MT-300GL
MT-400GL
MT-500GL
“Cool Grip” Gasless Flux Cored Guns
Instruction Manual
F-15-497-A 04 / 2005
2
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
3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
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
4
TABLE OF CONTENTS
5
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.
6
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.
7
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"
8
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.
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
17
• 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
18
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
19
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
20
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
21
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
Page is loading ...
23
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
24
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
25
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.
26
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
6
3
4
2
1
14
13
5
7
9
(spring on 0558004426 only)
Euro assembly - new (0558004426 complete)
Euro assembly - old (0558004426 can replace all)
27
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
6
3
4
2
1
14
13
5
7
9
8
10
11
12
15
19
Euro assembly - new (0558004426 complete)
Euro assembly - old (0558004426 can replace all)
15
(spring on 0558004426 only)
28
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
6
3
4
2
1
14
13
5
7
9
8
10
11
12
15
19
15
(spring on 0558004426 only)
Page is loading ...
Page is loading ...
31
REVISION HISTORY
Revision A - 04/2005 - Updated format, added euro assembly views to replacement parts section.1.
Page is loading ...
/