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Retrofitting a MillerMatic 35 Mig Gun

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  • #31
    Originally posted by Kevin
    When installing a new style gun on these older units the installation of a gas valve and an adapter to attach the gun to the feed system is required. Over the years a number of companies have manufactured kits for this but most of those kits have been discontinued. If you are looking for a kit I would suggest checking with Bernard or Tweco.

    The 3rd gun supplied with the Millermatic 35 was the GA-20C. They started using this gun in 1980 (JA448186) and any standard Miller gun such as the M-15 will work as a replacement gun.
    Can we assume, from that info, that Millermatic 35, after 1980, have a gas valve/soleniod in the cabinet?

    Thanks for sharing your info with us, Kevin!
    Millermatic350P/Python, MillermaticReach/Q300
    Millermatic175
    MillermaticPassport/Q300
    HTP MIG200
    PowCon 300SM, MK Cobramatic
    ThermalArc 185ACDC, Dynaflux Tig'r, CK-20
    DialarcHF, Radiator-1
    Hypertherm PowerMax 380
    Purox oxy/ace
    Jackson EQC
    -F350 CrewCab 4x4
    -LoadNGo utility bed
    -Bobcat 250NT
    -PassportPlus/Q300
    -XMT304/Optima/Spoolmatic15A
    -Suitcase8RC/Q400
    -Suitcase12RC/Q300
    -Smith oxy/propane
    -Jackson EQC

    Comment


    • #32
      Yes, the valve is mechanically actuated and on the same trigger is a wire (switch) that engergizes the wire spool.

      It dawned on me last night what you guys are saying about an electrically actuated gas valve. Simply route the trigger wire to both an electrical solenoid (to actuate new gas valve) and wire feed and leave the manual valve in the gun as to not have to re-plumb the gun. The manual valve only leaks at certain times and as we are both getting on in years cannot distinctly hear the leak and actually have to close the tank valve in between welds. Did I mention argon is very expensive?

      Can anyone recommend a valve that can easily be purchased at the local MILLER dealer?

      You guys are great!

      Comment


      • #33
        Yes, argon is through the roof right now, for some reason. At work, a 300 cu.ft. tank of it lasts only ~2.5 days per machine (we do production welding). We go through a 230 liter liquid argon tank every 3 weeks....

        One thought- have you called Miller parts dept to find out if the gas valve in that torch is still available as a replacement part?

        Barring that, If the Millermatic 35 after 1980 has a gas valve/soleniod in the cabinet, as I now suspect, I would first investigate to see if these parts can still be purchased, as that would be the easiest way to get a gas valve into your friend's machine. If not, then I would look to another, later model Millermatic that does have a gas valve in it (like a MM200, 250, etc) and see about availability of those parts and adapting that to your freind's machine.

        You may want to remove and/or by-pass the mechanical gas valve in your torch if using a gas valve in the machine, if the valve in your torch is leaking and can't be fixed.

        In one parts schematic I was looking at for, I think it was Millermatic 251, 252 or 350, the gas valve/solenoid (all one unit I think, from the picture) was, as I remember it, 12 volts and looked to be a good candidate for retrofit into something else. I wasn't looking for info on gas valve at that time, just got to thinking about that as I saw it on the schematic and parts list. The gas valve/soleniod is all one unit in my Cobramatic feeder too, as I remember it. It wouldn't surprise me if most of them now days are one unit.

        We have electric solenoid operated air valves on most of the machines at work that I work on often. On these, the soleniod is a seperate unit attatched to the top of the valve. I suspect a search of the Grainger or McMaster-Carr or Western Enterprises catalogs might come up with an inert-gas valve and a solenoid that could work for your application if one cannot be easily acquired from another welding machine.

        The parts schematics and parts lists for most Miller welding machines can be found on the last few pages of their owner's manuals, which are available for free download if you go to the 'Resources', then 'Owners Maunals' section, at the top of this website and search for the machine of your choice. You need to have Adobe Acrobat reader program on your computer to view the manuals in their .pdf file format. This has been a great resource to me since some of my machines are old and were purchased used so I didn't get a manual with them.
        Millermatic350P/Python, MillermaticReach/Q300
        Millermatic175
        MillermaticPassport/Q300
        HTP MIG200
        PowCon 300SM, MK Cobramatic
        ThermalArc 185ACDC, Dynaflux Tig'r, CK-20
        DialarcHF, Radiator-1
        Hypertherm PowerMax 380
        Purox oxy/ace
        Jackson EQC
        -F350 CrewCab 4x4
        -LoadNGo utility bed
        -Bobcat 250NT
        -PassportPlus/Q300
        -XMT304/Optima/Spoolmatic15A
        -Suitcase8RC/Q400
        -Suitcase12RC/Q300
        -Smith oxy/propane
        -Jackson EQC

        Comment


        • #34
          You are correct, when the gun was changed to a GA-20C in 1980 an electronic gas valve was added to the machine to control the gas supply. The drive housing was also changed at that time to accomodate the larger power pin on the GA-20C.

          Kevin
          Kevin Schuh
          Service Technician
          Miller Electric Mfg. Co.

          Comment


          • #35
            Again, Thanx Gentlemen.

            I think what will have to happen is to plumb in the newer valve in the machine and keep the mechanical valve in the gun as it has a special outlet design.

            Does this sound OK?

            Comment


            • #36
              Sounds like a plan to me. You may be able to put some fresh o-rings in the valve in the torch too, if it has them.
              Millermatic350P/Python, MillermaticReach/Q300
              Millermatic175
              MillermaticPassport/Q300
              HTP MIG200
              PowCon 300SM, MK Cobramatic
              ThermalArc 185ACDC, Dynaflux Tig'r, CK-20
              DialarcHF, Radiator-1
              Hypertherm PowerMax 380
              Purox oxy/ace
              Jackson EQC
              -F350 CrewCab 4x4
              -LoadNGo utility bed
              -Bobcat 250NT
              -PassportPlus/Q300
              -XMT304/Optima/Spoolmatic15A
              -Suitcase8RC/Q400
              -Suitcase12RC/Q300
              -Smith oxy/propane
              -Jackson EQC

              Comment


              • #37
                I forgot to say...

                Thanks, Kevin, for confirming that info about the gas valve for us, very helpful.
                Millermatic350P/Python, MillermaticReach/Q300
                Millermatic175
                MillermaticPassport/Q300
                HTP MIG200
                PowCon 300SM, MK Cobramatic
                ThermalArc 185ACDC, Dynaflux Tig'r, CK-20
                DialarcHF, Radiator-1
                Hypertherm PowerMax 380
                Purox oxy/ace
                Jackson EQC
                -F350 CrewCab 4x4
                -LoadNGo utility bed
                -Bobcat 250NT
                -PassportPlus/Q300
                -XMT304/Optima/Spoolmatic15A
                -Suitcase8RC/Q400
                -Suitcase12RC/Q300
                -Smith oxy/propane
                -Jackson EQC

                Comment


                • #38
                  And thanks to all you gentlemen again...

                  Comment


                  • #39
                    I know this is a really old post, but 10 years later, I'm needing to replace my gun on my Millermatic 35. It currently has a Bernard connector on it but I want to configure it to accept a standard Miller MIG gun. What I really need is an aftermarket coupler that I can can fit onto onto the MM35 and I think I've found one. Lincoln makes a K3347-1 which is described as "Gun Adapter Kit, Miller". It looks like its the right size and has the lug and nipple to connect the lead and hose to. I spoke with Lincoln but couldn't get verification. Can anyone verify or offer an alternative?
                    Attached Files
                    Millermatic 35
                    Miller TB302G
                    Ellis 1800
                    Smith & Victor Torches
                    Optrel Satellite
                    Arcair K4000
                    Ingersoll-Rand 175CFM Diesel Air Compressor
                    Home Made Welding Trailer

                    Comment


                    • #40
                      It looks right to me...Bob
                      Bob Wright

                      Comment


                      • #41
                        Well, I took the plunge and ordered the part along with the connection plug for the gas solenoid/drive motor. Will post the results when I'm done.
                        Millermatic 35
                        Miller TB302G
                        Ellis 1800
                        Smith & Victor Torches
                        Optrel Satellite
                        Arcair K4000
                        Ingersoll-Rand 175CFM Diesel Air Compressor
                        Home Made Welding Trailer

                        Comment


                        • #42
                          The upgrade is finished and everything worked out very well. I ordered the K3347-1 part from Lincoln which is a modern Miller Power Pin receptacle. My machine already had the solenoid kit put in so that part was there. I also ordered the 4 pin electrical receptacle that the gun trigger plugs into.

                          I had to source two more parts: an acrylic plate and plastic shoulder washers to isolate the mounting plate from the welder frame. Both came from ebay. I cut the mounting plate on my CNC plasma table.

                          While I was in there, I cleaned the drive wheels and replaced the missing Woodruff keys. I painted the outer case and ordered some new Miller logos for it.

                          The gun is a cheap aftermarket but runs Miller M25 consumables. My other guns are Bernard Q300/Q400. The MM35 is welding is going to a family member who is just getting into welding so he can update the gun when this one wears out.

                          The machine still welds like a dream and the drive is good and strong – even when the lead is coiled a bit tight. I’m kind of sad to see it go. I’ve build just about anything and everything with it and it’s been my main welder for the past 25 years or so. But I know it’s going to a good home.
                          Millermatic 35
                          Miller TB302G
                          Ellis 1800
                          Smith & Victor Torches
                          Optrel Satellite
                          Arcair K4000
                          Ingersoll-Rand 175CFM Diesel Air Compressor
                          Home Made Welding Trailer

                          Comment


                          • #43
                            Great. Glad it all worked out...Bob
                            Bob Wright

                            Comment


                            • #44
                              Greetings... As probably one of the last people on this side of the planet that owns a 1975 MM35S and still has the original equipment Miller gun installed, I am very interested in garybdavis's earlier posts this year. I have begun my upgrade project by installing a solenoid for the shielding gas (the mechanism in the original gun never worked correctly), and am very pleased to finally step into the 20th century, and not have the hassle of turning the gas on and off all the time.
                              However, it is time to take the next steps; I have purchased one of the aforementioned Lincoln K3347-1 adapters, and procured a copy of the original Miller upgrade instructions to guide me. What has evaded my search are the details on the 4 pin (it is 4 pin, yes?) trigger connector. The panel mount connector appears to be an Amphenol, are there any part numbers available for that? I assume the panel connectors are sockets, and the gun side has the pins?
                              I have a number of questions that would greatly assist my progress, but I don't want to post all of them online. If someone skilled in this transition would be kind enough to contact me, any information would be greatly appreciated. Any suggestions for a reasonable priced replacement for this gun (am on a tight budget with the holidays) would also be greatly appreciated. Thanks!

                              Happy Holidays to all.
                              Bob

                              Comment


                              • #45
                                I have a couple of questions, i see the lincoln adapter and not quite sure how you attach it to the plastic plate and would you still use a m25 gun like the black face model? i do see tweco makes a conversion kit which will work with the tweco guns. i hear the tweco guns are reliable but never used one. and lastly the black face has 10 capacitors where the white face has 6. can i just swap out the capacitor pack ? been using the black face for 30+ years but it has been worked hard. did not realize there was a difference until i just picked up a white face mm35 in way better shape then mine. of course gun is no good.
                                thanks for any input.

                                bob

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