ESAB Exeor MIG 4.0W², Exeor MIG 4.0G² Instruction manual

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Exeor MIG 4.0W² Exeor MIG 4.0G²

Instruction manual

0700 025 099 Rev. E / GB 20230214 V13_1-CX

TABLE OF CONTENTS

1. SAFETY...................................................................................................................... 8

1.1 Meaning of symbols ................................................................................................ 8

1.2 Safety precautions................................................................................................... 8

2. INTRODUCTION ...................................................................................................... 11

2.1 Shipment and packaging ....................................................................................... 11

3. TECHNICAL DATA ................................................................................................... 11

4. OPERATION ............................................................................................................ 14

4.1 Fitting the liner ....................................................................................................... 14

4.2 Equipping the torch ............................................................................................... 14

4.3 Fitting the central adaptor to the equipment .......................................................... 14

4.4 Connecting the cooling circuit ................................................................................ 15

4.5 Setting the level of shielding gas ........................................................................... 15

4.6 Checklist ............................................................................................................... 15

4.7 Changing wire ....................................................................................................... 15

4.8 Starting and stopping the welding process ............................................................ 15

5. REMOTE CONTROL ................................................................................................ 16

5.1 CX - Remote module ............................................................................................. 16

6. MAINTENANCE ........................................................................................................ 18

6.1 Overview ............................................................................................................... 18

6.2 Cable assembly ..................................................................................................... 18

6.3 Cleaning the wire feed ........................................................................................... 18

6.4 Steel liner / Plastic liner ......................................................................................... 18

6.5 Cleaning the swan neck ........................................................................................ 20

6.6 Checking the cooling system ................................................................................. 20

7. TROUBLESHOOTING .............................................................................................. 21

8. DISASSEMBLY AND DISPOSAL ............................................................................. 22

9. IN THE EVENT OF EMERGENCY ........................................................................... 22

10. ORDERING PARTS .............................................................................................. 22

11. ORDERING NUMBERS ........................................................................................ 23

12. REPLACING THE PCBA BOARD ......................................................................... 24

13. SPARE PARTS ..................................................................................................... 24

13.1 Exeor MIG 4.0W² BX, CX, DX ............................................................................... 24

13.2 Exeor MIG 4.0W² .................................................................................................. 26

13.3 Exeor MIG 4.0G² BX, CX, DX ................................................................................ 28

13.4 Exeor MIG 3.0G²/4.0G² ......................................................................................... 30

14. WEAR PARTS Exeor MIG 4.0W² .......................................................................... 31

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14.1 Contact Tips M8 .................................................................................................... 31

14.2 Contact Tips M6 .................................................................................................... 32

14.3 Steel liner .............................................................................................................. 32

14.4 PTFE liner ............................................................................................................. 33

14.5 PTFE liner with bronze front end ........................................................................... 33

14.6 PA liner with bronze front end ............................................................................... 33

15. WEAR PARTS Exeor MIG 4.0G² ........................................................................... 34

15.1 Contact Tips; Standard 16S-Series ....................................................................... 34

15.2 Steel liner .............................................................................................................. 35

15.3 PTFE liner ............................................................................................................. 35

15.4 PTFE liner with bronze front end ........................................................................... 35

15.5 PA liner with bronze front end ............................................................................... 36

Rights reserved to alter specifications without notice.

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1. SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER! Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING! Means potential hazards which could result in personal injury or loss of life.

CAUTION! Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual and follow all labels, employer´s safety practices and Safety Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with: ○ its operation

○ location of emergency stops ○ its function ○ relevant safety precautions ○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that: ○ no unauthorized person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck, or work is started with the equipment

3. The workplace must: ○ be suitable for the purpose

○ be free from drafts

4. Personal safety equipment: ○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could

become trapped or cause burns

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5. General precautions: ○ Make sure the return cable is connected securely ○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING! Arc welding and cutting can be injurious to yourself and others. Take precautions

when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves, or wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to EMF: ○ Route the electrode and work cables together on the same side of your

body. Secure them with tape when possible. Do not place your body between the torch and work cables. Never coil the torch or work cable around your body. Keep welding power source and cables as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

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NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only qualified people remove covers for maintenance and troubleshooting as necessary. Reinstall panels or covers and close doors when service is finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction. PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING! Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

NOTE!

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website.

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2. INTRODUCTION

The MIG / MAG welding torches of this series are exclusively intended for shielded- arc welding using inert gas (MIG) or active gas (MAG) for industrial and commercial use by suitably trained employees. The torches are only available in manual versions.

2.1 Shipment and packaging

The components are carefully checked and packaged; however, damage may occur during shipping.

2.1.1 Checking procedure on receipt of goods

Check that the shipment is correct by referring to the shipping note.

2.1.2 In case of damage

Check the package and components for damage (visual inspection).

2.1.3 In case of complaints

If the package and/or components have been damaged during shipment:

• Contact with the last carrier immediately.

• Keep the packaging (for possible inspection by the carrier or supplier, or for returning the goods).

2.1.4 Storage in an enclosed space

Ambient temperature for shipment and storage: -20 °C to +55 °C

Relative air humidity: up to 90% at a temperature of 20 °C

3. TECHNICAL DATA

Welding torch

Type of cooling* Liquid-cooled Liquid-cooled

Torch rating and duty cyle, using**

Carbon dioxide CO2

Mixed gas, Ar/CO

M21

Recommended gas flow

Wire diameter 0.8-1.6 mm 0.8-1.6 mm

Operating temperature***

Exeor MIG 4.0W² Exeor MIG 4.0W² CX

450 A / 100% DC 450 A / 100% DC

10-20 l/min 10-20 l/min

-10 °C to 40 °C -10 °C to 40 °C

* An appropriate cooling liquid must be used.

** The capacity may be reduced up to 30% when pulse welding.

*** When using liquid cooled torches in freezing conditions, use an adequate cooling liquid.

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Welding torch

Exeor MIG 4.0G² Exeor MIG 4.0G² CX

Type of cooling Gas-cooled Gas-cooled

Torch rating and duty cyle, using*

Carbon dioxide CO2

Mixed gas, Ar/CO

420 A / 60% DC 420 A / 60% DC

M21

Recommended gas flow

10-20 l/min 10-20 l/min

Wire diameter 0.8-1.6 mm 0.8-1.6 mm

Operating temperature

-10 °C to 40 °C -10 °C to 40 °C

* The capacity may be reduced up to 30% when pulse welding.

Duty cycle The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at

a certain load without overloading. The duty cycle is valid for 40 °C / 104 °F, or below.

General torch data with reference IEC 60974-7:2019

Type of guidance: Manual

Wire type: Standard round wire

Voltage rating: The control circuit and trigger switch are

rated for a voltage of 24 V, max. 1 A

Specifications of the torch cooling circuit (For liquid cooled torches only):

• minimum flow 1.2 l/min

• min. liquid pressure: 2.5 bar

• max. liquid pressure: 3.5 bar

• input temperature: max. 40 °C

• return temperature: max. 60 °C

• cooling capacity: minimum 1000 W, up to 2000 W depending on the application

Liquid cooled torches Return temperatures of more than 60 °C can shorten the lifetime of the torch or cause

damage or destruction of the torch. The cooler must always be filled with sufficient cooling liquid, refer to the instruction manual for the cooling unit. In case of a high thermal load on the torch, use a cooler with sufficient capacity. Use only special cooling fluid containing corrosion inhibitors for welding torches. For suitable products, contact your nearest ESAB dealer.

The ratings are valid for cable lengths from 3.0 to 5.0 m.

The rated loads refer to a standardized case of use. Under special conditions, e.g. in case of high heat reflection on the torch, the torch could overheat even when operated below the rated load. In this case choose a more powerful model or lower the duty cycle.

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Conditions of intended use

1. The welding torch should only be used within the above-mentioned technical specifications and for its intended purpose.

2. The type of torch must be chosen according to the welding application. The required duty-cycle and load, the type of cooling, guiding method and the wire diameter must be considered. If increased requirements exist, for example caused by pre-heated work pieces, high heat reflection in corners, etc. these must be considered by choosing a welding torch with adequate reserve in rated load.

3. The product must be protected from humidity and moisture during transport, storage and operation.

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4. OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY" chapter of this manual. Read it through before you start using the equipment!

CAUTION!

This product is intended for industrial use. In a domestic environment this product may

cause radio interference. It is the user's responsibility to take adequate precautions.

DANGER!

In the event of an emergency, the power supply must be switched off immediately. For further action in such circumstances, refer to the instruction manual for the power source for more information.

The welding torch can be used in any welding position. Contact with hot items might cause damage to the torch and the cable assembly. Do not drag the power source using the torch. Do not pull the cable assembly over sharp edges. Do not bend the cable assembly sharply.

4.1 Fitting the liner

Fit the correct wire guide liner for the application, as needed to suit the wire type and diameter. See chapter "MAINTENANCE" section "Steel liner / Plastic liner".

NOTE!

For information on how to install new liners and about correct assembly procedure, see the chapter entitled “Maintenance”

Steel liner = for steel wires

Plastic liner = for aluminium, copper, nickel and stainless-steel wires

4.2 Equipping the torch

The torch must be equipped according to the wire diameter and wire material. Choose the right liner, contact tip, tip adaptor, gas nozzle and gas diffuser (as applicable). A detailed overview of the suitable parts is found in the spare parts list for the torch.

Tighten the tip adaptor and the contact tip with an adequate tool.

Make sure that all required parts shown in the spare parts list, e.g. insulators, are installed. Welding without these items might cause immediate destruction of the torch.

4.3 Fitting the central adaptor to the equipment

1. Check that the wire guide liner is fitted correctly.

2. Insert the central plug into the socket on the wire feed unit and secure it by tightening the adaptor nut firmly by hand.

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4.4 Connecting the cooling circuit

Connect the liquid hoses to the cooling unit: blue for liquid flow forward from the cooler to the torch; red for heated liquid flow backwards from the torch to the cooler. Before using a liquid

-cooled torch, the air must be removed from the cooling circulation by running the cooler for a few minutes.

CAUTION!

Wrongly connected liquid hoses can cause overheating and damage of the torch neck and liquid-power cable. Regularly check the coolant level and throughput on the cooling unit. Insufficient cooling might cause overheating and damage of the torch neck and liquid-power cable.

NOTE!

To achieve an optimal gas and liquid flow, place the cable assemblies and the gas and liquid hoses as straight as possible. Kinked hoses will cause overheating and can damage the torch. Protect cables and supply hoses from damage.

4.5 Setting the level of shielding gas

Set the quantity of gas required on the gas regulator. The type and quantity of gas to be used depend on the welding task to be performed.

4.6 Checklist

Check the cable assembly before connecting it to the wire feed unit to confirm the wire liner is suitable for the wire diameter and type.

Check the front-end consumable parts on the swan neck, whether the correct contact tip etc. is being used for the wire diameter and type.

4.7 Changing wire

When changing the wire, ensure that the end of the wire is deburred.

Insert the wire into the wire feeding unit in accordance with the operating instructions.

When inserting the wire, press the wire jog button on the wire feed unit.

4.8 Starting and stopping the welding process

The wire feeder and the welding process will be started by pulling the torch trigger. Depending on the configuration of the welding machine, the welding process will be stopped by either letting go of the trigger or by pulling the trigger a second time. Refer to the instruction manual for the power source for more information.

DANGER!

The torch head might reach very high temperatures during operation, there is a risk of severe burns. Let it cool down under observation, there is risk of fire. Do not place the hot torch on or near heat-sensitive objects. For liquid-cooled torches, the cooling system should remain switched on for some minutes after the welding process has been stopped.

When leaving the workplace, the system must be secured against unintended operation, preferably by switching off the power source.

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5. REMOTE CONTROL

5.1 CX - Remote module

1 The Button to decrease the value 3 LEDs 2 The Button to increase the value

5.1.1 Starting procedure

When the torch is connected to the system, all LEDs will be lit in green.

5.1.2 Torch configuration

The function needs to be activated on the torch can be selected from the Inner control panel of RobustFeed Edge under “Menu → System settings → Torch remote configuration → CX Torch module”. Turn ON “Activate Remote functionality”, to enable the required function to be activated on torch. Only one function can be active at a time.

The torch remotes can be configured even if there are no torch remotes connected to the system. Changes in the configuration can have direct impact to the torch remote if it is connected and active.

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5.1.3 Functions

By pressing the buttons (1 & 2), the values of the selected function can be decreased and increased respectively

The decremental and incremental of the selected functional values are varied for a single button press as shown.

Function Value

JOBs 1 Job

Voltage 0.1 V

Arc length 0.1

Wire feed speed

2/4 stroke

0.1 m/min 4 inch/min Button 1 – 2 stroke Button 2 – 4 stroke

For Jobs function, the first 3 jobs represent the 3 LEDs. If a first job is activated, then first LED will be lit in green.

NOTE!

For Voltage, Arc length and Wire feed speed, the long press of buttons (1 & 2) will set to lower / upper limit values respectively.

5.1.4 Warning / Error

Warning

The warning codes are used to indicate the warning message to show the critical limits. Warning does not stop ongoing welding but prevent new welding until the warning has been cleared.

All the LEDs will be lit in yellow.

Error

The error codes are used to indicate that an error has occurred in the welding process. Errors will stop the welding and need to take the corrective action in the system.

All the LEDs will be lit in red.

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6. MAINTENANCE

6.1 Overview

NOTE!

Regular maintenance is important for safe and reliable operation.

Cleaning and replacement of the welding torch’s wear parts should take place at regular intervals to achieve trouble−free wire feed. Blow the wire guide clean regularly and clean the contact tip.

WARNING!

Before carrying out cleaning, servicing and repair work, the following shutdown procedure must be followed.

1. Switch off the power supply.

2. Close off the gas supply.

Make sure that the power supply and gas remain turned off all the time while servicing the equipment.

6.2 Cable assembly

Check the torch and cable assembly for damages prior to use. Damages must be repaired by qualified personnel before further use of the product.

6.3 Cleaning the wire feed

Disconnect the torch cable assembly from the equipment and lay it out straight.

Unscrew the nut and pull out the wire guide liner. Remove other parts from the swan neck.

Blow compressed air through the wire conduit from both ends in order to remove wire shavings.

Insert the liner into the wire conduit and screw the nut back on.

NOTE!

New liners must be cut to the correct length.

6.4 Steel liner / Plastic liner

If a wire feeding problem cannot be solved by exchanging the contact tip and cleaning the wire guide channel, the liner should be replaced.

Liner and welding wire should be inserted while the cable assembly is laid out straight.

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Installing a steel liner

1. Remove the sleeve nut from the central connector, remove the gas nozzle, contact tip and tip holder from the torch.

2. Insert the liner through the central connector and lock it with the sleeve nut.

3. Gently push back the front part of the liner into the torch as far as it will go, do not apply force. Mark the end of the torch neck on the liner.

4. Cut the liner to the correct length using a projectile "X" measured from the marking as shown in the figure.

Remove the liner from the torch and carefully smoothen its front end. If needed, grind down burred edges. Make sure the inner hole is completely open.

For insulated liners, remove the insulation at the front end so that the remaining insulation ends approximately at the front end of the torch handle.

Reinstall the liner and lock it with the sleeve nut. Install all equipment parts on the torch neck.

Cutting length

Welding torch Projectile "X"

Exeor MIG 4.0W² 12 mm

Exeor MIG 4.0G² 13 mm

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Installing a plastic liner

1. Remove the sleeve nut from the central connector, remove the gas nozzle, contact tip and tip holder from the torch.

2. Insert the liner through the central connector and lock it with the sleeve nut.

3. Gently push back the front part of the liner into the torch as far as it will go, do not apply force. Mark the end of the torch neck on the liner.

4. Cut the liner to the correct length using a projectile "X" measured from the marking as shown in the figure. Slightly chamfer the liner front end after the liner has been cut to the correct length.

NOTE!

If the liner has a bronze front end, first cut the plastic liner to a suitable length and let the bronze liner stick out approximately 40-50 mm from the torch neck. Attach the bronze liner to the front of the plastic liner and only then cut this liner assembly to the precise length.

If it is difficult to insert the liner into the torch, make a clean cut at the front end of the liner and chamfer the edges (e.g. with a pencil sharpener).

Install all equipment parts on the torch neck.

Cutting length

Welding torch Projectile "X"

Exeor MIG 4.0W² 9 mm

Exeor MIG 4.0G² 13 mm

6.5 Cleaning the swan neck

• Clean the inside of the gas nozzle regularly to remove welding spatter and spray with ESAB® anti-spatter agent.

• Check the consumables for visible damage and replace if necessary.

6.6 Checking the cooling system

Make sure that the cooling liquid is clean, change it if required. Impurities in the cooling liquid can obstruct the torch liquid channels. Always use suitable cooling fluid for torches with corrosion inhibitors.

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connections

7. TROUBLESHOOTING

If the measures described below are not successful, consult your dealer or the

manufacturer.

Read the operating instructions for the welding components, e.g. power source and wire

feed unit.

Problem Possible cause Action

Torch becomes too hot

Wire feeding problems

Porous welds

 Contact tip / tip holder not

tight enough

 Cooling system is not

working well

 Torch overstrained

 Cable assembly defective

 Contact tip is worn  Liner is worn / dirty

 Consumables used are not

suitable for the wire diameter or material

 Wire feeder not set-up

properly

 Cable assembly is bent or

laid out in small radii

 Wire is contaminated

 Gas swirl caused by spatter

adherence

 Too small or extremely high

gas flow in the torch

 Gas supply defective

 Air draft at the workplace  Moisture or contamination on

the wire or on the work piece

 Check and tighten hand-tight

 Check liquid flow, filling level

and cleanliness

 Observe technical data, if

needed, choose a different type

 Check cables, tubes, and

 Exchange contact tip  Check the liner, blow through in

both directions. Exchange if needed.

 Check with spare part list

 Check the wire feeding rolls, the

contact pressure and the spool brake

 Check the cable assembly and

lay it out straight

 Use a cleaning felt

 Clean the torch head, use gas

diffuser / spatter protection

 Check flow rate with

measurement tool

 Check flow rate and possible

leakage

 Install shielding  Check the wire and the work

piece, use less or different antispatter liquid

Variable arc

Welding process does not start

 Contact tip is worn  Wrong welding parameters

 Control cable is broken, or

the trigger is defective

 Exchange contact tip  Correct the welding parameters

 Check and repair the trigger

connections, clean the trigger switch or exchange it

8. DISASSEMBLY AND DISPOSAL

9. IN THE EVENT OF EMERGENCY

10. ORDERING PARTS

CAUTION!

Repair and electrical work should be performed by an authorized ESAB service

technician. Use only ESAB original spare and wear parts.

The Exeor torches are designed and tested in accordance with international and European standards IEC/EN 60974-7,2019. On completion of service or repair work, it is the responsibility of the person(s) performing the work to ensure that the product still complies with the requirements of the above standard.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation, and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures correct delivery.

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11. ORDERING NUMBERS

Ordering no. Denomination Type Notes

Water-cooled Exeor Torch

0700 025 727 Exeor MIG 4.0W² BX Welding torch 3 m with blind cover

0700 025 728 Exeor MIG 4.0W² BX Welding torch 4 m with blind cover

0700 025 729 Exeor MIG 4.0W² BX Welding torch 5 m with blind cover

0700 025 730 Exeor MIG 4.0W² CX Welding torch 3 m with CX Remote Control

0700 025 731 Exeor MIG 4.0W² CX Welding torch 4 m with CX Remote Control

0700 025 732 Exeor MIG 4.0W² CX Welding torch 5 m with CX Remote Control

0700 026 050 Exeor MIG 4.0W² Welding torch 3 m with blind cover

0700 026 051 Exeor MIG 4.0W² Welding torch 4 m with blind cover

0700 026 052 Exeor MIG 4.0W² Welding torch 5 m with blind cover

Gas-cooled Exeor Torch

0700 025 752 Exeor MIG 4.0G² BX Welding torch 3 m with blind cover

0700 025 753 Exeor MIG 4.0G² BX Welding torch 4 m with blind cover

0700 025 754 Exeor MIG 4.0G² BX Welding torch 5 m with blind cover

0700 025 755 Exeor MIG 4.0G² CX Welding torch 3 m with CX Remote Control

0700 025 756 Exeor MIG 4.0G² CX Welding torch 4 m with CX Remote Control

0700 025 757 Exeor MIG 4.0G² CX Welding torch 5 m with CX Remote Control

0700 026 053 Exeor MIG 3.0G² Welding torch 3 m with blind cover

0700 026 054 Exeor MIG 3.0G² Welding torch 4 m with blind cover

0700 026 055 Exeor MIG 3.0G² Welding torch 5 m with blind cover

0700 026 056 Exeor MIG 4.0G² Welding torch 3 m with blind cover

0700 026 057 Exeor MIG 4.0G² Welding torch 4 m with blind cover

0700 026 058 Exeor MIG 4.0G² Welding torch 5 m with blind cover

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12. REPLACING THE PCBA BOARD

CAUTION!

The replacing procedure should be carried out by authorized service technician.

For replacing the PCBA board, refer “Replacement instructions” section in the Service

manual (0700 026 112).

13. SPARE PARTS

13.1 Exeor MIG 4.0W² BX, CX, DX

Item Qty. Ordering no. Denomination Notes

300 1 0700 025 011 Torch neck 4.0W2

301 1 0700 026 101 Handle w/o torch neck; remote

301a 1 B01P600222 Blind Cover

301b 1 B01P600230 Handle Holder Screw

301c 1 B01P600231 Handle Holder Nut

301d 2 Screw

301e 1 B01P600229 Snap-in Plate

301f 2 Nut M3.5 DIN EN 24032

301g 2 B01P102090 Screw M3.5×20 T10

303 1 0700 025 748 Spare parts kit CX, water

303a

303b

303c

304a

0700 025 793 Trigger Unit with harness; for remote System with LED

CX PCBA with Harness

B01P600114 Housing Kit Exeor MIG CX

B01P600116 Push button cover Exeor MIG CX

EJOT Delta PT

WN 5451, 3.0×16

303a, 303b, 303c,

includes

305

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Item Qty. Ordering no. Denomination Notes

304b 1 0700 025 794 Trigger Unit with harness; non-remote System without LED

305

306

307

308 4 Hose clamp with ring

309

311

312 1 Screw

313 1 O-ring

314 2 Hose clamp with ring

317 1 0700 025 993 PVC-Gas hose

318 1 0700 025 994 PVC hose, braided

319 1 0700 026 092 Assembly outer hose 3 m

319 1 0700 026 093 Assembly outer hose 4 m

0700 025 082 PCBA LED f. Exeor Handle cpl.

0700 025 971 Cable support cpl.

0700 025 973 Quick connector

0700 025 951 Adaptor nut

0700 200 098 Liner locking nut

Ø9.0 OETIKER 15400021

M4×6; ISO 7048

TYPE H, 8.8 A2K

4.0×1.0 mm (ID×S) NBR 70 Shore A

Ø8.7 OETIKER 15400020

6 m, black,

4.5×1.5 mm 6 m, black,

5.0×1.5 mm

319 1 0700 026 094 Assembly outer hose 5 m

320 1 0700 025 983 Water-power cable 3 m

320 1 0700 025 984 Water-power cable 4 m

320 1 0700 025 985 Water-power cable 5 m

321 1 0700 026 000 Wire conduit 3 m

321 1 0700 026 001 Wire conduit 4 m

321 1 0700 026 002 Wire conduit 5 m

322 1 0700 026 082

322 1 0700 026 083

322 1 0700 026 084

Control cable kit 3 m, with Euro connector for Exeor torches

Control cable kit 4 m, with Euro connector for Exeor torches

Control cable kit 5 m, with Euro connector for Exeor torches

323 1 0700 026 003 Cable assembly 3 m Including 322

323 1 0700 026 004 Cable assembly 4 m Including 322

323 1 0700 026 005 Cable assembly 5 m Including 322

0700 025 099

- 25 -

13.2 Exeor MIG 4.0W²

Item Qty. Ordering no. Denomination Notes

300 1 0700 025 011 Torch neck 4.0W2

301 1 0700 026 102 Handle w/o torch neck

301a 1 B01P600222 Blind Cover

301b 1 B01P600230 Handle Holder Screw

301c 1 B01P600231 Handle Holder Nut

301d 2 Screw

301e 1 Nut

301f 1 B01P102090 Screw M3.5×20 T10

304a 1 B01P600237 Trigger Unit 2-poles without LED

306 1 0700 025 971 Cable support cpl.

307 2 0700 025 973 Quick connector

308 4 Hose clamp with ring

309 1 0700 025 951 Adaptor nut

310 1 0700 025 970 Central connector W

311 1 0700 200 098 Liner locking nut

312 1 Screw

313 1 O-ring

314 2 Hose clamp with ring

EJOT Delta PT

WN 5451, 3.0×16

DIN EN 24032

M4×6; ISO 7048

TYPE H, 8.8 A2K

4.0×1.0 mm (ID×S) NBR 70 Shore A

M3.5

Ø9.0 OETIKER 15400021

Ø8.7 OETIKER 15400020

0700 025 099

- 26 -

Item Qty. Ordering no. Denomination Notes

317 1 0700 025 993 PVC-Gas hose

318 1 0700 025 994 PVC hose, braided

319 1 0700 026 092 Assembly outer hose 3 m

319 1 0700 026 093 Assembly outer hose 4 m

319 1 0700 026 094 Assembly outer hose 5 m

320 1 0700 025 983 Water-power cable 3 m

320 1 0700 025 984 Water-power cable 4 m

320 1 0700 025 985 Water-power cable 5 m

321 1 0700 026 000 Wire conduit 3 m

321 1 0700 026 001 Wire conduit 4 m

321 1 0700 026 002 Wire conduit 5 m

322 1 0700 025 989 Control cable cpl. 3 m

322 1 0700 025 990 Control cable cpl. 4 m

322 1 0700 025 991 Control cable cpl. 5 m

323 1 0700 026 098 Cable assembly 3 m

6 m, black,

4.5×1.5 mm 6 m, black,

5.0×1.5 mm

323 1 0700 026 099 Cable assembly 4 m

323 1 0700 026 100 Cable assembly 5 m

0700 025 099

- 27 -

13.3 Exeor MIG 4.0G² BX, CX, DX

Item Qty. Ordering no. Denomination Notes

300 1 0700 026 091 Torch neck S Exeor MIG 4.0G²

301 1 0700 026 101 Handle w/o torch neck; remote

301a 1 B01P600222 Blind Cover

301b 1 B01P600230 Handle Holder Screw

301c 1 B01P600231 Handle Holder Nut

301d 2 Screw

301e 1 B01P600229 Snap-in Plate

301f 1 Nut

301g 1 B01P102090 Screw M3.5×20 T10

303 1 0700 026 143 Spare parts kit CX, gas

303a 1 CX PCBA with Harness

303b 1 B01P600114 Housing Kit Exeor MIG CX

303c 1 B01P600116 Push button cover Exeor MIG CX

EJOT Delta PT

WN 5451, 3.0×16

DIN EN 24032

303a, 303b, 303c,

M3.5

includes

305

304a 1 0700 025 793 Trigger Unit with harness; for remote System with LED

304b 1 0700 025 794 Trigger Unit with harness; non-remote System

305 1 0700 025 082 PCBA LED f. Handle cpl.

306 1 0700 025 971 Cable support cpl.

307 1 0700 025 951 Adaptor nut

without LED

0700 025 099

- 28 -

Item Qty. Ordering no. Denomination Notes

308 1 0700 026 109

308 1 0700 026 110

308 1 0700 026 111

309 1 0700 200 098 Liner locking nut

310 1 Screw

311 1 O-ring

312 1 0700 026 034 Power cable 3 m

312

313 1 0700 026 092 Assembly outer hose 3 m

313

1 0700 026 035

1 0700 026 036

1 0700 026 093 Assembly outer hose 4 m

1 0700 026 094 Assembly outer hose 5 m

Control cable kit 3 m, gas with Euro connector for Exeor torches

Control cable kit 4 m, gas with Euro connector for Exeor torches

Control cable kit 5 m, gas with Euro connector for Exeor torches

Power cable 4 m

Power cable 5 m

M4×6 ISO 7048

TYPE H, 8.8 A2K

4.0×1.0 mm (ID×S) NBR 70 Shore A

314 1 101P002005 Hex nut M10×1

315 1 0700 026 095 Cable assembly 3 m Includes 308

315 1 0700 026 096 Cable assembly 4 m Includes 308

315 1 0700 026 097 Cable assembly 5 m Includes 308

0700 025 099

- 29 -

13.4 Exeor MIG 3.0G²/4.0G²

Item Qty. Ordering no. Denomination Notes

300 1 0700 026 091 Torch neck S Exeor MIG 4.0G²

301 1 0700 026 102 Handle w/o torch neck

301a 1 B01P600222 Blind Cover

301b 1 B01P600230 Handle Holder Screw

301c 1 B01P600231 Handle Holder Nut

301d 2 Screw

301e 1 Nut

301f 1 B01P102090 Screw M3.5×20 T10

304a 1 B01P600237 Trigger Unit 2-poles without LED

306 1 0700 025 950 Cable support cpl.

307 1 0700 025 951 Adaptor nut

308 1 0700 200 101 Central connector G

309 1 0700 200 098 Liner locking nut

310 1 Screw

311 1 O-ring

312a 1 361P3LBB30 Power Cable 3 m, 70 qmm

312a 1 361P3LBB40 Power Cable 4 m, 70 qmm

EJOT Delta PT

WN 5451, 3.0×16

DIN EN 24032

M4×6 ISO 7048

TYPE H, 8.8 A2K

4.0×1.0 mm (ID×S) NBR 70 Shore A

M3.5

312a 1 361P3LBB50 Power Cable 5 m, 70 qmm

312b 1 361PXL8130 Power Cable 3 m, 50 qmm

312b 1 361PXL8140 Power Cable 4 m, 50 qmm

312b 1 361PXL8150 Power Cable 5 m, 50 qmm

314 1 101P002005 Hex nut M10×1

0700 025 099

- 30 -

14. WEAR PARTS Exeor MIG 4.0W²

1. Gas nozzle 4. Insulation bushing

2. Contact tip M8 × 37 5. Contact tip M6 × 27

3. Tip adaptor M8 6. Tip adaptor M6

Ordering no. Denomination Notes Ø Length

0458 464 882 Gas nozzle Standard 16 mm 80 mm

0458 465 882 Gas nozzle Conical 14 mm 80 mm

0458 470 882 Gas nozzle Straight 19 mm 80 mm

0366 394 001 Tip adaptor M6 - - 40.6 mm

0460 819 001 Tip adaptor M8 Cu - - 31.6 mm

0700 025 851 Tip adaptor M8 brass - - 31.6 mm

0458 874 001 Insulation washer - - -

14.1 Contact Tips M8

Exeor MIG 4.0W² Gas / wire Ø

0468 502 003 0.8 - W0.8 / 1.0

CO2

Mix/Ar M8

0468 502 004 0.9 0.8 W1.0 / 1.1

0468 502 005 1.0 0.9 W1.0 / 1.2

0468 502 006 1.2 - W1.2 / 1.4

0468 502 007 1.2 1.0 W1.2 / 1.5

0468 502 008 1.4 1.2 W1.4 / 1.7

0468 502 009 1.6 - W1.6 / 1.9

0468 502 010 - 1.6 W1.6 / 2.1

0700 025 099

- 31 -

14.2 Contact Tips M6

Exeor MIG 4.0W² Gas / wire Ø

0468 500 001 0.6 - W0.6 / 0.8

0468 500 002 - 0.6 W0.8 / 0.9

0468 500 003 0.8 - W0.8 / 1.0

0468 500 004 0.9 0.8 W0.9 / 1.1

0468 500 005 1.0 0.9 W1.0 / 1.2

0468 500 006 1.2 - W1.2 / 1.4

0468 500 007 1.2 1.0 W1.2 / 1.5

0468 500 008 1.4 1.2 W1.4 / 1.7

0468 500 009 1.6 - W1.6 / 1.9

0468 500 010 - 1.6 W1.6 / 2.1

M6 × 27 M8 × 37

CO2

Mix/Ar M6

14.3 Steel liner

Ordering no. Ø Length Notes Exeor MIG 4.0W²

0700 025 822 0.9 – 1.2 3 m Red HD X

0700 025 823 0.9 – 1.2 4 m Red HD X

0700 025 824 0.9 – 1.2 5 m Red HD X

0700 025 825 1.4 – 1.6 3 m Grey HD X

0700 025 826 1.4 – 1.6 4 m Grey HD X

0700 025 827 1.4 – 1.6 5 m Grey HD X

0700 025 099

- 32 -

Exeor MIG 4.0W²

14.4 PTFE liner

Ordering no. Ø Length Notes

0700 200 089 0.8 – 1.0 3 m Blue X

0700 200 090 0.8 – 1.0 4 m Blue X

0700 025 811 0.8 – 1.0 5 m Blue X

0700 200 091 1.0 – 1.2 3 m Red X

0700 200 092 1.0 – 1.2 4 m Red X

0700 025 812 1.0 – 1.2 5 m Red X

0700 025 813 1.2 – 1.6 3 m Yellow X

0700 025 814 1.2 – 1.6 4 m Yellow X

0700 025 815 1.2 – 1.6 5 m Yellow X

Exeor MIG 4.0W²

14.5 PTFE liner with bronze front end

Ordering no. Ø Length Notes

0700 026 073 0.8 3 m blue X

0700 026 074 0.8 4 m

0700 026 075 0.8 5 m

0700 026 076

0700 026 077 1.0

0700 026 078 1.0

0700 026 079

0700 026 080

0700 026 081

1.0 3 m red X

1.2 – 1.6 3 m yellow X

1.2 – 1.6 4 m

1.2 – 1.6 5 m

4 m

5 m

blue

red

yellow

14.6 PA liner with bronze front end

Ordering no. Ø Length Notes

0700 025 099

0700 025 816 0.8 – 1.0 3 m Anthracite X

0700 025 817 0.8 – 1.0 4 m Anthracite X

0700 025 818 0.8 – 1.0 5 m Anthracite X

0700 025 819 1.2 – 1.6 3 m Anthracite X

0700 025 820 1.2 – 1.6 4 m Anthracite X

0700 025 821 1.2 – 1.6 5 m Anthracite X

- 33 -

15. WEAR PARTS Exeor MIG 4.0G²

1. Gas nozzle

2. Contact tip 16S-Series

3. Diffuser HD54-16

4. Insulation bushing

Ordering no. Denomination Notes Ø Length

12401200 Gas nozzle, HD24L-50 Option

12401201 Gas nozzle HD24L-62 Standard

12401202 Gas nozzle, HD24L-75 Option

15401136 Diffuser, HD54-16 Standard - 49.6 mm

0700025854 Insulation bushing -

12,7 mm

(1/2")

15,9 mm

(5/8")

19,5 mm

(.767")

17,5 mm

(.688")

80 mm

6,0 mm

(.236")

15.1 Contact Tips; Standard 16S-Series

Exeor MIG 4.0G Stock No.

Mix/Ar M8x1.25

11601102 0.90 mm (.035") 1.12 mm (.044")

11601103 1.00 mm (.040") 1.22 mm (.048")

Wire Size (mm / in)

Tip I.D. (mm / in)

M8x1.25

11601104 1.20 mm (.045") 1.37 mm (.054")

11601105 1.30 mm (.052") 1.65 mm (.064")

11601106 1.60 mm (1/16") 1.85 mm (.073")

11601113 AL 1.20 mm (3/64") 1.50 mm (.059")

11601114 AL 1.60 mm (1/16") 2.08 mm (.082")

0700 025 099

- 34 -

38.1 mm (1.50")

Exeor MIG 4.0W²

15.2 Steel liner

Ordering no. Ø Length Notes Exeor MIG 4.0G²

0700 025 822 0.9 – 1.2 3 m Red HD X

0700 025 823 0.9 – 1.2 4 m Red HD X

0700 025 824 0.9 – 1.2 5 m Red HD X

0700 025 825 1.4 – 1.6 3 m Grey HD X

0700 025 826 1.4 – 1.6 4 m Grey HD X

0700 025 827 1.4 – 1.6 5 m Grey HD X

15.3 PTFE liner

Ordering no. Ø Length Notes

Exeor MIG 4.0G²

0700 200 089 0.8 – 1.0 3 m Blue X

0700 200 090 0.8 – 1.0 4 m Blue X

0700 025 811 0.8 – 1.0 5 m Blue X

0700 200 091 1.0 – 1.2 3 m Red X

0700 200 092 1.0 – 1.2 4 m Red X

0700 025 812 1.0 – 1.2 5 m Red X

0700 025 813 1.2 – 1.6 3 m Yellow X

0700 025 814 1.2 – 1.6 4 m Yellow X

0700 025 815 1.2 – 1.6 5 m Yellow X

15.4 PTFE liner with bronze front end

Ordering no. Ø Length Notes

0700 026 073 0.8 3 m blue X

0700 025 099

0700 026 074 0.8 4 m

0700 026 075 0.8 5 m

0700 026 076

0700 026 077 1.0

0700 026 078 1.0

0700 026 079

0700 026 080

0700 026 081

1.0 3 m red X

4 m

5 m

1.2 – 1.6 3 m yellow X

1.2 – 1.6 4 m

1.2 – 1.6 5 m

- 35 -

blue

red

yellow

15.5 PA liner with bronze front end

Ordering no. Ø Length Notes

0700 025 816 0.8 – 1.0 3 m Anthracite X

0700 025 817 0.8 – 1.0 4 m Anthracite X

0700 025 818 0.8 – 1.0 5 m Anthracite X

0700 025 819 1.2 – 1.6 3 m Anthracite X

0700 025 820 1.2 – 1.6 4 m Anthracite X

0700 025 821 1.2 – 1.6 5 m Anthracite X

Exeor MIG 4.0G²

0700 025 099

- 36 -

0700 025 099

- 37 -

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00

manuals.esab.com

For contact information visit esab.com

ESAB Exeor MIG 4.0W², Exeor MIG 4.0G² Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual