ESAB “Cool Grip" Gasless Flux Cored Guns User manual

Brand: ESAB

Model: “Cool Grip" Gasless Flux Cored Guns

Category: Welding System

Type: User manual

MT-300GL

MT-400GL

MT-500GL

“Cool Grip” Gasless Flux Cored Guns

Instruction Manual

F-15-497-A 04 / 2005

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper

use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

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

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” 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 be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

TABLE OF CONTENTS

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Technical Speciﬁcations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.2 Gun Amperage Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.3 Gooseneck Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.4 Assemblies & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.1 Liner Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.2 Gun Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.3 Wire Feeder Euro Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.4 Front End Parts Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.0 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.1 Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.2 Gooseneck Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Section / Title Page

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation or operating

procedures, be sure to read and follow the safety

precautions listed below as well as all other manuals,

material safety data sheets, labels, etc. Failure to observe

Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation

and can injure skin and eyes. Hot metal can cause

burns. Training in the proper use of the processes

and equipment is essential to prevent accidents.

Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and

goggles are also required.

2. Use a face shield ﬁtted with the correct ﬁlter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when operat

ing or observing operations. Warn bystanders not

to watch the arc and not to expose themselves to

the rays of the electric-arc or hot metal.

3. Wear ﬂameproof gauntlet type gloves, heavy long-

sleeve shirt, cuﬄess trousers, high-topped shoes,

and a welding helmet or cap for hair protection, to

protect against arc rays and hot sparks or hot metal.

A ﬂameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuﬀs, or pockets. Sleeves and collars should

be kept buttoned, and open pockets eliminated from

the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ﬂammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can ﬂy far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS --

Heat from

ﬂames and arcs can start ﬁres. Hot

slag or sparks can also cause ﬁres and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec

tive non-ﬂammable covering. Combustible materials

include wood, cloth, sawdust, liquid and gas fuels,

solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in ﬂoors or wall openings and cause a hid-

den smoldering ﬁre or ﬁres on the ﬂoor below. Make

certain that such openings are protected from hot

sparks and metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might

produce ﬂammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have ﬁre extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable ﬁre extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

create a ﬁre hazard.

6. After completing operations, inspect the work area

to make certain there are no hot sparks or hot metal

which could cause a later ﬁre. Use ﬁre watchers when

necessary.

7. For additional information, refer to NFPA Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO NOT

use AC welding current in damp areas,

if movement is conﬁned, or if there is

danger of falling.

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

3. Connect the work cable to the workpiece. A poor

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and power

source.

6. Make sure that all parts of your body are insulated

from work

and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn oﬀ the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for speciﬁc grounding recommenda

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur

rent ﬂowing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eﬀects which

are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of

your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conﬁned spaces. Do

not breathe fumes and gases. Shield

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for speciﬁc ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ﬁttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or ﬁxtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ﬂames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeﬀerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualiﬁed personnel perform the instal

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualiﬁed to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Means hazards which could result

in minor personal injury.

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• Insulated and re-positionable 45, 60 and 80 degree aluminum gooseneck

• Can be easily coverted to a gas shielded gun

• Use the contact tip of your choice

• Replacable liner extends to back of contact tip

• Spring Strain reliefs improve cable life

• Central Euro Style Connector (cc) for quick positive connection to wire feeder

• Unique ergonomic small diameter molded handle for unmatched operator safety, comfort and

unlimited durability

MT-300/400/500GL GUN FEATURES

MT-300GL

MT-400GL

MT-500GL

SECTION 2 DESCRIPTION

Thank you for selecting the ESAB “Cool Grip” Fluxcored Gasless Gun. It is made from durable materials and

components engineered to perform in a rugged, welding environment. Your gun is designed and manufac

tured to the highest quality standards, and has undergone numerous quality checks and tests to ensure high

performance. The instructions and illustrations in this Technical Guide make it easy to maintain your “Cool

Grip” gun. Please read, understand, and follow all safety procedures. Keep this Technical Guide booklet as a

handy reference when ordering gun parts and special options.

THANK YOU

SECTION 2 DESCRIPTION

Model 100% Duty Cycle* 60% Duty Cycle

MT-300GL 250 amps 300 amps

MT-400GL 400 amps 450amps

MT-500GL 500 amps 550 amps

*Duty Cycle = 10 min. base

2.1 - TECHNICAL SPECIFICATION

2.2 GUN AMPERAGE RATING

NOTE: Ratings are based on tests that comply with NEMA

ARC Welding Section Standard 11-6-1975 for Duty Cycle.

“The time period of one complete cycle shall be 10 min-

utes” (60% = 6 minutes). National Electrical Manufacturers

Association, 2101 L Street N.W. Washington D.C. 20037.

2.3 GOOSENECK DIMENSIONS

GOOSENECK A B ° C D

952949 (300/400A) 2.65” (67.3mm) 45 5.20” (132.1mm) 3” (76.2mm)

952950 (300/400A) 3.57” (90.7mm) 60 5.97” (151.6mm) 3” (76.2mm)

952951 (300/400A) 4.87” (123.7mm) 80 5.43” (137.9mm) 3” (76.2mm)

952952 (500A) 2.64” (67.1mm) 45 7.75” (196.9mm) 4” (101.6mm)

952953 (500A) 3.95” (100.3mm) 60 7.57” (192.3mm) 4” (101.6mm)

952954 (500A) 5.58” (141.7mm) 80 7.14” (181.4mm) 4” (101.6mm)

Each of the following guns have a shock washer, tip adaptor,

nozzle insulator and heat shield. Liners and contact tips must be

ordered separately

45 Deg. 60 Deg. 80 Deg.

MT-300GL, 10 ft. (2.7m) 37713* 37722* 37731*

MT-300GL, 12 ft. (3.6m) 37714* 37723* 37732*

MT-300GL, 15 ft. (4.5m) 37715 37724 37733*

MT-400GL, 10 ft. (2.7m) 37716* 37725* 37734*

MT-400GL, 12 ft. (3.6m) 37717* 37726* 37735*

MT-400GL, 15 ft. (4.5m) 37718 37727 37736*

MT-500GL, 10 ft. (2.7 m) 37719* 37728* 37737*

MT-500GL, 12 ft. (3.6 m) 37720* 37729* 37738*

MT-500GL, 15 ft. (4.5 m) 37721 37730 37739*

* - Available upon request

2.4 - ASSEMBLIES and ACCESSORIES

2.4.1 Gun Assemblies 2.4.2 HEAT SHIELD

Heat Shield PN-952987

Heat shield attaches to gun goose

neck and is adjustable to the com-

port of the operator. Position and

ajdust locking collar as required.

Adjusting Collar

STEP #2

• Feed liner into the euro connector and completely

through the unicable using short strokes to avoid

kinking. Twist liner clockwise if necessary.

• Seat liner retainer with o-ring to shoulder inside liner

seat.

• Secure by tightening liner set screw. Do not over-

tighten.

STEP #3

• Trim conduit liner to 5/8” (16 mm) stick out.

• Remove any burr that may obstruct wire feed, espe-

cially on ﬂat wire type conduit liner.

3.1 LINER INSTALLATION

STEP #1

Ensure power source is oﬀ and torch is re-

moved from feeder before proceeding.

• Remove insulator nozzle, tip and tip adaptor

and loosen liner set screw using 5/64” (2 mm)

Allen wrench supplied with the gun.

• With torch straightened, grip conduit liner

with pliers and remove.

• Liners and contact tips are not supplied with guns and must be ordered and

installed separately. Follow the simple instructions below for proper installation

Liners for MT-300GL, 400GL & 500GL

(10, 12 & 15 ft.)

Hard Wires

.030 (0.8mm) ...................................................................... 37031

.035 (0.9mm) ...................................................................... 37032

.045-1/16 (1.2-1.6mm) .................................................... 37033

5/64-3/32 (2-2.4mm) ....................................................... 37034

7/64-1/8 (2.8-3.2mm) ....................................................952948

SECTION 3 INSTALLATION

3.2 -GUN INSTALLATION

3.2.1 INSTALLING GUN TO WIRE FEEDER

• Feed the welding wire through wire feeder connector by hand and tighten drive rolls.

• Be sure to use the correct outlet wire guide recommended for use with the wire feeder being used

• Insert the gun Euro Connector into the mating connector of the wire feeder and tighten securely with the hand

nut of the gun connector assembly.

3.3 WIRE FEEDER EURO ADAPTOR ASSEMBLY

( for ESAB MIG-35 or DIGIMIG Wire Feeders)

Gun

Euro Connector

Wire Feeder

Euro Connector

EURO ADAPTOR ASSEMBLY

Part Number - 20572

• Use this adaptor assembly when connecting to an ESAB Mig-35 or Digimig wire feeder either 2 roll or 4 roll mod-

els.

• Insert the gun Euro Connector into the mating connector of the wire feeder and tighten securely with the hand

nut of the gun connector assembly.

• Be sure to use the outlet wire guide recommended for the wire size and type being used. Several outlet guides are

included with the adaptor assembly.

SECTION 3 INSTALLATION

3.4 – FRONT END PARTS INSTALLATION

3.4.1 INSULATOR NOZZLE AND CONTACT TIP

IMPORTANT

• Shock washer must be in place before welding to maintain insulation of gooseneck armor.

• Be sure all parts are tightened well before welding.

• To prevent scoring of the tip adaptor, do not use pliers.

Removal and Replacement

• Pull insulator nozzles oﬀ with a clockwise twisting motion.

• When installing nozzle, exposed insulator should nest inside shock washer to assure concentricity.

• Remove tip adaptor using 5/8" (16 mm) wrench

• Shock washers are positioned on the end of the gooseneck with the insulated counterbore facing the nozzle.

• Replace tip adaptor with deep counterbore toward the gooseneck. Tighten until retainer and shock washer are

secure.

• Install contact tip and tighten using pliers. See chart below for corrent contact tip.

Note:

Contact Tips manufactured by ESAB, Tregaskiss and Lincoln can be used with this tip

adapter. Tip lengths will vary. Use of the tip insulator during welding is a customer

choice. Tip extension and/or recess from the tip insulator nozzle will vary depending on

the contact tip manufacturer and size chosen.

ESAB Contact Tips

ContactTip Inside Diameter

Wire Type & Size Part No. in. (mm)

Hard, Cored & Soft Wires

.030 in. (0.8 mm) Q403-1-30 .039 (.9)

.035 in. (0.9 mm) Q403-1-35 .044(1)

.045 in. (1.2 mm) 17765 .062 (1.6

.052 in. (1.4 mm) 17778 .062 (1.6)

1/16 in. (1.6 mm) 948835 .072 (1.8)

5/64 in. (2.0 mm) 948832 .094 (2.4)

3/32 in. (2.4 mm) 948833 .123 (3.1)

7/64 in. (2.8mm) Q603-764 .120 (3.2)

1/8 In. (3.1 m) Q603-18 .144(3.6)

SECTION 3 INSTALLATION

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4.1 SWITCH REPLACEMENT

• Remove both mounting screws with 5/16” nut driver.

• Ease switch out of switch housing by gently pulling up

on leads.

• Remove switch from switch lead connectors with needle

nose pliers.

• Push switch lead connectors ﬁrmly onto switch terminals with

needle nose pliers.

• Depress switch plunger and nest back into housing.

• Fit switch housing into nest on handle (switch leads must

lie parallel).

• Align housing holes with threaded holes in body and insert

mounting screws.

• Start both screws ﬁrst before tightening with 5/16” nut driver

to even alignment.

IMPORTANT

• Use manufacturers screws to ensure proper length, hardness

and tolerance.

• Twist handle lock nut in direction of arrow.

• Pull handle lock nut away from handle.

• Remove switch from pocket in handle.

• Remove switch from switch lead connectors with needle nose

pliers.

• Push new switch lead connectors ﬁrmly onto switch terminals

with needle nose pliers.

• Fit new switch into pocket on handle; switch leads must lie

parallel.

• Reinstall handle lock nut on hnadle.

MT-300GL Gun

MT-400GL and 500GL Gun

STEP #1

MT-400GL and 500GL Gun

STEP #2

SECTION 4 MAINTENANCE

4.2 GOOSENECK REPLACEMENT

• Place gooseneck in vise.

• Remove both switch housing mounting screws with 5/16”

nut driver.

• Slide handle back exposing connector cone and cone nut.

• Loosen connector cone from gooseneck using a 7/8”

wrench.

• Remove from vise and unthread gooseneck by hand.

• Remove body by releasing 2 set screws with 1/8” Allen

wrench.

• Cable connection between cone and nut should not be

disturbed.

STEP #1

• Internal threads - 3/8” x 24 (front-end only).

• External threads - 9/16” x 18 (both ends).

• Insert gooseneck up to shoulder in body.

• Align gooseneck radius between switch housing

mounting holes on body for desired switch loca-

tion.

• Tighten body set screws with a 1/8” Allen wrench. Use

only vibration proof set screws supplied with gun.

• Thread gooseneck into connector cone (hand tighten).

• Place gooseneck in vise and tighten with the 7/8”

wrench to within 1/8” (3.2 mm) spacing between the

connector cone and body.

STEP #2

STEP #3

• Reposition handle and switch.

• Reinstall handle lock nut.

STEP #4

SECTION 4 MAINTENANCE

SECTION 5 REPLACEMENT PARTS

5.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on

the unit nameplate.

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this

equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone

numbers.

5.2 Ordering

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

Note

5.0 Replacement Parts

The ESAB “Cool Grip” Gasless Fluxcored Gun and parts are warranted to be free of defects in material and/or

workmanship for 90 days. If, within that period, any ESAB Gun part is found to be defective under normal

and recommended use, ESAB will, at their option, repair, replace or issue credit for the value of the defective

unit. Claims against this warranty must be submitted through a Factory Authorized Distributor. All parts

and/or equipment returned to ESAB must have a Return Authorization Number obtained by calling (843)

664-4416.

WARRANTY POLICY

For technical support and special applications, please call ESAB Technical Services Department at (843) 664-

4416. Our trained technicians are available between 8:00 AM and 5:00 PM EST and will answer your application

or repair questions. ESAB employees build Welding Systems for the world’s welding professionals. We are

always striving to improve our products and services, and we would appreciate receiving your suggestions

and comments. Please contact us immediately if you experience any safety or operating problems.

SECTION 5 REPLACEMENT PARTS

Hand Nut - 0558004428

Euro Body - 0558004427

Euro Handle - 0558004429

Euro Body - 952970

Hand Nut - 952664

Handle - 952969

Terminal Housing - 0558001632

Spacer Euro A/C - 0558001633

(spring on 0558004426 only)

Euro assembly - new (0558004426 complete)

Euro assembly - old (0558004426 can replace all)

SECTION 5 REPLACEMENT PARTS

Hand Nut - 0558004428

Euro Body - 0558004427

Euro Handle - 0558004429

Euro Body - 952970

Hand Nut - 952664

Handle - 952969

Terminal Housing - 0558001632

Spacer Euro A/C - 0558001633

Euro assembly - new (0558004426 complete)

Euro assembly - old (0558004426 can replace all)

(spring on 0558004426 only)

SECTION 5 REPLACEMENT PARTS

Euro assembly - new (0558004426 complete)

Euro assembly - old (0558004426 can replace all)

Hand Nut - 0558004428

Euro Body - 0558004427

Euro Handle - 0558004429

Euro Body - 952970

Hand Nut - 952664

Handle - 952969

Terminal Housing - 0558001632

Spacer Euro A/C - 0558001633

(spring on 0558004426 only)

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REVISION HISTORY

Revision A - 04/2005 - Updated format, added euro assembly views to replacement parts section.1.

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ESAB “Cool Grip" Gasless Flux Cored Guns User manual

Brand: ESAB

Model: “Cool Grip" Gasless Flux Cored Guns

Category: Welding System

Type: User manual

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