whole system. All the explode parts pictures I can find do not match my system. I have two black boxes at the welder where the cable exists. One is marked"
Tweco MIG-KWIK no 4 MK Connector. The other, which mounts close to the welder wall is just marked Tweco and has what appears to be the gas connection and has a large set screw in the side. Is there any exploded parts view that shows how this thing is to be assembled?

Klyde.

 

[shenion]

Loosen the large set screw, will have to be several turns. Then the gun will just pull out.

Remove the tip on the gun.

In the brass part that slides into the KWIK adapter, will be a set screw. loosen it and the liner will slide out (lay torch in a straight line makes it easier.)

New one slides in and tighten screw.. Will need to be cut to length, usually about 5/16" past end of gun (it gets pushed in when you screw in the tip.) Instructions on cutting length on the box.

The Tweco catalog has exploded views.

I have the older style adapter on mine but it is similar. I you need pictures, let me know,

 

[klyde]

I've been thru the Tweco catalog and can't find any exploded parts view that matches my set up. None seem to show the two modules at the exit of the welder. To say I'm frustrated would rival classical english understatement. Surely somewhere there are instructions with an exploded parts view on how to apply the mod kit to adapt the Tweco no. 4 gun to the MillerMatic 35 ?

 

[shenion]

The catalog has an exploded view of the #4 gun.

The adapter is in a different catalog for the KWIK adapter.

If it is a Tweco #4 gun, I have one. It is not complicated. Here's a pic:

That may be my #2 gun, they are very similar (#4 would be longer.)

As I said, post pics of the setup. Removing the gun is easy.

Edit: Here's a pic of my #4 gun and spare liner: