Instruction/ maintenance manual of the product 3035 Miller Electric
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Processes OM-1216 205 917D 2006 − 09 Description MIG (GMAW) W elding Wire Feeder Spool Gun Spoolmat e 303 5 And 3545 Spoolma te 303 5 Spoolma te 354 5 ™ File: Wire Feeder V isit our website at www.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-1216 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown i n the adjoining symbols.
OM-1216 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
OM-1216 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
OM-1216 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .
OM-1216 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
OM-1216 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
OM-1216 Page 7 2-3 . Da ngers supplém entair es en relation avec l’installa tion, le f onc tionneme nt et l a maintena nce Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables.
OM-1216 Page 8 2-5. Princi pales nor mes de sécurit é Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .
OM-1216 Page 9 SECTION 3 − INST ALLA TION 3-1. Specifications For Spoolmate 3035 Wire Diameter Range Approximate Wire Feed Range Cooling Method Maximum Spool Size W eld Circuit Rating Overall Dimensions W eight .023 Thru .035 in (0.8 Thru 0.9 mm) Aluminum Wire .
OM-1216 Page 10 3-3. Connecting Spool Gun T o Millermatic 210 3 802 998-C 1 2 4 Rear Panel 5 6 1 Barbed Fitting . If spool gun gas hose is equipped with a pre-installed barbed fitting, cut off fitting from end of hose. Connect spool gun gas hose to barbed fitting.
OM-1216 Page 1 1 3-4. Installing Wire Spool And Threading W elding Wire Ref. 801 891-B T ools Needed: 1 Thumb Screw 2 Spool Cover Remove thumb screw and spool cover . 3 Hub T ension Nut 4 Wire Spool Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.
OM-1216 Page 12 3-5. Removing Existing Barrel And Installing Contact Adapter 802 379-B 1 Base Nut Location Remove base nut from handle. 2 Handle Section Remove handle section from gun. 3 Drive Roll Assemblies Remove drive roll assemblies. 4 Nut Remove nut from barrel.
OM-1216 Page 13 SECTION 4 − OPERA TION 4-1. Controls sb5.1* 6/92 − S-0621-C / 804 386-A . Spool Gun On/Off switch in Millermatic 185 Hobart IronMan 210 or IronMan 250 must b e i n O n position for spool gun operation (see Field Kit 207 642 instructions).
OM-1216 Page 14 5-2. Changing Drive Rolls 801 893-B T ools Needed: Y T urn Off power at welding power source first. 1 Drive Roll Cover Remove cover . Changing Push Roll: T o remove push roll: 2 Push Roll Screw 3 W asher 4 Push Roll Remove screw and washer , and lift out drive roll.
OM-1216 Page 15 5-3. Changing Liner Ref. 801 891-B T ools Needed: Y T urn Off power at welding power source first. 1 Nozzle 2 Contact Tip 3 Liner Remove and replace liner . Reinstall parts as shown. 1 2 3 5-4. T roubleshooting T rouble Remedy Gun tube assembly loose.
OM-1214 Page 16 Notes.
OM-1216 Page 17 SECTION 6 − ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram 186 451.
OM-1216 Page 18 SECTION 7 − P ARTS LIST . Hardware is common and not available unless listed. 801 900-F 3 2 32 28 31 33 29 19 30 18 17 27 22 21 20 14 11 10 4 9 8 7 6 5 4 2 1 40 41 42 43 39 38 36 37 35 34 23 26 25 24 13 15 16 12 Figure 7-1.
OM-1216 Page 19 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly for Spoolmate 3035 1 PB1 186 416 TRIGGER SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1216 Page 20 . Hardware is common and not available unless listed. 802 577-C 3 2 32 36 28 31 33 37 34 41 42 43 29 19 35 38 39 40 30 26 25 27 22 21 20 11 10 4 9 8 7 6 5 4 23 24 14 13 15 16 12 18 17 2 1 Figure 7-2.
OM-1216 Page 21 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-2. Complete Assembly For Spoolmate 3545 1 PB1 186 416 TRIGGER SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1216 Page 22 204 161 1 2 3 4 5 6 Figure 7-3. Spoolmate Optional Hose & Cables Extension Kit Description Part No. 194 996 Item No. Figure 7-3. Spoolmate Hose & Cables Extension Kit Quantity 1 172 171 FITTING, hose, brass 1 . . . . . . . . . .
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compan y 1635 West Spenc er St reet Applet on, W I 54914 USA International He adquarters .
An important point after buying a device Miller Electric 3035 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric 3035 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric 3035 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric 3035 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric 3035 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric 3035, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric 3035.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric 3035. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric 3035 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
