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

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1 INSTRUCTIONS for F 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 diameter wires long distances quick disconnect convenience repairable front end for easy low cost maintenance 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 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 in. software MIG-41 Gun (25-ft. long) for 3/64-in. soft wire MIG-41 Gun (25-ft. long) for 1/16-in. soft wire 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 ft. x soft (.035) (.035/.9mm) (#10)* (25-ft.) FT. X 3/64 soft (3/64) (3/64/1.2mm) ft. x 1/16 soft (1/16) (1/16/1.6mm) Be sure this information reaches the operator. You can get extra copies through your supplier.

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3 II. EQUIPMENT & ACCESSORIES A. REQUIRED EQUIPMENT 1. Power Control Assembly P/N Provides power for torch pull motor on MIG 35, Digimig, Digipulse Feeders. 2. Wire Feeder Connector Assembly - P/N (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 connections. Each connector assembly is also supplied with coolant in (P/N 19089) and coolant out (P/N 19090) hose assemblies. The hose assemblies 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 fittings on the other for connecting to coolant kit fittings 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 recommended for torch cooling. Use of the WC-8 coolant recirculator (see below) using a specially formulated torch coolant (P/N 156F05, 1 gal. container) is recommended for torch cooling. The coolant also provides anti-freeze protection down to -34 F. 3. Push-Pull Torch Control Kilt (Mig 4HD) Water Kit (Mig 4HD) Feed Roll for Wire Feeder Select the proper feed roll for your particular wire feeder from Table Coolant Recirculator, P/N (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 cylinder rack of any power supply truck. Use Torch Coolant, P/N 156F05 (1 gal. container) only. Unit has a tank capacity of 1/5 gal.) Two coolant hose assemblies, 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 accessories so that the torch can be used with other wire sizes, see Table Curved Front Body, P/N Available for replacing straight front body of standard MIG- 41 gun assembly. Wire Guide P/N (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 ????? ????? / ????? / ????? Hard / Requires use of Collet Nut 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, and 3/64-in. wires. Remove support liner when using 1/16-in. wire. Liners and include collet and O-ring Liner includes collet and O-ring 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 Nozzles P/N Size No No No No. 12 Spotweld

4 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 connection 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 tightened. For Hard Wire: 1. Remove the liner positioner nut from the inlet connector. 2. Lay the gun cable out relatively straight. 3. Insert the bare end of the steel liner into the connector and inch through the torch until it butts to a stop. 4. Measure the distance from the end of the inlet connector to the liner ferrule shoulder as shown below. 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. INLET CONNECTOR END OF GUN CABLE LINER POSITIONER NUT INLET CONNECTOR END OF GUN CABLE LINER POSITIONER NUT DISTANCE MEASURED LINER FERRULE COLLET O-RING LINER 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 assembly 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 illustrated below. PLASTIC LINER EXTENSION SUPPORT LINER (.030,.035 & 3/64 SOFT WIRE ONLY) 4 GUIDE TUBE (See Table 3) (No Support Liner Used) 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 control 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 chassis 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 supply 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. Connect them to wire feeder as shown in Fig. 2.

5 DRIVE ROLL CAP (pull up to remove) Do not adjust preset in cap knobs. Fig. 1 - MIG-41 Push-Pull Gun 2. Connect the coolant hoses (19089 and supplied 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 (Bsize to coolant adaptor; C-size to power block adaptor). 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 extends 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 connected from the wire feeder control and attached to the accessory support assembly of the wire feeder. For more details refer to Insert for F 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 illustrations): WIRE FEEDER CONNECTOR ASSY (MIG-31, 31A) (MIG-35, DIGIMIG) 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 pickup 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 female connector end of the lead back into the gun cable. 4. Reassembly the 3-piece adaptor support. 3-PC ADAPTOR SUPPORT VOLTAGE PICK-UP LEAD TIE WRAP DISCONNECT POWER CONTROL ASSY INLET CONNECTOR END OF GUN COOLANT IN HOSE ASSY COOLANT OUT HOSE ASSY Fig. 2 - Typical MIG-41 Push-Pull Gun Set-Up 5

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7 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 assembly. 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 accomplished 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 directed into guide tube opening in the wire guide of gun. 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 precautions. 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 leakage. V. MAINTENANCE 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 requires 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 system has been completely filled. NOZZLE BODY & CLAMP * (included w / 19258) 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 persons to inspect, clean, or repair this equipment. Use only recommended genuine ESAB replacements 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. container - 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. Replacement parts may be ordered from your welding products distributor or ESAB Welding & Cutting Systems, Customer Service Dept., Florence, SC. FRONT BODY ASSY includes: NOZZLE BODY & CLAMP INSULATOR ASSY CONTACT TIP - See Table 3 NOZZLE - See Table 3 (No. 10 supplied with torch) *TIP ADAPTOR OPT. ACCY: 45 CURVED FRONT BODY Requires: WIRE GUIDE includes: LINER INSULATOR ASSY (included w/19258) WIRE GUIDE LOCK NUT (located in torch body under drive roll cap) * Nozzle Body & Clamp replacement requires using Nozzle Body Replacement Tool Kit Fig. 3 - Replaceable Front End Parts 7

8 DRIVE ROLL CAP w/hardware TORCH BODY (Includes items marked ) (2) O-RING See Fig. 3 (2) KNOB (2) SPRING (2) BALL SCREW DRIVE ROLL (0.030 ) (0.035 ) (0.045 ) (1/16 ) GAS FITTING CONDUIT FITTING CABLE SUPPORT ADAPTOR NUT ADAPTOR BLOCK FEMALE WIRE CONN O-RING NUT, IDLER ARM IDLER ARM IDLER ROLL TRIGGER SWITCH SCREW SCREW, M3X WASHER DRIVE ROLL SEAT ADAPTOR SUPPORT (3 PCS) NUT SCREW TRIGGER WIRE (27 LG.) MALE WIRE CONN (4) SCREW, M3X (4) SCREW HANDLE (2 PC) SCREW, HANDLE NUT GEAR MOTOR GAS HOSE (27 lg.) HOSE CLAMP WIRE CONDUIT (25 lg.) POWER CABLE (25 lg.) OUTER CABLE COVER (25 lg.) PLUG COOLANT HOSE OUT (15 lg.) (RED) COOLANT HOSE IN (26 LG.) (BLUE) PLUG (COOLANT IN ) 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. MOTOR CONTROL WIRE (27-1/2 lg.) Early version gun assemblies used cable support & clamp Fig. 4 - Basic MIG-41 Gun Assembly - P/N SOCKET (COOLANT OUT ) } Not Shown LINER (0.030 /0.035,3/64 X 27 lg.) (3/64 x 27 lg.) (1/16 X 27 lg.) included with COLLET (LINER - 1/16 WIRE) particular liner COLLET (LINER /64 WIRE) O-RING (LINER) ADAPTOR INSULATOR SET SCREW POWER PLUG ADAPTOR BLOCK SET SCREW GAS HOSE (Supplied w/19315) ADAPTOR PLUG (MIG-35) (MIG-31) (2) FEMALE CONN. w/lead POWER CABLE Supplied SUPPORT LINER (w/19260) SUPPORT LINER (w/19259) COOLANT IN HOSE ASSY COOLANT OUT HOSE ASSY SWITCHCORD Includes PLUG OPTIONAL ACCY.: PLUG COVER Fig. 5 - Wire Feeder Connector Assy. (MIG-35, DIGIMIG) (MIG-31) F A 10/97 2M Printed in U.S.A.