ESAB MIG-41 Push-Pull Gun Troubleshooting instruction

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