INSTRUCTIONS for
MIG-41
PUSH-PULL GUN
FEATURES/BENEFITS
F-14-363-A
October, 1997
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
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation
and safe practices for electric welding equipment, we urge you to read our booklet, “Precautions and Safe
Practices for Electric Welding and Cutting,” Form 52-529. Do NOT permit untrained persons to install, operate,
or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully
understand these instructions. If you do not fully understand these instructions, contact your supplier for further
information. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment.
Table 1 - A vailable MIG-41 Push-Pull Gun Assemblies
MIG-41 Gun (25-ft. long) for 0.035-in. software .......................600979
MIG-41 Gun (25-ft. long) for 3/64-in. soft wire .........................600980
MIG-41 Gun (25-ft. long) for 1/16-in. soft wire .........................604290
ideal for feeding aluminum or other small diam-
eter wires long distances
quick disconnect convenience
repairable front end for easy low cost mainte-
nance
ideal for new installations or retrofits
MIG-41 Gun Assembly Components Included with torch assembly
T orch Length Contact Tip Drive Roll Liner Nozzle Basic Gun
P/N x Wire Size P/N P/N P/N P/N P/N
600979 25-ft. x 0.035” soft 632793 (.035) 19269 (.035/.9mm) 19304 (#10)* (25-ft.)
600980 25-FT. X 3/64” soft 632795 (3/64) 19270 (3/64/1.2mm) 19304
604290 25-ft. x 1/16” soft 632797 (1/16) 19736 (1/16/1.6mm) 19305
Be sure this information reaches the operator.
Y ou can get extra copies through your supplier.
2
II. EQUIPMENT & ACCESSORIES
A. REQUIRED EQUIPMENT
1. Power Control Assembly P/N 19310. Provides
power for torch pull motor on MIG 35, Digimig,
Digipulse Feeders.
2. Wire Feeder Connector Assembly - P/N 19260
(Mig-35, Digimig, Digipulse)
Provides quick connect and disconnect of gun to
wore feeder (see Figs. 2 & 5). It includes power
cable, switchcord, and gas hose with fitted 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 T orch Control Kilt (Mig 4HD) 34327.
4. Water Kit (Mig 4HD) 34325
5. Feed Roll for Wire Feeder
Select the proper feed roll for your particular wire
feeder from Table 3.
6. Coolant Recirculator, P/N 33739 (WC-8C). Unit
is capable of recirculating coolant at the rate of 1
gpm which is more than adequate for protecting
the torch. It is equipped with 8-ft. input power cord
that plugs into a standard 1 15V AC recept acle. The
WC-8 with its 9-3/4 in. square base fits into a cylinder rack of any power supply truck. Use T orch Coolant, P/N 156F05 (1 gal. container) only . Unit has a
tank capacity of 1/5 gal.) T wo 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 accesso-
ries so that the torch can be used with other wire
sizes, see Table 3.
2. 45° Curved Front Body, P/N 19757 - Available
for replacing straight front body of standard MIG41 gun assembly . Wire Guide P/N 19758 (includes
plastic liner P/N 19759) is required for use with
this assembly .
III. INSTALLATION
A. INSTALL DRIVE ROLL IN TORCH
1. Pull off drive roll cap from gun handle. (See Fig.
1.)
2. Flip idler arm to the down position.
3. Remove screw and washer.
4. Engage drive roll to the drive roll seat and then
reassemble washer and screw. Tighten screw
firmly with screwdriver.
5. Close idler arm and then reinstall drive cap. Do
not adjust preset tension of cap knobs.
Table 3 - Recommended Mig-41 Gun Accessories
(8.4m) Guide Tub Feed Roll (Wire Feeder)
Wire Wire Contact Contact Tip Liners Drive Mig 4HD Mig-35 Mig-35
Type Size Tube Long Short 28 Ft. Roll Connector Connector Mig 4hd Digimig
Soft 0.030 — — 632791 19304 19268 — ????? 21158 — 2075304
0.035 996104 632794 632793 19304 19269 — ????? 21158 — 2075304
3/64 996105 632796 632795 19304 19270 — ????? 21159 — 2075301
1/16 996106 632798 632797 19305 19736 — ????? 21159 — 2075298
Hard 0.030 — — 632791 19868 19268 19871 19873 21155 — 2075300
0.035 996104 632794 632793 19868 19269 19871 19873 21156 2075313 2075303
0.045 996105 632796 632795 19869 19270 19872 19874 21156 2075311 2075302
1/16 996106 632798 632797 19870 19736 19872 19874 21157 2075308 2075299
Requires use of Collet Nut 18961.
Plastic liners are used for soft wires and extend through the wire feeder connector. A support liner
supplied with the connector is used with 0.030, 0.035 and 3/64-in. wires. Remove support liner when
using 1/16-in. wire. Liners 19304 and 19305 include collet 19306 and O-ring 19307. Liner 19737
includes collet 19774 and O-ring 19307.
Steel liners are used for hard wires. They DO NOT extend through the wire feeder connector. Select
the appropriate guide tube for assembly into the wire feeder connector. The support liner is not used
in the connector with hard wires.
? Requires Guide Bushing, P/N 17997.
3
Nozzles
P/N Size
No. 8 18958
No. 10 18959
No. 12 18960
No. 12 Spotweld 18996
B. INST ALL 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
COLLET
LINER POSITIONER
NUT
LINER
O-RING
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
DISTANCE
MEASURED
GUIDE TUBE (See Table 3)
(No Support Liner Used)
LINER FERRULE
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 A C
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.
SUPPORT LINER
(.030, .035 & 3/64 SOFT WIRE ONLY)
D. CONNECT MIG-35 WIRE FEEDER CONNEC-
TOR ASSEMBL Y 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.
4
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 19090 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. VOLT AGE PICK-UP LEAD
St arting 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-14-350 packed with
the Digipulse 450 System.
The pick-up lead is NOT required if using the MIG-41
gun with any other wire feeder. It is recommended that
it be disconnected from the gun as follows (see illustrations):
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 - 19798
TIE WRAP
DISCONNECT
WIRE FEEDER CONNECTOR ASSY. 19259 (MIG-31, 31A)
19260 (MIG-35, DIGIMIG)
INLET CONNECTOR
END OF GUN
Fig. 2 - Typical MIG-41 Push-Pull Gun Set-Up
POWER CONTROL ASSY . 19310
COOLANT “IN” HOSE ASSY. - 19089
COOLANT “OUT” HOSE ASSY. - 19090
5
6
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 - 18930 *
(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 P ARTS
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. - 19258
includes: NOZZLE BODY & CLAMP - 18930
INSULATOR ASSY. - 18924
CONTACT TIP - See Table 3
NOZZLE - See Table 3
(No. 10 supplied with torch)
*TIP ADAPTOR - 18927
OPT. ACCY: 45° CURVED FRONT BODY - 19757
Requires: WIRE GUIDE - 19758
includes: LINER - 19759
INSULATOR ASSY. - 18924
(included w/19258)
WIRE GUIDE - 19991
LOCK NUT - 19264 (located in torch body
under drive roll cap)
* Nozzle Body & Clamp replacement requires using Nozzle Body Replacement Tool Kit - 19092
Fig. 3 - Replaceable Front End Parts
7
DRIVE ROLL CAP w/HARDWARE
- 19265
TORCH BODY - 19847
(Includes items marked)
(2) O-RING - 19776
See Fig. 3
NUT, IDLER ARM - 19848
IDLER ARM - 19282
IDLER ROLL - 19266
TRIGGER SWITCH - 19279
SCREW - 19284
ADAPTOR SUPPORT (3 PCS) - 19285
ADAPTOR NUT - 18402
ADAPTOR BLOCK - 19283
FEMALE WIRE CONN. - 18407
O-RING - 18406
NUT - 18404
SCREW - 18405
TRIGGER WIRE (27’ LG.) - 19297
MALE WIRE CONN. - 18408
SCREW, M3X10 - 19290
WASHER - 19267
DRIVE ROLL SEAT - 19271
(2) KNOB - 19287
(2) SPRING - 19286
(2) BALL - 19288
SCREW, HANDLE - 19291
NUT - 19289
GEAR MOTOR - 19280
GAS HOSE (27’ lg.) - 19294
HOSE CLAMP - 19295
WIRE CONDUIT (25’ lg.) - 19296
POWER CABLE (25’ lg.) - 19300
DRIVE ROLL (0.030”) - 19268
SCREW - 18405
(4) SCREW, M3X18 - 19292
(4) SCREW - 19293
HANDLE (2 PC) - 19278
OUTER CABLE COVER (25’lg.) - 19299
(0.035”) - 19269
(0.045”) - 19270
(1/16”) - 19736
GAS FITTING - 19275
CONDUIT FITTING - 19274
CABLE SUPPORT - 19775
COOLANT HOSE “IN”
(26’ LG.) - 19301 (BLUE)
PLUG (COOLANT “IN”) - 950615
Plug (950797) and socket (950798) on the Power
Control Assembly (19310) are polarized. If either
have to be replaced, mark leads and reconnect to
appropriate pins/sockets.
ADAPTOR INSULA TOR - 19316
ADAPTOR BLOCK - 19315
SET SCREW - 19319
GAS HOSE (Supplied w/19315)
Supplied
SUPPORT LINER - 19309 (w/19260)
SUPPORT LINER - 19308 (w/19259)
COOLANT “IN” HOSE ASSY . - 19089
COOLANT “OUT” HOSE ASSY. - 19090
PLUG - 950797
MOTOR CONTROL WIRE
(27-1/2’lg.) - 19298
Not Shown
LINER (0.030”/0.035”,3/64 X 27’lg.) - 19304
(3/64” x 27’ lg.) - 19305
(1/16” X 27” lg.) - 19737
COLLET (LINER - 1/16” WIRE) - 19774
COLLET (LINER - .030—3/64” WIRE) - 19306
O-RING (LINER) - 19307
COOLANT HOSE “OUT” (15” lg.) - 19302 (RED)
SOCKET (COOLANT “OUT”) - 950614
• Early version gun assemblies used cable support 19273 & clamp 19272.
Fig. 4 - Basic MIG-41 Gun Assembly - P/N 19257
SET SCREW - 19318
POWER PLUG - 19314
ADAPTOR PLUG - 19320 (MIG-35)
(2) FEMALE CONN. w/LEAD - 19317
POWER CABLE - 19339
SWITCHCORD - 19340
Includes PLUG - 2062336
OPTIONAL ACCY.: PLUG COVER - 2062337
Fig. 5 - Wire Feeder Connector Assy . (MIG-35, DIGIMIG) - 19260
(MIG-31) - 19259
- 19313 (MIG-31)
included with
particular liner
}
F-14-363-A 10/97 2M Printed in U.S.A.
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