ESAB MIG-41 Push-Pull Gun Troubleshooting instruction

Brand: ESAB

Model: MIG-41 Push-Pull Gun

Type: Troubleshooting instruction

INSTRUCTIONS for

F-14-363-A

October, 1997

MIG-41

PUSH-PULL GUN

FEATURES/BENEFITS

 couples up with most feeders to create a high

performance push-pull system

 all electric drive automatically synchronizes with

wire feeder

 liquid cooled design usable up to 450 amps;

uses ST16/21/21M consumables

 ideal for feeding aluminum or other small diam-

eter wires long distances

 quick disconnect convenience

 repairable front end for easy low cost mainte-

nance

 ideal for new installations or retrofits

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation

and safe practices for electric welding equipment, we urge you to read our booklet, “Precautions and Safe

Practices for Electric Welding and Cutting,” Form 52-529. Do NOT permit untrained persons to install, operate,

or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully

understand these instructions. If you do not fully understand these instructions, contact your supplier for further

information. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment.

Table 1 - Available MIG-41 Push-Pull Gun Assemblies

MIG-41 Gun (25-ft. long) for 0.035-in. software .......................600979

MIG-41 Gun (25-ft. long) for 3/64-in. soft wire .........................600980

MIG-41 Gun (25-ft. long) for 1/16-in. soft wire .........................604290

MIG-41 Gun Assembly Components Included with torch assembly

Torch Length Contact Tip Drive Roll Liner Nozzle Basic Gun

P/N x Wire Size P/N P/N P/N P/N P/N

600979 25-ft. x 0.035” soft 632793 (.035) 19269 (.035/.9mm) 19304 (#10)* (25-ft.)

600980 25-FT. X 3/64” soft 632795 (3/64) 19270 (3/64/1.2mm) 19304

604290 25-ft. x 1/16” soft 632797 (1/16) 19736 (1/16/1.6mm) 19305

Be sure this information reaches the operator.

You can get extra copies through your supplier.

II. EQUIPMENT & ACCESSORIES

A. REQUIRED EQUIPMENT

1. Power Control Assembly P/N 19310. Provides

power for torch pull motor on MIG 35, Digimig,

Digipulse Feeders.

2. Wire Feeder Connector Assembly - P/N 19260

(Mig-35, Digimig, Digipulse)

Provides quick connect and disconnect of gun to

wore feeder (see Figs. 2 & 5). It includes power

cable, switchcord, and gas hose with fitted con-

nections. Each connector assembly is also sup-

plied with coolant “in” (P/N 19089) and coolant “out”

(P/N 19090) hose assemblies. The hose assem-

blies are fitted with double-check quick-connects

on one end that directly connect to coolant fittings

on the MIG-41 gun, and standard CGA coolant fit-

tings on the other for connecting to coolant kit fit-

tings on wire feeder. The connector assemblies

include a support liner used with the 0.030/0.035

and 3/64 liners. The support liner is not used with

the 1/16-in. liner.

NOTE: Due to the high electrical conductivity, use of

tap water or commercial anti-freeze is NOT rec-

ommended for torch cooling. Use of the WC-8

coolant recirculator (see below) using a spe-

cially formulated torch coolant (P/N 156F05, 1

gal. container) is recommended for torch cool-

ing. The coolant also provides anti-freeze pro-

tection down to -34° F.

3. Push-Pull Torch Control Kilt (Mig 4HD) 34327.

4. Water Kit (Mig 4HD) 34325

5. Feed Roll for Wire Feeder

Select the proper feed roll for your particular wire

feeder from Table 3.

6. Coolant Recirculator, P/N 33739 (WC-8C). Unit

is capable of recirculating coolant at the rate of 1

gpm which is more than adequate for protecting

the torch. It is equipped with 8-ft. input power cord

that plugs into a standard 115V AC receptacle. The

WC-8 with its 9-3/4 in. square base fits into a cylin-

der rack of any power supply truck. Use Torch Cool-

ant, P/N 156F05 (1 gal. container) only. Unit has a

tank capacity of 1/5 gal.) Two coolant hose assem-

blies, P/N 40V76 will be required for connecting

recirculator to the wire feeder mounted with the

coolant kit fittings. The recirculator cannot be set

up for solenoid valve shutoff.

B. OPTIONAL ACCESSORIES

1. Other Contact Tips or Tubes, Liners, and

Nozzles - For replacement or additional accesso-

ries so that the torch can be used with other wire

sizes, see Table 3.

2. 45° Curved Front Body, P/N 19757 - Available

for replacing straight front body of standard MIG-

41 gun assembly. Wire Guide P/N 19758 (includes

plastic liner P/N 19759) is required for use with

this assembly.

III. INSTALLATION

A. INSTALL DRIVE ROLL IN TORCH

1. Pull off drive roll cap from gun handle. (See Fig.

1.)

2. Flip idler arm to the down position.

3. Remove screw and washer.

4. Engage drive roll to the drive roll seat and then

reassemble washer and screw. Tighten screw

firmly with screwdriver.

5. Close idler arm and then reinstall drive cap. Do

not adjust preset tension of cap knobs.

Table 3 - Recommended Mig-41 Gun Accessories

(8.4m) Guide Tub Feed Roll (Wire Feeder)

Wire Wire Contact Contact Tip Liners Drive Mig 4HD Mig-35 Mig-35

Type Size Tube Long Short 28 Ft. Roll Connector Connector Mig 4hd Digimig

Soft 0.030 — — 632791 19304 19268 — ????? 21158 — 2075304

0.035 996104 632794 632793 19304 19269 — ????? 21158 — 2075304

3/64 996105 632796 632795 19304 19270 — ????? 21159 — 2075301

1/16 996106 632798 632797 19305 19736 — ????? 21159 — 2075298

Hard 0.030 — — 632791 19868 19268 19871 19873 21155 — 2075300

0.035 996104 632794 632793 19868 19269 19871 19873 21156 2075313 2075303

0.045 996105 632796 632795 19869 19270 19872 19874 21156 2075311 2075302

1/16 996106 632798 632797 19870 19736 19872 19874 21157 2075308 2075299

 Requires use of Collet Nut 18961.

 Plastic liners are used for soft wires and extend through the wire feeder connector. A support liner

supplied with the connector is used with 0.030, 0.035 and 3/64-in. wires. Remove support liner when

using 1/16-in. wire. Liners 19304 and 19305 include collet 19306 and O-ring 19307. Liner 19737

includes collet 19774 and O-ring 19307.

 Steel liners are used for hard wires. They DO NOT extend through the wire feeder connector. Select

the appropriate guide tube for assembly into the wire feeder connector. The support liner is not used

in the connector with hard wires.

? Requires Guide Bushing, P/N 17997.

Nozzles

P/N Size

No. 8 18958

No. 10 18959

No. 12 18960

No. 12 Spotweld 18996

B. INSTALL LINER

For Soft Wire:

1. Lay gun cable out relatively straight.

2. Remove liner positioner nut.

3. Insert end of plastic liner into opening at inlet con-

nection end of cable, and then inch liner through

cable until it butts to a stop. Inch the liner back and

forth to be sure it is seated. Then pull liner back

about 1/4”. When assembling the 1/16-in. liner,

whipping the cable/hose bundle from side to side

will facilitate the assembly. It is also advisable to

remove any sharp edges (tapered end) from the

liner end.

4. Slide collet on liner and up and into inlet connector

end of cable, and then slide O-ring up to collet.

Finally, slide liner positioner nut onto the liner and

engage it to the connector. The small teeth inside

the slotted collet will keep the liner tight in the gun

and cable when the liner positioner nut is hand tight-

ened.

5. The liner should be extending several inches past

the positioner nut. Insert the liner through the wire

feeder connector assembly, including the support

tube for 0.030/0.035 liners. (The support tube

should be removed for 1/16-in. wire.)

6. Connect the wire feeder connector assembly to the

gun cable hand tight.

7. Trim the liner. When wire feeder connector assem-

bly is assembled to the accessory support of the

wire feeder, the liner should be trimmed as close

as possible but not touching the feed roll as illus-

trated below.

For Hard Wire:

1. Remove the liner positioner nut from the inlet con-

nector.

2. Lay the gun cable out relatively straight.

3. Insert the bare end of the steel liner into the con-

nector and inch through the torch until it butts to a

stop.

4. Measure the distance from the end of the inlet con-

nector to the liner ferrule shoulder as shown be-

low.

5. Remove the liner and cut this amount off the bare

end of the liner. Remove burrs both inside and

outside cut end.

6. Reassemble liner.

7. Reassemble positioner nut and tighten.

C. MOUNT POWER CONTROL ASSEMBLY

1. The Power Control Assembly (19310) is supplied

with two tube clamps and screws for mounting on

the frame of the MIG-35 Wire Feeder as shown in

Fig. 2. Threaded holes are provided in the box for

the screws.

2. Insert the cord with 3 leads through strain relief of

the wire feeder control assembly along with its con-

trol cord. Connect the black and white leads to the

same terminals as the gas solenoid valve. TB2-3

& TB2-4 on MIG-35; T1-2 & T1-3 on Digimigs —

refer to appropriate wire feeder instruction booklet

or see Fig. 2A.) Connect green to appropriate chas-

sis ground. The connections will supply 110 V AC

to the power control assembly.

3. Connect the cord with socketed connector to the

mating connector of gun. This connection will sup-

ply 42 V to the drive motor of the gun.

D. CONNECT MIG-35 WIRE FEEDER CONNEC-

TOR ASSEMBLY LEADS

1. The Wire Feeder Connector Assembly is equipped

with power cable, gas hose, and switch cord. Con-

nect them to wire feeder as shown in Fig. 2.

INLET CONNECTOR

END OF GUN CABLE

LINER POSITIONER

NUT

COLLET

O-RING

PLASTIC LINER EXTENSION

SUPPORT LINER

(.030, .035 & 3/64 SOFT WIRE ONLY)

INLET CONNECTOR

END OF GUN CABLE

LINER POSITIONER

NUT

DISTANCE

LINER FERRULE

MEASURED

GUIDE TUBE (See Table 3)

(No Support Liner Used)

LINER

2. Connect the coolant hoses (19089 and 19090 sup-

plied with the Wire Feeder Connector Assembly)

to the mating coolant hose connectors of the gun.

The other end of the hoses are fitted with standard

CGA fittings designed to connect to wire feeders

mounted with optional coolant kit components (B-

size to coolant adaptor; C-size to power block adap-

tor).

E. VOLTAGE PICK-UP LEAD

Starting December 1, 1986, each MIG-41 gun includes

a voltage pick-up lead for connecting to the Digipulse

450 Pulsed Mig Welding system for better arc voltage

sensing. This lead has a single pin connector and ex-

tends about 8-in. from the wire feeder connector end

of the gun cable. The pick-up lead connects only to

Digipulse 450 system modified for this connection. The

modified units can be identified by locating a small

single-pin connector in the red wire externally con-

nected from the wire feeder control and attached to

the accessory support assembly of the wire feeder. For

more details refer to Insert for F-14-350 packed with

the Digipulse 450 System.

The pick-up lead is NOT required if using the MIG-41

gun with any other wire feeder. It is recommended that

it be disconnected from the gun as follows (see illus-

trations):

1. Loosen the 3-piece adaptor support lock nut at wire

feeder connector end by turning it to the left and

then slide towards from end. The loose adaptor

support half can then be lifted off.

2. Cut nylon tie-wrap securing the folded over pick-

up lead to power cable and discard the tie-wrap.

3. Disconnect the pick-up lead from the lead in the

cable and discard the pick-up lead. Tuck the fe-

male connector end of the lead back into the gun

cable.

4. Reassembly the 3-piece adaptor support.

Fig. 1 - MIG-41 Push-Pull Gun

Fig. 2 - Typical MIG-41 Push-Pull Gun Set-Up

3-PC ADAPTOR SUPPORT

VOLTAGE PICK-UP LEAD - 19798

TIE WRAP

DISCONNECT

POWER CONTROL ASSY. -

19310

COOLANT “IN” HOSE ASSY. - 19089

COOLANT “OUT” HOSE ASSY. - 19090

INLET CONNECTOR

END OF GUN

WIRE FEEDER CONNECTOR ASSY. -

19259 (MIG-31, 31A)

19260 (MIG-35, DIGIMIG)

DRIVE ROLL CAP (pull up to remove)

Do not adjust preset

in cap knobs.

F. FEEDING WIRE

1. With MIG-41 Gun completely installed and all

power OFF, feed wire by hand through the feed

rolls of the wire feeder and guide the end of the

wire into the liner of the wire feeder connector as-

sembly. Then close the feed roll clamp.

2. Pull the drive roll cap off gun and flip idler arm down.

Remove nozzle and contact tip from front end of

gun.

3. Lay the gun and cable out straight and then inch

the wire through the cable. Inching can be accom-

plished from either the wire feeder or gun.

4. When wire reaches the drive roll, make sure the

wire fits into the groove of the drive roll and is di-

rected into guide tube opening in the wire guide of

gun.

The drive roll components and wire are electrically

hot when gun trigger is depressed.

5. When wire appears out of the front end of gun,

reassemble contact tip and nozzle. Close idler arm

and reinstall the drive roll cap . Do not adjust the

pre-set tension in the cap knobs. Do not inch

the wire using the control inch button when

the wire is completely through the torch and

the idler arm closed. Birdnesting will occur at

the feeder.

IV. OPERATIONS

A. ADJUSTMENTS

1. Before welding, ease tension on the wire feeder

feed rolls if necessary. (See appropriate wire feeder

instruction booklet.) They should not be tight

enough to shave the wire. Proper wire feeding re-

quires the pull motor of the gun and the push at

the wire feeder working together.

2. Before welding, also be sure the torch gas system

has been thoroughly purged and the coolant sys-

tem has been completely filled.

Whenever welding above 250 amps, a No. 14 filter

lens should be worn on your protective helmet. Up

to 250 amps, use a No. 12 filter lens. Refer to page

2 of this booklet for additional operating precau-

tions.

CAUTION: Do not drop gun or remove spatter from

nozzle by hitting the front end against a

hard surface. This may damage the front

end and/or motor assembly. A damaged

front end can cause gas or coolant leak-

age.

V. MAINTENANCE

If this equipment does not operate properly, stop

work immediately and investigate the cause of the

malfunction. Maintenance work must be performed

by an experienced person, and electrical work by

a trained electrician. Do not permit untrained per-

sons to inspect, clean, or repair this equipment.

Use only recommended genuine ESAB replace-

ments parts.

A. NOZZLES

Spatter can be removed from the inside of the nozzle

with a hand reamer or file. Adherence of spatter can

be minimized and removal made easier by coating the

inside of the nozzle with No. 65 Nozzle Anti-Spatter

Compound (4-oz. container - P/N 03N65; 1-qt. con-

tainer - P/N 08N75).

VI. REPLACEMENT PARTS

All replacement parts are keyed in Figs. 3, 4 and 5.

Order replacement parts by part number and part

name. Do not order by part number alone. Replace-

ment parts may be ordered from your welding prod-

ucts distributor or ESAB Welding & Cutting Systems,

Customer Service Dept., Florence, SC.

Fig. 3 - Replaceable Front End Parts

CONTACT TIP - See Table 3

NOZZLE - See Table 3

(No. 10 supplied with torch)

*TIP ADAPTOR - 18927

OPT. ACCY: 45° CURVED FRONT BODY - 19757

Requires: WIRE GUIDE - 19758

includes: LINER - 19759

FRONT BODY ASSY. - 19258

includes: NOZZLE BODY & CLAMP - 18930

INSULATOR ASSY. - 18924

(included w/19258)

WIRE GUIDE - 19991

LOCK NUT - 19264 (located in torch body

under drive roll cap)

NOZZLE BODY & CLAMP - 18930 *

(included w / 19258)

* Nozzle Body & Clamp replacement requires using Nozzle Body Replacement Tool Kit - 19092

Fig. 5 - Wire Feeder Connector Assy. (MIG-35, DIGIMIG) - 19260

(MIG-31) - 19259

Fig. 4 - Basic MIG-41 Gun Assembly - P/N 19257

F-14-363-A 10/97 2M Printed in U.S.A.

DRIVE ROLL CAP w/HARDWARE

- 19265

TORCH BODY - 19847

(Includes items marked)

(2) O-RING - 19776

See Fig. 3

 NUT, IDLER ARM - 19848

 IDLER ARM - 19282

 IDLER ROLL - 19266

TRIGGER SWITCH - 19279

SCREW - 19284

SCREW, M3X10 - 19290

WASHER - 19267

DRIVE ROLL SEAT - 19271

ADAPTOR SUPPORT (3 PCS) - 19285

ADAPTOR NUT - 18402

ADAPTOR BLOCK - 19283

FEMALE WIRE CONN. - 18407

O-RING - 18406

NUT - 18404

TRIGGER WIRE (27’ LG.) - 19297

MALE WIRE CONN. - 18408

COOLANT HOSE “IN”

(26’ LG.) - 19301 (BLUE)

PLUG (COOLANT “IN”) - 950615

 Plug (950797) and socket (950798) on the Power

Control Assembly (19310) are polarized. If either

have to be replaced, mark leads and reconnect to

appropriate pins/sockets.

Not Shown

LINER (0.030”/0.035”,3/64 X 27’lg.) - 19304

(3/64” x 27’ lg.) - 19305

(1/16” X 27” lg.) - 19737

COLLET (LINER - 1/16” WIRE) - 19774

COLLET (LINER - .030—3/64” WIRE) - 19306

O-RING (LINER) - 19307

}

PLUG - 950797

MOTOR CONTROL WIRE

(27-1/2’lg.) - 19298

ADAPTOR INSULATOR - 19316

ADAPTOR BLOCK - 19315

GAS HOSE (Supplied w/19315)

Supplied

SUPPORT LINER - 19309 (w/19260)

SUPPORT LINER - 19308 (w/19259)

COOLANT “IN” HOSE ASSY. - 19089

COOLANT “OUT” HOSE ASSY. - 19090

ADAPTOR PLUG - 19320 (MIG-35)

- 19313 (MIG-31)

(2) FEMALE CONN. w/LEAD - 19317

POWER CABLE - 19339

SWITCHCORD - 19340

Includes PLUG - 2062336

OPTIONAL ACCY.: PLUG COVER - 2062337

SET SCREW - 19319

SET SCREW - 19318

POWER PLUG - 19314

SCREW - 18405

DRIVE ROLL (0.030”) - 19268

(0.035”) - 19269

(0.045”) - 19270

(1/16”) - 19736

GAS FITTING - 19275

CONDUIT FITTING - 19274

CABLE SUPPORT - 19775

(4) SCREW, M3X18 - 19292

(4) SCREW - 19293

HANDLE (2 PC) - 19278

SCREW, HANDLE - 19291

NUT - 19289

GEAR MOTOR - 19280

GAS HOSE (27’ lg.) - 19294

HOSE CLAMP - 19295

WIRE CONDUIT (25’ lg.) - 19296

POWER CABLE (25’ lg.) - 19300

SOCKET (COOLANT “OUT”) - 950614

included with

particular liner

• Early version gun assemblies used cable support 19273 & clamp 19272.

COOLANT HOSE “OUT” (15” lg.) - 19302 (RED)

OUTER CABLE COVER (25’lg.) - 19299

(2) KNOB - 19287

(2) SPRING - 19286

(2) BALL - 19288

SCREW - 18405

ESAB MIG-41 Push-Pull Gun Troubleshooting instruction

ESAB MIG-41 Push-Pull Gun Troubleshooting instruction

ESAB MIG-41 Push-Pull Gun Troubleshooting instruction

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