ESAB PP36 Plus Push-Pull Mig Welding Gun Instruction manual

PP36 Plus

Push-Pull MIG Welding Gun

Instruction Manual

0558011520 June 30, 2011

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

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 be­fore installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompa­nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc­tions 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 imme­diately. 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 ser­vice facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

WARNING: These Safety Precautions are

for your protection. They summarize pre­cautionary information from the references

listed in Additional Safety Information sec­tion. 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 tted with the correct lter and

cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
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 ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess 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 ameproof apron may also be desirable as protec­tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, 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-ammable partition or
curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.

1.1 Safety - English

FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:

1. Remove all combustible materials well away from
the work area or cover the materials with a protec­tive non-ammable 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 oors or wall openings and cause a hid­den smoldering re or res on the oor 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 ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.

5. Do not use equipment beyond its ratings. For ex­ample, overloaded welding cable can overheat and
create a re 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 re. Use re 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 Protec­tion 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 conned, or if there is
danger of falling.

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con­nected 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.

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 conned spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.

Therefore:

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda­tions. Do not mistake the work lead for a ground
cable.

ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur­rent owing through any conduc­tor 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 eects which

are unknown.

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, stain­less 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 opera­tions. 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 ir­ritation 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 discom­fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.

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 vio­lently 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 ttings in good
condition. Follow manufacturer's operating instruc­tions for mounting regulator to a compressed gas
cylinder.

1. Always have qualied personnel perform the instal­lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied 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.

2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar­riages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures 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 con­nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.
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 Jeerson Davis Highway,
Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for

electric arc welding and cutting equip­ment, 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"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung­sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand­book.

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 Atten­tion! Be Alert! Your safety is involved.

Means immediate hazards which,
if not avoided, will result in im­mediate, 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.

SECCION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las
referencias listadas en la sección "Información Adi­cional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS-­Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,

como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.

2. Use una careta que tenga el ltro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las per­sonas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-

pas calientes con una cortina adecuada no-amable
como división.

6. Use careta protectora además de sus gafas de segu-

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de
las amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:

1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases amables, solventes,
pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté to­talmente limpia y libre de substancias que puedan
producir gases inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.

4. Tenga siempre a la mano equipo extintor de fu­ego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspec­cione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.

7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corri-

ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.

SECCION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de
tierra física.

3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condi­ciones. Reemplaze cables rotos, dañados o con
conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mien­tras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.

8. Use guantes secos y sin agujeros antes de energizar
el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones especícas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETI­COS - Son peligrosos. La corriente
eléctrica uye através de cualquier
conductor causando a nivel local

Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes proced­imientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios

sin ventilación. No inhale el humo

o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cad­mio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico per­siste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomen­daciones especícas en la ventilación.

SECCION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se uti­liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de Cali­fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados
correctamente, pueden romp­erse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adapta­dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablil­leros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los

1. Siempre tenga personal cualicado para efec­tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado para hacer el
trabajo.

2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.

6. Use el equipo sólo para el propósito que fue
diseñado. No modique el equipo en ninguna
manera.

INFORMACION ADICIONAL DE SEGURI­DAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

SECCION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig­nican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.

Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.

Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.

Signica el posible riesgo que
puede resultar en menores daños
a la persona.

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution

provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurez­vous de lire et de suivre les précautions de sécurité ci­dessous, dans les manuels, les ches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de

plaques protectrices appropriées an de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas re­garder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes an de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininammable an de vous proté­ger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recom­mandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
Les personnes se trouvant à proximité doivent égale­ment porter des lunettes étanches par dessus leur
lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combus­tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. Les
matériaux combustibles incluent le bois, les vête­ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.

2. Les étincelles et les projections de métal incan­descent peuvent tomber dans les ssures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra­vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauer et provoquer un in­cendie.

6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.

7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.

SECTION 1 SÉCURITÉ

1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de
terre électrique.

3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion an d'éviter le risque
de choc électrique mortel.

4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom­magés.

5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte­électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.

7. Si vous devez eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe­ment sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever
vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉ­TIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-

teur produit des champs électriques
et magnétiques localisés. Le soudage et le cou­rant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour cer­tains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour
la santé.

3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même
côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée
de votre corps.

LES VAPEURS ET LES GAZ -- peuvent

causer un malaise ou des dommages

corporels, plus particulièrement
dans les espaces restreints. Ne re­spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila­tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lor­sque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ven­tilation n'est pas adéquate. Cessez votre travail an
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spéciques
concernant la ventilation.

SECTION 1 SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques consid­éres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES -­La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un

échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles­sures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne xez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas bran­ché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des
ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre dis­position par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe­ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez ja­mais un équipement s'il présente une défectuosité
quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.

6. Utilisez l'équipement conformément à son usage
prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELA­TIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precau­tions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman­dées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

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"

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.

ATTENTION

Signie un danger qui peut entraîner des blessures
corporelles mineures.

TABLE OF CONTENTS

Subject Page #

Safety………………………………………………………………………… 3

Disclaimer…………………………………………………………………… 2
Fact Sheet and Ordering Information…………………………………….. 16

Introduction …………………………………………………………………. 18
Use of this Manual …………………………………………………………. 18
User Responsibility ………………………………………………………… 18
Personal Protection ………………………………………………………… 18
Fire Safety ………………………………………………………………….. 18
Electrical Shock …………………………………………………………….. 19
Ventilation Requirements ………………………………………………….. 19
Equipment Maintenance ………………………………………………… … 19
Push Pull Plus Product Description ……………………………………… 20
Power Supply Description …………………………………………………. 20
Power Supply Installation ………………………………………………… 20
ESAB Central Adapter System Description ……………………………… 20
Installation……………………………………………………………………. 20
Push Pull Adapter Kit Installation ………………………………………… 21
Liner Installation Instructions……………………………………………… 24
Steel Monocoil Liners ……………………………………..……………… 24
Teflon Liners ……………………………………………………….……… 24
Drive Rolls …………………………………………………………………. 25
Swan Neck Wire and Neck Liner Guide ………………….…………….. 25
Drive Roll Pressure Adjustment ………………………………………… 25
Consumables ………………………………………………………………. 26
Gas Diffusor…………………………………………………………………. 26
Contact Tip Holder …………………………………..…………………… 26
Contact Tip ………………………………………….……………………… 26
Nozzle…………………………………………………….………………… 26
Maintenance …………………………………………….……………..…… 28
General Inspection and Cleaning ……………………………………… 28
Adapter Kit Maintenance ………………………………………………… 28
Push Pull Gun Maintenance …………………………………………….. 28
Troubleshooting Guide……………………………………………………… 29
Gun Body Diagram ……………………………………………………….. 34

15

16 17

INTRODUCTION

The purpose of this manual is to explain the installation, operation, and maintenance of the ESAB Welding & Cutting
Products PP36 Plus Push-Pull Welding Gun.
This manual is not to be regarded as a training program, but as a guide for experienced personnel.
The training of personnel to effectively and safely install, operate, and maintain ESAB product is the responsibility of the
owner and user. ESAB Welding & Cutting Products originated and exclusively owns the information contained in this
manual. The manual is supplied only to provide information to the owner or user of the equipment, it is not a license for
reproduction of the equipment or equipment design. The owner or user has no right to give the information contained in
the manual to others.
Read carefully and make sure you understand this complete manual before attempting to operate, install, or maintain the
equipment. The equipment and this manual are intended for use only by persons familiar with the safety precautions
required for the use, installation, and maintenance of arc welding equipment. Do not permit untrained p ersonnel to
operate, install or maintain the equipment.

USE OF THIS MANUAL

This manual is divided into sections for ease when performing particular operations. The entire manual is to be read
before any work is performed.
Throughout this manual special safety precautions are highlighted in the following manner:

WARNING!

This precaution if not carefully followed can lead to serious personal injury and/or death!

CAUTION!

This precaution if not carefully followed can lead to minor personal injury and/or damage to the equipment!

Additionally, special information is highlighted in the following manner:

NOTE:
This information is included to ease assembly and/or separate instructions, which if not followed can lead to
decreased efficiency or incorrect operation of the equipment.

USER RESPONSIBILITY

It is the owner's and/or user's responsibility to make themselves aware of and to comply with the co des and regulations
applicable to the installation, use, and maintenance of this equipment in the country, state, or territory of use. ESAB
Welding & Cutting Products will not accept liability for the non-compliance of the owner or user with applicable laws or
codes.

PERSONAL PROTECTION

WARNING!

Skin burns and eye burns from exposure to ultra-violet rays generated by an electric arc or hot metal are more
severe than sunburn.

Always use a face shield with the correct filter and cover plates to protect your eyes, face, neck, ears, and scalp from arc
rays and sparks, both when operating or merely observing.
Do not allow bystanders or those working in the area to look at the arc or expose themselves to the rays.
Wear flameproof gauntlet-type gloves, and clothing.
Protect other nearby personnel against arc rays and hot sparks with a nonflammable partition.
Wear safety glasses or goggles when in a work area. Use safety glasses with side shields when chipping slag or grinding.

WARNING!

Chipped slag can be hot and can travel considerable distance! Bystanders should also wear safety glasses!

Certain welding processes can produce excessively high noise levels and require ear protection.

FIRE SAFETY

WARNING!

Hot slag or sparks can cause serious fires when in contact with combustible solids, liquids, or gases.

Remove all combustible materials from the welding area or completely cover the materials with a non-flammable covering.
Examples of combustible materials are wood, clothing, sawdust, gasoline, kerosene, paints, solvents natural gases,
acetylene, and propane.
Hot sparks or molten metal can fall into cracks in floors or walls and cause a hidden fire. Cover all openings accordingly.
Have fire-extinguishing equipment on hand for immediate use.

18

ELECTRICAL SHOCK

WARNING!

Live electrical parts can cause severe burns, or fatal shock to the body. Severity of electrical shock is determined
by the path and the amount of current passing through the body.

Never allow live metal parts to touch bare skin or any wet clothing. Be sure gloves are dry.
When standing on metal or welding in a damp area, make certain that you are well insulated by wearing dry gloves,
rubber soled shoes, and by standing on a dry board or platform.
Keep cables away from sharp metal edges and objects, which can cut or puncture cables. Do not stress cables
mechanically by pulling equipment, or electrically by overloading. Worn or damaged cables should be replaced.
When not welding, turn off the equipment as accidental grounding can cause over-heating or create a fire hazard.
Keep clothing, work area, cables, welding guns, and welding machines dry. Fix water leaks immediately.

VENTILATION REQUIREMENTS

WARNING!

Welding gases and fumes can cause discomfort and physical harm, especially in a confined spac e.

Provide adequate ventilation in the work area at all times either by natural or mechanical means.
Do not weld galvanized steel, zinc, lead, beryllium, or cadmium without proper ventilation to prevent breathing these
fumes and gases.
Do not weld in proximity of chlorinate hydrocarbon vapors coming form degreasing or spraying operations. The heat or a rc
rays can react with solvent vapors to form phosgene gas (highly toxic!) and other irritant gases. If you develop momentary
eye, nose or throat irritation during welding, this is an indication of inadequate ventilation. Stop work and take the
necessary steps to improve ventilation in the welding area.
If ventilation is not adequate to remove all fumes and gases, use a fresh air respirator.

EQUIPMENT MAINTENANCE

WARNING!

Faulty or improperly maintained equipment can result in physical injury or death through electric shock or fires.

Have only qualified personnel perform installation, maintenance, and trouble-shooting. Do not perform any electrical work
unless qualified.
Always disconnect the welding machine from the power source when performing any maintenance work inside the
machine.
Cables, welding gun, grounding wire, connections, power cord, and welding machine must be maintained in safe working
order.
Keep all safety devices and cover plates in place.
Always use equipment for its intended purpose. Do not modify!

19

PUSH PULL PLUS PRODUCT DESCRIPTION

The ESAB Push-Pull welding guns are designed to enable feeding of normally difficult to feed welding wires over long
distances with a smooth and consistent feed rate.
The ideal application for these welding guns is in welding with "soft" aluminum wires. It can also be used for steel as well
as stainless steel wires. These welding guns can be u sed for wire sizes from .03 0"- .062" when fitted with the correct
liners, tip, and drive roll.

CAUTION!

These units, though designed to withstand normal industrial use, are precision tools. Do NOT knoc k spatter out
of the nozzle by banging the gun! Do NOT throw the unit! Avoid dropping the unit! Damage to the motor or
welding head may result.

POWER SUPPLY

The unit uses a direct current slave motor located in the handle of the welding gun to maintain tension on the wire.
Power for the motor is obtained from the ESAB wire feeder. This power supply connects in parallel to the wire feeder
motor, and provides torque sensitive power.

How it works.

When the feeder motor is switched on, it supplies the same DC voltage to the gun as the feeder motor. The speed of the
pull motor is inhibited by the wire speed feed, which is controlled by the main wire drive unit. This results in a tensioning of
the wire in the liner, providing smooth and stable feeding.

CAUTION!

The ESAB feeder motor power supply must be used!
Obtaining current from any other source that does not contain similar electrical circuitry could result in improper
wire feeding, wire shaving, and damage to the pull motor.

ESAB CENTRAL ADAPTER SYSTEM

The ESAB Central Adapter System is a recognized world standard, which allows rapid and easy changing of MIG guns
attached to the wire feeder. The system connects power, gas, and trigger circuit with a few turns of the locking nut. This
system allows the ESAB Push Pull gun to be mounted to any Aristo Feed 3004 or Origo Feed 304 or 3004 type wire
feeder. Special center guides, outlet guides and drive rolls are available for feeding aluminum and other soft wires or
difficult to feed MIG/MAG wires.

NOTE: For additional assistance with above see on page ??? of this manual

INSTALLATION

Connect the 23 pin connector plug to the 23 pin receptacle supplied with the Push Pull adapter kit installed in the wire
feeder.
The adapter kits are supplied including a wire feed speed CAN interface for feeders so equipped, or a 23 pin motor power
only receptacle. In the case of the latter, the wire feed speed is controlled only by the wire feeder as set.

NOTE: For additional assistance with above see page 6 of this manual

20

ADAPTER KIT INSTALLATION INSTRUCTIONS

WARNING!
Disconnect the welding machine from the power source to prevent shorts
and/or electrical shock.
NOTE: These are generalized installation guidelines. Installation may vary slightly due to various feeder designs.

Can adapter board, filter board and cable set connected to the control board of the wire feeder

Adapter option with wire feed speed adjustment for welding gun with potentiometer, part number 0459 681 8 81

The adapter board is delivered with machine ID 7.
Switch 13S2 is used for activating / deactivating the wire feed speed potentiometer on the welding gun. When the switch
is in position B, the potentiometer on the gun is active and the control panel of the feeder is inactive. In position A the
control panel is active and the potentiometer on the gun is inactive.
If the wire feeder is controlled by an Aristo Pendant U8², switch 13S2 has to be in position B, then external or internal
control of the wire feed speed can be selected by the U8².

Pull motor option without wire feed speed adjustment, part number 0459 020 883

This option includes connectors 13XS25, 13XS20 and wires 1389, 1390.

Circuit board layout, CAN adapter and filter board

21

Connection instructions from Ser. No. 451-xxx-xxxx,

The above installation procedure is used for ESAB wire feeders with M2, MA4, MA6, MA23, MA24, U6 control panels
installed.

22

The above installation procedure is used for ESAB wire feeders with the U8² control pendant installed. (continued)
(continued from previous page)

Note: These instructions are included with the kits. If there is a discrepancy, the kit instructions take precedence.

1. To assemble the Adapter kit you will need a razor knife, also a screwdriver with a #25 Torx
bit, and follow the above pictographic instructions.

2. Before loading wire or welding, check to ensure that the proper liner, contact tip, and or drive rolls are installed for
the wire size you are using. Refer to sections of this manual covering those items.
Attach the Welding gun to the feeder and adapter kit. If using a Water-cooled gun be sure to hook up the water
lines to a suitable cooling device.

3. The control panels M2, MA4, MA6 and U6 must have software version 1.21M or later. Wire feeders from serial no.
451--508--xxxx and with built--in control panels have this version. If an Aristo Pendant U8 is used, this must have
software version 1.20K or later.

You are now ready to inch wire through the gun.

®

bit, and a #2 Phillips

23

LINER INSTALLATION INSTRUCTIONS

Below are instructions for the installation of liners in the ESAB Push Pull guns.

STEEL MONOCOIL LINERS

A. Lay the gun in a straight line. Then remove the liner positioner nut (the hex nut on the rear of the gun). Remove the old
liner (if installed) by pulling outward on the brass collet.
B. Insert the bare end of the new liner into the liner "stud" on the rear of the gun. Inch the liner through the cable assembly
until you feel it stop against the gun body. You will notice that some of the liner is still exposed at the back end (inlet side)
of the gun. Accurately measure the amount of liner sticking out (from the end of the threaded stud to the bottom edge of
the collet head).
Now remove the liner and cut off this measured section minus 1/8” from the bare end of the liner. Reinstall the liner and
hex nut. Tighten the hex nut to secure the liner.
C. Be sure that the correct wire guide tube is inserted into the feeder Central Adapter. Thread the gun onto the Adapter.

TEFLON LINER INSTALLATION

A. Lay the gun in a straight line. Then remove the liner positioner nut (the hex nut on the rear of the gun). Remove the old
liner by pulling outward on the brass collet.
B. Unpack the teflon liner you have selected. You will notice that the brass collet is close to one end of the liner but not in
a fixed position, and is backed by a small o-ring. Find the end of the liner without the collet, and using a manual pencil
sharpener, shave this end of the liner to a smooth taper. Leave a small area of flat on this sharpened end so as not to
make gouges or weaken the end of the liner. Taking time to make a neat taper will be worth the effort when the gun is in
operation.

NOTE:
This taper is to ensure that the liner seats properly into the gun body. Failure to follow this procedure could
result in erratic wire feeding, and bird nesting.

C. Insert the tapered end of the liner into the liner "stud" on the rear of the gun. Feed the liner through the cable assembly
until you feel it stop against the gun body. Check the viewing hole inside the front drive assembly to verify that the liner
has been fully inserted.

NOTE:
Use care not to kink the liner while feeding it into the gun. A kinked liner will result in improper or poor wire
feeding, and must be replaced.

D. While holding forward pressure on the liner, slide the collet and o-ring up to the liner "stud". The collet will not go the
entire way in the stud due to the collets taper. Install the liner position nut over the liner and tighten slightly. (Do not over­tighten). For use with outlet guide tube part numbers 0558006891, 0558006892, and 0558006893, the liner length
extending from the tightened Liner Position Nut should be trimmed to 1.75” (or 44.5mm).

*See diagram below

NOTE:
If installed correctly the liner will have a slight compression on it inside the cable. This compression will
eliminate any slack, which might have a negative effect on feeding. Over tightening of the liner positioner nut will
result in wire feed problems, due to pinching of the wire.

E. If using a liner with an outside diameter of 4.4mm or larger a guide tube support is not necessary. If using a liner

4.3mm or smaller in diameter, slide the brass guide tube support over the liner. *In general if the guide tube fits over the
liner, use it.

*See diagram below

24

NOTE:
When inching wire though the gun, it may be necessary to open the drive roll cap and set the wire speed feed
very slow. Watch the inlet guide at the guns drive roll and when the wire appears, carefully guide it into the out
let guide. If the wire speed it too fast the wire will hit on the front of the gun body and bird nest at the feeder.

DRIVE ROLLS

The Drive rolls are designed for the specific wire size you are using. Be sure to install the correct size! When looking at
the drive rolls you will notice that there is a groove on each end. These grooves are for the same wire size and allow the
drive roll to be flipped over for double the life.
To replace the drive rolls you will need a straight screwdriver and 10mm open end wrench.
IMPORTANT! - Drive rolls are loosened in a clockwise direction and tightened in counter-clockwise direction
Be careful to not use excessive force with the screwdriver and wrench, or damage to the gun could occur.
Do not use a screwdriver with a thicker blade than the slot in the drive roll shaft. Deforming the shaft can cause the shaft
to break or make removal of the drive roll impossible.
Hold the shaft still with the screwdriver while turning the drive roll with the 10mm wrench.

SWAN NECK LINER

Neck liners are for 4 types of swan necks are available.
Two sizes neck liners for each standard and extended 180˚ degree necks, and for the 45˚ degree standard and extended
necks.
A. Remove the swan neck from the gun body by un-screwing the swan neck retaining nut.
B. Unthread the swan necks plastic inlet guide
C. Unthread the neck liner from the guide.
D. Thread a new neck liner into the swan neck inlet guide.
E. Re-install the wire guide assembly into the swan neck, and tighten
F. Thread the neck onto the gun body, and hand tighten.

See Fact Sheet page for correct neck liner for wire size and neck being used.

DRIVE ROLL PRESSURE ADJUSTMENT

The drive roll tension knob provides adjustment for various wire types and sizes. The best resu lts
can be obtained by starting with the pressure knob turned outward (counter clock-wise), and slowly
turning inward (clock-wise) until just enough pressure is applied to feed the wire.

NOTE:
Too much pressure can deform soft wires

25

CONSUMABLES

GAS DIFFUSORS

A. The gas diffusor is a ceramic type insulator, which installs between the swan neck and the contact tip holder. This
device keeps spatter from building up in the gas ports, and between the nozzle and tip holder. If the gas diffusor is not
installed, spatter will accumulate causing gas flow problems, and short circuits.

Diffusor

CONTACT TIP HOLDER

A. The contact tip holder is threaded onto the swan neck with a normal right-hand thread. To install and/or remove the
contact tip holder, you should use a 12mm wrench. This part should be installed more tight than the contact tip. Do not
use thread-locking compounds!

NOTE:
Use care and do not over-tighten the contact tip holder as damage to the swan neck threads will result.
NOTE:
Thread the contact tip holder on slowly. This will allow the Teflon liner to seat properly. A small piece of welding
wire may be inserted through the tip holder to aid in positioning the liner as the contact tip holder is installed.

Tip Holders

CONTACT TIP

A. The contact tip is threaded into the tip holder with normal right-hand thread. The contact tip is designed to transfer
current to the welding wire, and should only be used with the wire size it is designed for. To install and/or remove the
contact tip, you should use an 8mm wrench.

NOTE:
The contact tip should not be installed as tight as the contact tip holder. This will aid in removal of the contact tip
at the next contact tip change.

Tips Nozzle

NOZZLE

The nozzle is a simple slip on type. It is held in place on the tapered nozzle seat by pressure from the spring clip on
the nozzle. Installation and removal will be easier if a clockwise turning motion is used while pushing on or pulling off.
Changing the tip holder to a longer or shorter one to perform short-arc or spray welding is recommen ded. Sliding the
nozzle to recess or expose the contact tip is not recommended and can result in damage to the swan neck.

26

27

MAINTENANCE

GENERAL INSPECTION AND CLEANING

A regular inspection and upkeep schedule will substantially increase the life of the equipment.
Periodically clean dirt and accumulated particles from around the drive rolls and wire guides, by blowing out with
compressed air. Check all gas, electrical connections, and hardware for damage or looseness. Inspect cables, wires, and
hoses for cracked, frayed, or otherwise damaged outer jackets. Remember that one damaged component can cause
harm to others. If necessary send your gun in for expert repairs.

WARNING!

When performing inspection or maintenance on the welding gun, be aware of possible shock hazards.
Disconnect the welding gun from the machine. Only qualified personnel should perform installation and
maintenance.

CAUTION!

Do not use any equipment that is not operating properly! Correct the problem before using the equipment. Use
only Genuine ESAB parts.
NOTE:
The time periods for procedures are based on an eight-hour workday. If your use exceeds thes e criteria,
decrease the time between maintenance and checks.

ADAPTER KIT MAINTENANCE

In the ESAB Central Adapter System one part requires periodic replacement. The steel or brass or plastic guide tubes
should be inspected any time they are removed for changing wire size or spools. Bends, nicks, burns and wear grooves
are all reasons to replace the guide tubes.

PUSH PULL GUN MAINTENANCE

Other than general inspection and consumable replacement certain tasks should be performed on a periodic basis:

PERFORM DAILY

A. Check the rear Central Adapter nut at the feeder connection and the swan neck retaining nut. Tighten by hand if loose.
B. Open the drive roll cover, and with compressed air, clean the area around the drive roll of metallic particles.

CAUTION!
Use proper eye protection when using compressed air!
NOTE:
Use of solvents for cleaning is not recommended, and could damage the motor and cable hoses.

C. Check the drive roll for wear and tightness.
D. Inspect the nozzle for wear and spatter build up. A worn out nozzle will be loose on the nozzle seat.

CAUTION!

Do not knock spatter out of the nozzle by banging the gun! Use a pair of nozzle cleaning pliers or the equivalent
to prevent damage to the gun. Remember this is a precision hand tool!

G. Check the contact tip, contact tip holder, and gas diffusor for wear and tightness. Replace and/ or tighten as necessa ry.

PERFORM WHEN CHANGING WIRE SIZES OR SPOOLS

A. Disconnect the gun from the machine.
B. Open the drive roll cap.
C. Using compressed air at a maximum of 30 psi (2.1 bar), blow into the liner from the rear (feeder end) to remove wire
particles.

CAUTION!

Use proper eye protection when using compressed air.

D. Close the drive roll cover and re-connect the gun to the machine.

Universal Power Supply for ESAB®
Push-Pull MIG Guns

28

TROUBLE SHOOTING GUIDE

POROSITY

Porosity is caused by four main possibilities:

- Base metal contamination

- Filler metal contamination

- Atmosphere in the weldment including gas turbulence

- Welding parameters

ESAB has found that most porosity problems are directly related to a gas problem, followed by problems with
base metal contamination.

Problem Probable Cause Solution

Porosity

Drafts, wind, fans, exhaust

ducts,etc.

Impurities on base metal a. Remove all contaminants form the surfaces to be welded. Paint, mill scall, rust, grease, and other

Too high oxygen content a. Fix or replace gas mixing apparatus.

Moisture in gas a. Replace system filter, and or dryers.

Leaks in gas distribution

system

Drafts, wind, fans, exhaust

ducts,etc.

Impurities on the base metal. a. Remove all contamination from the surfaces to be welded. Paint, mill scale, rust, grease and other

Unsuitable joint fit-up. a. Minimize gaps or provide backing.

Spatter in nozzle and on

contact tip.

Too high or too low gas flow

Nozzle damaged. a. Replace nozzle. A nozzle with uneven edges gives rise to turbulence in the gas flow. Do not hit nozzle

Too long a stick-out a. Generally, set the stick-out at about 15 times the diameter of the wire being used. If a longer or shorter

Misdirected welding gun a. Direct the gun at the weld puddle when critical areas like external corners, edges and joints with wide

Excessively wide weld pool a. The width of the weld pool should not exceed 1.3 times the diameter of the nozzle. The shielding gas

Damaged, kinked or leaking

gas hose.

Damaged or missing nozzle

insulator

a. Protect the work area from drafts with curtains or screens. Drafts can easily draw away the shielding
gas from the weld pool leaving it without sufficient protection.
b. Use tapered or bottleform nozzles when drafts are unavoidable.

contaminants can cause porosity in welds.
b. Use specific wire/gas mixtures for the types of impurities you are working with.

a. Fix leaks.
a. Protect the work piece from drafts with curtains or screens. Drafts can easily draw away the shielding

gas from the weld pool leaving it without sufficient gas protection.
contamination can cause porosity in the weld.

a. Clean the nozzle and the contact tip regularly. Spatter on these parts causes turbulence in the gas
flow, causing air to become mixed into the shielding gas resulting in porosity. Do not hit nozzle to remove
spatter, use a suitable scraper.
a. Consult your welding engineer for proper flow rate. Check accuracy of regulator using Gas Flow Meter,

rate.

(P/N 19043) which is available from your authorized ESAB Distributor.
b. Too low a gas flow rate gives insufficient protection to the weld pool. Too high a gas flow rate causes
turbulence in the gas shield, which in turn can suck in air resulting in porosity.

to remove spatter, use a suitable scraper.
stick-out than normal is required, consult your Authorized ESAB Distributor about the availability of

special nozzles. Many types are available.
gaps are encountered. A too sharply inclined welding gun can cause porosity due to miss-direction of the

shielding gas from the nozzle or air entrapment.
will insufficiently protect a wider weld pool when air gets mixed into the outer layer of the gas stream. If

necessary, a shielding gas post-flow should be applied. Consult your Authorized ESAB Distributor about
the availability of special nozzles that may help you weld wide joints.
a. Inspect and repair or repla ce as necessary. Consult your Authorized ESAB Distributor for Genuine
ESAB replacement parts.
a. Inspect and replace as neces sary. Consult your Authorized ESAB Distributor for Genuine ESAB
replacement parts.

29

TROUBLE SHOOTING GUIDE GENERAL

Problem Probable Cause Solution

Erratic wire feed Slipping feed rolls. a. Check that the feed roll size is correct for the wire size being used. Increase the drive roll pressure

Unstable arc Incorrect setting of voltage

Coil brake incorrectly adjusted. a. Set the brake so that the coil immediately stops rotating as soon as welding is interrupted. If the brake

Spatter Too fast or too slow wire feed in

Clogged or worn liner a. Dust, particles of copper, drawing lubricants, metal or flux and other forms of contamination rapidly

Liner too long or too short. a. Check the length of the liner and either trim if too long, or replace the liner if too short. Proper feed of

Spatter on wire a. An unprotected coil of wire quickly collects dust and other airborne contamination. If grinding is being

and/or current.

Defects in wire feed.

Worn contact tip. a. When the opening of the contact tip has become too badly worn the wire will no longer be in

Impurities on the base metal. a. Paint, mill scale, rust, silicon scale or flux deposits from previous weld runs from an insulating layer

Poor contact between ground a. Securely attach the ground cable as close to the cable and work-piece. point of welding as possible on

Loose power connection a. Check to insure welding power connection on the power source is tight, the connection on the wire

Stick-out too long a. Adjust the contact tip to work distance to a minimum of 3/8" for short arc welding with small diameter

relation to the arc voltage.

Too long arc. a. Adjust the wire feed and voltage so that the arc is in accordance with good welding practice for the

Damaged contact tip. a. If the contact tip becomes worn the filler will not be in constant contact and the arc will become unsta

Inclination of welding gun too

Faulty power source. a. Have the power source checked for faulty conditions such as broken wires and faulty contact.

Incorrect start. a. A lot of spatter occurs if the stick out is too great and if the welding gun is held too far from the work

Incorrect pulse parameters. a. Consult the user manual for your power supply or a qualified we lding engineer. Uneven wire feed.

Impurities on the base metal. a. Paint, mill scale, rust and other contamination on the base metal form an insulating layer causing an

Poor ground contact a. Inspect ground cable for loose connection s, fr aying and cuts. Correct any problem areas found and

Too long stick-out (short-arc

welding)

Incorrect polarity a. Check for correct polarity. Follow the electrode manufacturer’s recommendation.

great.

until the wire feed is even. Do not apply excessive pressure as this can damage the wire surface and
may cause copper coating to loosen from steel wires or metal shavings to be formed from soft wires like
aluminum which will be drawn into the wire feed conduit and will rapidly clog the liner. When welding with
flux cored wires, excessive drive roll pressure may open the wire seam and allow flux or m metal powers
to escape.

clog the liner so that the feed is impeded. A liner which has been in use for an extended period of time
becomes worn and saturated with dirt and must be replaced.
b. When changing wire, remove the contact tip from the front end of the gun and blow out the liner with
clean, dry compressed air from the back of the gun. Note: Wear sa fety goggles when using compressed
air to clean liner. Insure proper safety procedures are followed to avoid possible serious eye injury..

the weld-ing wire is dependent upon the correct length of the liner. Consult the operating instructions for
the gun or contact your local Authorized ESAB Distributor for further information.

per-formed in the vicinity, particles can become attached to the wire, severely interfering with the wire
feed. Replace with clean wire and keep it protected with a cover.

is too hard it will cause the feed rolls to slip, resulting in uneven wire feed. If it is too loose, overrun of the
wire will occur, causing tangles of the wire, irregular tension on the feed mechanism and irregular arc
characteristics.
a. Set the wire feed in relation to the arc voltage in such a way that the arc burns evenly and stable. In
spray arc welding, set the wire feed so that short-circuiting ceases and so that the filler metal is
transferred in a spray across the arc.

a. Find the cause of the interference and correct the condition. (See section "Erratic wire feed.)

continuous electrical contact, which will result in an unstable arc and an increase in spatter.

causing an unstable arc. Clean the surface to be welded.
the work piece. Clean the surfaces to ensure good contact.

b. Connect ground to both wo rking pieces to be joined. Clean ba se metal with dedicated stainless steel
wire brush when welding aluminum.

feeder is tight, the connection to the Adaptor block is tight, and the connection of the gun to the Adaptor
block is tight.

wires.
a. Set the wire feed rate and voltage in accordance with good welding practices as recommended by a
qualified welding engineer.

joint to be welded. The distance from the welding gun to the work piece should be about 1/2" to 1". If the
arc is too long there will be spatter, usually in the direction of the weld.

ble. A contact tip contaminated with spatter will cause uneven wire feed resulting in further spatter.
a. The angle of the gas nozzle relative to the work piece should be between 45 to 90 degrees. If the

angle is too small, the wire suns parallel to the weld pool, resulting in spatter in the direction of welding.

piece when striking the arc. Try to start with as short a stick-out as possible and with the welding gun as
close to the starting point as possible. If a large ball end is formed on the end of the welding wire remove
it by cutting the wire with sharp wire cutters. It is helpful if the wire is cut to a point. Always remove the
ball end before striking an aluminum arc. Check welding ground connection.

Uneven wire feed give rise to heavy spatter. Find the cause of the disturbance and correct the condition
before proceeding.

unstable arc, which results in heavy spatter. Clean the surfaces to be welded.

attach the ground cable directly to the work pie ce after having cleaned the contact surface first. POOR
GROUND CONTACT IS THE MOST COMMON CAUSE OF UNSTABLE MIG WELDING CONDITIONS.
a. The stick-out should be 15 times the diameter of the electro de being used. With increasing stick-out
the current is reduced and the arc voltage rises, giving a longer unstable arc and increased spatter.

30

TROUBLE SHOOTING GUIDE GENERAL

GAS/AIR COOLED GUNS

Problem Probable Cause Solution

Gun too Hot

Loose power connection a. Check to insure power connection on the power source is tight, the connection on the wire feeder is

Loose Bikox connection. a. Remove handle assembly and Adaptor support. Check to insure the Bikox connection to the swan

Damaged Bikox assembly. a. Visually inspect the Bikox assembly for cuts and tears. Replace Bikox assembly if necessary.

Consumable items loose or worn. a. Remove nozzle from gun and inspect contact tip and contact tip holder/gas diffuser for wear and

Capacity of gun being exceeded. a. Note complete weld parameter including welding current (AMPS), welding voltage, wire feed speed,

Poor ground.

a. Inspect ground cable for loose connections, fr aying and cuts. Correct any problem areas found. Clea n
clamping area to insur e good contact. Securely attach ground cable to work piece as close as possible to
the point of welding. Insure good connection to welding power source.

tight, the connection to the Adaptor block is tight, and the conn ec tio n of the gun to the Adaptor block is
tight.

neck is tight and the Bikox connection to the Adaptor block is tig ht.

tightness, replace or tighten as necessary.
type and size of wire, type of gas and flow rate of gas and consult your local Authorized ESAB

Distributor.

TROUBLE SHOOTING GUIDE GENERAL

WATER COOLED GUNS

Problem Probable Cause Solution

Gun too hot Poor water flow. a. Insure water flow is unrestricted and provides a minimum of 1.5 qts. Per minute of flow at pressure not

Direction of flow reversed. a. Insure that water flow direction is into the gun through the blue water line and out of the gun through

Interrupted water flow. a. Insure that water cooler runs for a minimum of 5 minutes after weld is completed. This insures proper

to exceed 65 psi.

the red water line.

post-weld cooling can take place through the entire gun and cableassembly.

Water leaks Water cooling source not turned

Loose power connection a. Check to insure power connection on the power source is tight, the connection on the wire feeder is

Capacity of gun being exceeded. a. Note complete weld parameter including welding current (AMPS), welding voltage, wire feed speed,

Cable assembly damaged a. See above.

Excessive coolant pressure a. Insure water flow is unrestricted and provides a mini mum of 1.5 qts per minute of flow at pressure not

Dirty coolant. a. Clean coolant unit after first disconnecting it from line volt age and draining old coolant fluid. Consult

Poor ground a. Inspect ground cable for loose connections, fray ing and cuts . Co rre ct any problem areas found. Clean

on during welding.

Swan neck damaged a. See above.

the manufacturer of the unit for proper procedure. Refill unit with fresh clean coolant fluid.

clamping area to insur e good contact. Securely attach ground cable to work piece as close as possible to
the point of welding. Insure good connection to welding power source.

tight, the connection to the Adaptor block is tight and the conn ection of the gun to the Adaptor block is
tight.

type and size of wire, type of gas and flow rate of gas and consult your local Authorize d ESAB
Distributor.
a. The use of a water-cooled MIG gun without water, even for very short periods of time, will destroy the
power cable located inside the cable assembly. Longer periods of use without water will destroy the swan
neck of the gun in addition to multiple components within the cable assembly.

to exceed 65 psi. Make corrections as needed. Repl a ce crimp style clamps on all water connections and
tighten water connections prior to starting the w eldin g process again.

31

TROUBLE SHOOTING GUIDE GENERAL

PUSH PULL GUNS

Problem Probable Cause Solution

Erratic wire feed
or burn back.

Improper contact tip size . a. Check and replace as nece ssary.
Poor ground. a. Inspect ground cable for loose connections, fraying and cuts . Co rre ct any problem areas found.

Incorrect tension on wire feeder a. Check that the feed roll size and groove type is drive rolls. correct for the wire size and type being

Liner improperly installed. a. Inspect or replace as necess ary.

Liner kinked or clogged. a. Inspect or replace as nece ss ary.

Liner positioner nut too tight. a. Check and adjust as necessary. If the nut has been tightened excessively on liner material other

Improper liner type being used. a. Generally, ESAB recommends the use of either Teflon or Polyamide liner for soft wires such as

Incorrect or worn pull motor drive

Loose power connection. a. Check to insure power connection on the power source is tight, the connection on the wire feeder is

Impurities on the base metal. a. Paint, mill scale, oxidation and other impurities on the base metal form an insulating layer causing

Drive roll cap not fully seated. a. Check to insure that the Drive roll cap assembly is complete and fully seated on the torch body.

Incorrect polarity. a. Check for correct polarity. Follow the wire manufacturers recommended specifications.

Coil brake applied too ha rd or too

Damaged contact tip. a. If the contact tip becomes worn the filler metal will not be in constant contact and the arc will

Burn back control not adjusted

properly.

Crater-fill mode in use. a. Crater-fill mode is intended for the termination of a weld. Consult operating instructions provided

used. ESAB recommends the use of U-g roove drive rolls for soft wires such as aluminum. Set the
pres-sure of the drive rolls so that just enough pressure is present to feed the wire but loose enough
so that the movement of the wire can be stopped without causing a bird nest of the wire. Do not apply
excessive pres-sure as this can damage the wire.

than steel, the collet can compress the liner material causing pinching of the wire.

aluminum. If in doubt as to which liner should be used in your case, contact your local authorized
ESAB Distributor.
a. Check or replace as necess ary.

roll.

Clean clamping area to insure good contact. Securely attach ground cable to work piece as close as
possible to the point of welding. Insure good connection to welding power source.

tight, the connection to the Adaptor block is tight and the conn ection of the gun to the Adaptor block is
tight.

an unstable arc. Clean the surface to be welded.

a. Set the brake so that the coil immediately stops rotating as soon as welding is interrupted. If the

soft.

brake is applied too hard it will cause the feed rolls to slip, resulting in uneven wire feed. If the brake is
applied too soft, the coil will tend to "coast" and result in uneven wire feed. This is most noticeable by
a changing arc length when welding.

become unstable. A contact tip contaminated with spatter will cause uneven wire feed resulting in
further spatter.
a. If the power source control is equipped with a burn bac k control feature check to insure proper
adjustment. Consult operating instructions provided with power source and wire feeder and follow the
manufacturer’s recommendation.

with power source and wire feeder and follow the manufacturer’s recommendation.

32

Repair Parts

33

34

ITEM NO. ESAB P/N DESCRIPTION

1 0558101469 WIRE INLET GUIDE ASSEMBLY PP36PLUS
2a 0558101467 Swanneck 180 Degree STD
2b 0558101468 Swanneck 45 Degree STD
2c 0558101465 Swanneck 45 Degree EXT
2d 0558101466 Swanneck 180 Degree EXT

3 0558101470 GAS DIFFUSOR STD (sold in 2's)
4a 0558101471 HOLDER TIP M8 SPRAY ARC (sold in 2's)
4b 0558101472 HOLDER TIP M8 SHORT ARC (sold in 2's)
4c 0558101473 HOLDER TIP M6 SPRAY ARC (sold in 2's)
4d 0558101474 HOLDER TIP M6 SHORT ARC (sold in 2's)

--

-

*5 0558101475 CONTACT TIP 030'' M8 AL (sold in 5's)

- 0558101476 Contact Tip .035" AL (sold in 5's)

- 0558101477 Contact Tip .040" AL (sold in 5's)

- 0558101478 Contact Tip .3/64" AL (sold in 5's)

- 0558101479 Contact Tip 1/16" AL (sold in 5's)

--

-

*5 0558101480 CONTACT TIP 030'''' M8 CU (sold in 5's)

- 0558101481 Contact Tip .035" CU (sold in 5's)

- 0558101482 Contact Tip .040" CU (sold in 5's)

- 0558101483 Contact Tip .045" CU (sold in 5's)

- 0558101484 Contact Tip .062" CU (sold in 5's)

--

-

*5 0558101485 CONTACT TIP 030'' M6 AL (sold in 5's)

- 0558101486 Contact Tip .035" AL (sold in 5's)

- 0558101487 Contact Tip .040" AL (sold in 5's)

- 0558101488 Contact Tip .045" AL (sold in 5's)

- 0558101489 Contact Tip .062" AL (sold in 5's)

0558101490 CONTACT TIP 030'''' M6 CU (sold in 5's)
0558101491 Contact Tip .035" CU (sold in 5's)
0558101492 Contact Tip .040" CU (sold in 5's)
0558101493 Contact Tip .045" CU (sold in 5's)
0558101494 Contact Tip .062" CU (sold in 5's)

--

-

6 0558101495 Nozzle Cylindrical 20MM (sold in 2's)

- 0558101496 Nozzle Conical 16MM (Standard) (sold in 2's)

- 0558101497 Nozzle Conical Small 14MM (sold in 2's)

- 0558101498 Nozzle Conical Heavy Duty 16MM

- 0558101499 Nozzle Spot Weld 20MM

--

7 0558101500 Neckliner Orange .035" - .045" F/180 STD

- 0558101501 Neckliner Orange .030" - .045" F/45 STD

- 0558101502 Neckliner Blue .052" - .062" F/180 STD

- 0558101503 Neckliner Blue .052" - .062" F/45 STD

7 -EXT 0558101504 Neckliner Orange .035" - .045" F/180 EXT

- 0558101505 Neckliner Orange .030" - .045" F/45 EXT

- 0558101506 Neckliner Blue .052" - .062" F/180 EXT

- 0558101507 Neckliner Blue .052" - .062" F/45 EXT

STANDARD M8 CONTACT TIPS

OPTIONAL M8 CONTACT TIPS

OPTIONAL M6 CONTACT TIPS

NOZZLES

8 0558101508 Handle Complete
9 0558101509 Trigger Switch

35

ITEM

NO.

CABLE ASSEMBLIES

10 0558101525 CABLE ASSY 15' A/C PP PLUS
10 0558101526 CABLE ASSY 25' A/C PP PLUS

8 0558101508 Handle Complete

9 0558101509 Trigger Switch
11 0558101527 TORCH BODY/ GEAR MOTOR CPL A/C PP
12 0558101528 MOTOR/GEARBOX 42V 19.5:1
13 0558101529 COVER CAP DRIVE ROLL HINGED PP PLUS
15 0558101535 Hose Gas 4.9 X 7.9mm bulk (100FT)
16 0558101536 Clamp Hose 8.7mm w/bridge (2 required)
17 0558101537 Wire 2 Conductor Bulk (200FT)
18 0558101538 Male Connector Trigger Wire (2 required)
19 0558101539 Connector Female (2 required)
20 0558101540 Insulating Sleeve (2 required)
21 0558101541 Wire 3 Conductor bulk (100FT)
22 0558101542 Male Pin Connector
23 0558101543 Connector Female
25 0558101544 CLAMP CABLE COVER BOTTOM
26 0558101545 CLAMP CABLE COVER TOP
27 0558101546 SUPPORT BOTTOM ROUND HD
28 0558101547 SUPPORT TOP ROUND HD
29 0558101548 HOLE PLUG F/500.0415 & 500.0416
30 0558101549 POTENTIOMETER KIT
31 0558101550 Socket Head Screw M4 X 30

ESAB P/N DESCRIPTION

36

32 0558101551 SCREW PAN HEAD ERGO HANDLE (2 required)
33 0558101552 SCREW SLOTTED HEAD M4X6
34 0558101553 CAP COVER INSULATING F/500.0213
35 0558101554 ADAPTOR POWER CABLE A/C PP PLUS
36 0558101555 NUT ADAPTOR
37 0558101556 BLOCK ADAPTOR REAR A/C PP PLUS

38 Part of Liner Liner Collet- Not sold separately

37

ESAB Welding & Cutting Products, Florence, SC

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:
Telephone: [phone] / Fax: [phone] Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:
Telephone: [phone] / Fax : [phone] Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: [phone] Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:
Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: [phone]

Hours: 7:30 AM to 5:00 PM EST

or

visit us on the web at http://www.esabna.com

The ESAB web site oers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support