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PP36 Plus Push-Pull MIG Welding Gun

1. Nozzle damaged 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 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 a Replace nozzle A nozzle with uneven edges gives rise to turbulence in the gas flow Do not hit nozzle to remove spatter use a suitable scraper 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 stick out than normal is required consult your Authorized ESAB Distributor about the availability of special nozzles Many types are available Misdirected welding gun a Direct the gun at the weld puddle when critical areas like external corners edges and joints with wide 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 Excessively wide weld pool a The width of the weld pool should not exceed 1 3 times the diameter of the noz
2. 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 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 be fore installing or operating this equipment USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompa nying labels and or inserts when installed operated maintained and repaired in accordance with the instruc tions 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 imme diately Should such repair or replacement become necessary the manufacturer recommends that a telephone or written request for service advice be made to t
3. ech Be sure the power source frame chassis is con nected to the ground system of the input power Connect the workpiece to a good electrical ground Connect the work cable to the workpiece A poor or missing connection can expose you or others to a fatal shock Use well maintained equipment Replace worn or damaged cables Keep everything dry including clothing work area cables torch electrode holder and power source Make sure that all parts of your body are insulated from work and from ground 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 Put on dry hole free gloves before turning on the power Turn off the power before removing your gloves Refer to ANSI ASC Standard Z49 1 listed on next page for specific grounding recommenda tions Do not mistake the work lead for a ground cable ELECTRIC AND MAGNETIC FIELDS May be dangerous Electric cur aan rent flowing through any conduc SN tor causes localized Electric and Magnetic Fields EMF Welding and cutting current creates EMF around welding cables and welding machines Therefore 1 2 Welders having pacemakers should consult their physician before welding EMF may interfere with some pacemakers Exposure to EMF may have other health effects which are unknown SAFETY PREC
4. The heat or arc 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 used for wire sizes from 030
5. chispas 4 Chispas y part culas de metal caliente puede alojarse en las mangas enrolladas de la camisa el ruedo del pantal n o los bolsillos Mangas y cuellos deber n mantenerse abotonados bolsillos al frente de la camisa deber n ser cerrados o eliminados 5 Proteja a otras personas de los rayos del arco y chis pas calientes con una cortina adecuadano flamable como divisi n 6 Use careta protectora adem s de sus gafas de segu ridad cuando est removiendo escoria o puliendo SEGURIDAD La escoria puede estar caliente y desprenderse con velocidad Personas cercanas deber n usar gafas de seguridad y careta protectora p FUEGO Y EXPLOSIONES El calor de A las flamas y elarco pueden ocacionar f fuegos Escoria caliente y las chispas pueden causar fuegos y explosiones Por lo tanto 1 Remueva todo material combustible lejos del rea de trabajo o cubra los materiales con una cobija a prueba defuego Materiales combustibles incluyen madera ropa l quidos y gases flamables solventes pinturas papel etc 2 Chispas y part culas de metal pueden introducirseen las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios Aseg rese de que toda grieta y agujero est cubierto para proteger lugares adyacentes contra fuegos 3 No corte suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo est to talmente limpia y libre de substancias que puedan prod
6. 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 a Consult the user manual for your power supply or a qualified welding engineer Uneven wire feed Uneven wire feed give rise to heavy spatter Find the cause of the disturbance and correct the condition before proceeding a Paint mill scale rust and other contamination on the base metal form an insulating layer causing an unstable arc which results in heavy spatter Clean the surfaces to be welded a Inspect ground cable for loose connections fraying and cuts Correct any problem areas found and attach the ground cable directly to the work piece 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 electrode being used With increasing stick out the current is reduced and the arc voltage rises giving a longer unstable arc and increased spatter a Check for correct polarity Follow the electrode manufacturer s recommendation 30 TROUBLE SHOOTING GUIDE GENERAL GAS AIR COOLED GUNS Probable Cause Solution Gun too Hot Poor ground a Inspect ground cable for loose connections fraying and cuts Correct any proble
7. un seau d eau un seau de sable ou un extincteur portatif Assurez vous d tre bien instruit par rapport l usage de cet quipement 5 Assurez vous de ne pas exc der la capacit de l quipement Par exemple un c ble de soudage surcharg peut surchauffer et provoquer un in cendie 6 Unefois les op rations termin es inspectezl aire de travail pour assurer qu aucune tincelle ou projec tion de m tal incandescent ne risque de provoquer un incendie ult rieurement Employezdes guetteurs d incendie au besoin 7 Pour obtenir des informations suppl mentaires 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 0 CHOC LECTRIQUE Le contact avec des pi ces lectriques ou les pi ces de mise a 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 1 Assurez vous que le chassis de la source d alimentation est branch au syst me de mise a la terre de l alimentation d entr e 2 Branchez la pi ce traiter une bonne mise de terre lectrique 3 Branchez le c ble de masse la pi ce traiter et assurezune bonne connexion afin d viter le risque de choc lectrique mortel 4 Utilisez toujours un quipement correctement entretenu
8. Remplacez les cables us s ou endom mag s 5 Veillez a garder votre environnement sec incluant les v tements l aire de travail les c bles le porte lectrode torche et la source d alimentation 6 Assurez vous que tout votre corps est bien isol de la pi ce traiter et des pi ces de la mise la terre 7 Sivous devezeffectuer votre travail dans un espace restreint ou humide ne tenez vous pas directe ment sur le m tal ou sur la terre tenez vous sur des planches s ches ou une plate forme isol e et portez des chaussures a semelles de caoutchouc 8 Avant de mettre l quipement sous tension isolez vos mains avec des gants secs et sans trous 9 Mettez l quipement hors tension avant d enlever vos gants 10 Consultez ANSI ASC Standard Z49 1 list la page suivante pour des recommandations sp cifiques concernant les proc dures de mise la terre Ne pas confondre le c ble de masse avec le c ble de mise la terre CHAMPS LECTRIQUES ET MAGN 7 TIQUES comportent un risque de amp danger Le courant lectrique qui AR passe dans n importe quel conduc teur produit des champs lectriques et magn tiques localis s Le soudage et le cou rant de coupage cr ent des champs lectriques et magn tiques autour des c bles de soudage et l quipement Par cons quent 1 Un soudeur ayant un stimulateur cardiaque doit consulter son m decin avant d entreprendre une op ration de soudage Les cham
9. VA 22202 SECURITE ENTRETIEN DE L QUIPEMENT Un quipe ment entretenu de fa on d fectueuse ou inad quate peut causer des blessures graves ou mortelles Par cons quent 1 Efforcez vous de toujours confier les t ches d installation de d pannage et d entretien un personnel qualifi N effectuez aucune r paration lectrique moins d tre qualifi cet effet 2 Avant de proc der une t che d entretien l int rieur de la source d alimentation d branchez l alimentation lectrique 3 Maintenez les c bles les fils de mise la terre les branchements le cordon d alimentation et la source d alimentation en bon tat N utilisez ja mais un quipement s il pr sente une d fectuosit quelconque 4 N utilisez pasl quipement de fa on abusive Gardez l quipement l cart de toute source de chaleur notamment des fours de l humidit des flaques d eau de l huile ou de la graisse des atmosph res corrosives et des intemp ries 5 Laissez en place tous les dispositifs de s curit et tous les panneaux de la console et maintenez les en bon tat 6 Utilisez l quipement conform ment son usage pr vu et n effectuez aucune modification INFORMATIONS SUPPL MENTAIRES RELA TIVES LA S CURIT Pour obtenir de l information suppl mentaire sur les r gles de s curit observer pour l quipement desoudage l arc lectriqueetle coupage demandezun exemplaire dulivret Preca
10. destroy the on during welding 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 Swan neck damaged a See above 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 to exceed 65 psi Make corrections as needed Replace crimp style clamps on all water connections and tighten water connections prior to starting the welding process again 31 TROUBLE SHOOTING GUIDE GENERAL PUSH PULL GUNS Problem Probable Cause Solution Erratic wire feed or burn back 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 used ESAB recommends the use of U groove 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 Liner improperly installed a Inspect or replace as necessary Liner kinked or clogged a Inspect or replace as necessary Liner positioner nut too tight a Check and adjust as necessary If the
11. 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 results 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 Pressure roll Drive roll shaft Drive roll Drive roll tension knob 23 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 e e 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 co
12. source with VDE standard volt amp characteristic V 14V 0 05xA When pulse MIG welding reduce rating by 35 This applies to any MIG torch Wire diameters 030 035 040 045 3 64 062 1 16 0 8mm 0 9mm 1 0mm 1 2mm 1 6mm Shown with ext 45 Weight of 15 ft Torch complete 10 85 Ibs 4 92kg Weight of 25 ft Torch complete 16 40 Ibs 7 44kg Dimensions of torch body Top of Torch to Bottom of handle 6 3 8 16 19cm Handle minor diameter 1 3 8 3 49cm Length of body and cable support 7 17 8cm Length of standard neck E 15 24cm Length of extended neck 9 22 86cm PP36 Plus Consumables and Accessories Gun assemblies include standard neck 3 64 Drive roll liners HD 8mm contact tip short tip holder and 5 8 nozzie Necks require liner tip holder tip and nozzle PP36 Plus extended 45 9 neck 0558101465 PP36 Plus extended 180 9 neck 0558101466 PP36 Plus standard 180 6 neck 0558101467 PP36 Plus standard 45 6 neck 0558101468 Replacement neck inlet guide 0558101469 Neck liners choose for length of neck and wire size used For extended 45 9 neck 10 71 Ig 272mm Neckliner Orange 030 045 0558101505 Neckliner Blue 052 062 0558101507 For extended 180 9 neck 8 62 Ig 219mm Neckliner Orange 030 045 0558101504 Neckliner Blue 052 062 0558101506 For standard 180 6 neck 5 63 Ig 143mm Neckliner Orange 030 045 standard 05
13. 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
14. 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 these 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
15. wire feed speed adjustment for welding gun with potentiometer part number 0459 681 881 The adapter board is delivered with machine ID 7 Switch 1382 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 U8 switch 13S2 has to be in position B then external or internal control of the wire feed speed can be selected by the U8 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 Wire feeder with built in control panel The above installation procedure is used for ESAB wire feeders with M2 MA4 MA6 MA23 MA24 U6 control panels installed Wire feeder controlled by U8 NOTE the switch must be in position B 22 The above installation procedure is used for ESAB wire feeders with the U8 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 al
16. 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 knock 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
17. 08 0558101509 andle Complete rigger Switch I 2a 1 ta o de AH ees aa S El E a ES Set e a AAA A A AS AA LS o SSA A WER A ay sees E EA A A PS EA A EA 7 EXT a Ll A A EEN Y O 35 ARA AO 1Y lan BBM UN a SNJ D 15 16 26 D 25 H 13 20 32 gt 5 17 31 ESS oo 22 Ref Ref ky 24 Motor Leads in vinyl sheath Green not used insulate 29 21 Potentiometer Leads marked with sleeve near outlet AM a p 2 ell T ER 3 AN naa Um S H 37 27 28 a a 2 8 36 i 38 MEM ESAB P N DESCRIPTION SN aa CABLE ASSEMBLIES CABLE ASSY 15 A C PP PLUS CABLE ASSY 25 A C PP PLUS EA a osseiois08 Handle Complete ls osssrorsos Trigger Switch TORCH BODY GEAR MOTOR CPL A C PP MOTOR GEARBOX 42V 19 5 1 COVER CAP DRIVE ROLL HINGED PP PLUS Hose Gas 4 9 X 7 9mm bulk 100FT Clamp Hose 8 7mm w bridge 2 required Wire 2 Conductor Bulk 200FT Male Connector Trigger Wire 2 required Connector Female 2 required 20 osseioisao Insulating Sleeve 2 required o osseioisar Wire 3 Conductor bulk 100FT o558101542 Male Pin Connector ComnectorFomale CLAMP CABLE COVER BOTTOM CLAMP CABLE COVER TOP SUPPORT BOTTOM ROUND HD SUPPORT TOP ROUND HD HOLE PLUG F 500 0415 8 500 0416 POTENTIOMETER KIT Socket Head Screw M4 X 30 36 0558101551 SCREW PAN HEAD
18. 496 Nozzle Conical Small 1 2 0558101497 Nozzle Conical Heavy Duty 5 8 0558101498 Nozzle Spot Weld 3 4 0558101499 Conduit Liners choose for wire size and type Liner Hi Life 030 3 64 17 ft Aluminum std 0558101515 Liner Hi Life 030 3 64 28 ft Aluminum std 0558101516 Liner Hi Life 052 1 16 17 ft Aluminum 0558101517 Liner Hi Life 052 1 16 28 ft Aluminum 0558101518 Liner 024 030 17 ft Hard Wire 0558101510 Liner 035 045 17 ft Hard Wire 0558101511 Liner 035 045 28 ft Hard Wire 0558101512 Liner 052 062 17 ft Hard Wire 0558101513 Liner 052 062 28 ft Hard Wire 0558101514 Conduit Liners continued choose for wire size and type Liner C TFE 024 030 17 ft Stainless St 0558101519 Liner C TFE 024 030 28 ft Stainless Stl 0558101520 Liner C TFE 035 045 17 ft Stainless Stl 0558101521 Liner C TFE 035 045 28 ft Stainless Stl 0558101522 Liner C TFE 052 062 17 ft Stainless St 0558101523 Liner C TFE 052 062 28 ft Stainless St 0558101524 Drive Rolls choose for wire size Drive Roll PP36 030 0 8mm 0558101530 Drive Roll PP36 035 0 9mm 0558101531 Drive Roll PP36 040 1 0mm 0558101532 Drive Roll PP36 3 64 1 2mm standard 0558101533 Drive Roll PP36 1 16 1 6mm 0558101534 Replacement Pressure roll Assy 0558101557 ESAB Wire Feeder Accessories required to connect PP36 Plus For CAN Controlled Wire Feeders MA23 MA24 U6 U8 Adapter Kit with Wire Feed Spee
19. 58101500 Neckliner Blue 052 062 0558101502 For standard 45 6 neck 7 80 Ig 198mm Neckliner Orange 030 045 standard 0558101501 Neckliner Blue 052 062 0558101503 Tip Holders and Diffusor choose for spray arc short arc and tip size Gas Diffusor 0558101470 Holder Tip M8 Spray Arc standard short 0558101471 Holder Tip M8 Short Arc long 0558101472 Holder Tip M6 Spray Arc short 0558101473 Holder Tip M6 Short Arc long 0558101474 Contact Tips choose for wire size type and tip size Contact Tip M8 030 Aluminum 0558101475 Contact Tip M8 035 Aluminum 0558101476 Contact Tip M8 040 Aluminum 0558101477 Contact Tip M8 3 64 Aluminum standard 0558101478 Contact Tip M8 1 16 Aluminum 0558101479 Contact Tip M8 030 Hard Wire 0558101480 Contact Tip M8 035 Hard Wire 0558101481 Contact Tip M8 040 Hard Wire 0558101482 Contact Tip M8 3 64 Hard Wire 0558101483 Contact Tip M8 1 16 Hard Wire 0558101484 Contact Tip M6 030 Aluminum 0558101485 Contact Tip M6 035 Aluminum 0558101486 Contact Tip M6 040 Aluminum 0558101487 Contact Tip M6 3 64 Aluminum 0558101488 Contact Tip M6 1 16 Aluminum 0558101489 Contact Tip M6 030 Hard Wire 0558101490 Contact Tip M6 035 Hard Wire 0558101491 Contact Tip M6 040 Hard Wire 0558101492 Contact Tip M6 3 64 Hard Wire 0558101493 Contact Tip M6 1 16 Hard Wire 0558101494 Nozzles Nozzle Cylindrical 3 4 0558101495 Nozzle Conical 5 8 Standard 0558101
20. 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 necessary 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 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 param
21. AUTIONS 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 confined spaces Do not breathe fumes and gases Shield ing gases can cause asphyxiation Therefore 1 Always provide adequate ventilationin the workarea by natural ormechanical means Do not weld cut or gouge on materials such as galvanized steel stain less steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials 2 Donot operate near degreasing and spraying opera tions 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 ir ritation 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 discom fo
22. ERGO HANDLE 2 required 0558101552 SCREW SLOTTED HEAD M4X6 32 CAP COVER INSULATING F 500 0213 ADAPTOR POWER CABLE A C PP PLUS ss 0558101555 NUT ADAPTOR 36 37 0558101556 BLOCK ADAPTOR REAR A C PP PLUS 38 Part of Liner Liner Collet Not sold separately 37 ESAB Welding amp Cutting Products Florence SC COMMUNICATION GUIDE CUSTOMER SERVICES CUSTOMER SERVICE QUESTIONS Telephone 800 362 7080 Fax 800 634 7548 Hours 8 00 AM to 7 00 PM EST Order Entry Product Availability Pricing Order Information Returns ENGINEERING SERVICE Telephone 843 664 4416 Fax 800 446 5693 Hours 7 30 AM to 5 00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8 00 AM to 5 00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information and Registrations WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YO
23. GA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 A EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore SAFETY PRECAUTIONS 1 Always have qualified personnel perform the instal lation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified 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 equipmentaway from heat sources such as furnaces wet conditions such as water puddles oil or grease corrosive atmospheres and inclement weather 5 Keepall 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 ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc welding and cutting equip ment 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 AmericanWelding
24. 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 over tighten 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 LINER COLLET POSITION NUT BRASS GUIDE TUBE DIE gt O RING PTFE EURO PLUG PREVENTS GAS LOSS OR PA LINER WIRE FEED ROLL 24 NOTE When inching wire though the gun it may be necessary to open the drive roll cap an
25. Society 550 N W LeJuene Road Miami FL 33126 are recommended to you 1 ANSI ASC Z49 1 Safety in Welding and Cutting 2 AWSC5 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 5 AWSC5 5 Recommended Practices for Gas Tung sten Arc Welding 6 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP Safe Practices Reprint Welding Hand book 8 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances throughout this manual Means Atten MEANING OF SYMBOLS As used tion Be Alert Your safety is involved Means immediate hazards which if not avoided will result in im ANEI mediate serious personal injury or loss of life Means potential hazards which AMENTS could result in personal injury or loss of life Means hazards which could result A Zee in minor personal injury SAFETY PRECAUTIONS SECCION 1 1 2 Safety Spanish ADVERTENCIA Estas Precauciones de Se A guridad son para su protecci n Ellas hacen resumen de informacion proveniente de las referencias listadas en la secci n Informaci n Adi cional Sobre La Seguridad Antes de hacer cualquier instalaci n o procedimiento de operaci n aseg rese de leer y seguirlas precauciones de seguridad li
26. U DO NOT KNOW WHOM TO CALL Telephone 800 ESAB 123 Fax 843 664 4462 Hours 7 30 AM to 5 00 PM EST or visit us on the web at http www esabna com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback amp Support MT ESAB ESAB Welding amp Cutting Products PO Box 100545 Florence SC 29501 0545
27. ard or too soft a Check for correct polarity Follow the wire manufacturers recommended specifications a Set the brake so that the coil immediately stops rotating as soon as welding is interrupted If the 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 Damaged contact tip a If the contact tip becomes worn the filler metal will not be in constant contact and the arc will become unstable A contact tip contaminated with spatter will cause uneven wire feed resulting in further spatter Burn back control not adjusted properly a If the power source control is equipped with a burn back control feature check to insure proper adjustment Consult operating instructions provided with power source and wire feeder and follow the manufacturer s recommendation Crater fill mode in use a Crater fill mode is intended for the termination of a weld Consult operating instructions provided with power source and wire feeder and follow the manufacturer s recommendation 32 Repair Parts 33 ITEM NO ESAB P N DESCRIPTION 0558101469 IRE INLET GUIDE ASSEMBLY PP36PLUS 0558101467 wanneck 180 Degree STD 0558101468 0558101465 0558101466 0558101470 0558101471 OLDER TIP M8 SPRAY ARC so
28. d Control 0459681881 For CAN amp Analog Wire Feeders M12 M13 MA23 MA24 U6 U8 Adapter Kit without Wire Feed Speed Control 0459020883 For CAN amp Analog Wire Feeders M12 M13 MA23 MA24 U6 U8 Torch Strain Relief use is recommended 0457341881 Feed Rolls and Guides for Aristo amp Origo Feed 3004 for Aluminum Wire Center Guides 1 req d Center Guide 0 030 0 035 0558007171 Center Guide 3 64 0558007172 Center Guide 1 16 0558007173 Outlet Guides 1 req d Outlet Guide 0 030 0 035 0558006891 Outlet Guide 3 64 0558006892 Outlet Guide 1 16 0558006893 Feed Rolls 4 req d Feed Roll Polished 0 035 3 64 0558007835 Feed Roll Polished 3 64 1 16 0558007836 INTRODUCTION The purpose of this manual is to explain the installation operation and maintenance of the ESAB Welding amp 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 amp 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 othe
29. d 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
30. e tierra fisica 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 el ctrico fatal Use el equipo solamente si esta en buenas condi ciones Reemplaze cables rotos da ados o con conductores expuestos Mantengatodoseco incluyendosu ropa el rea de trabajo los cables antorchas pinza del electrodo y la fuente de poder Asegurese que todas las partes de su cuerpo estan insuladas de ambos la pieza de trabajo y tierra Nose pare directamente sobre metalo tierra mien tras trabaja en lugares estrechos o reas h medas trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma Use guantes secos y sin agujeros antes de energizar el equipo Apage el equipo antes de quitarse sus guantes Use como referencia la publicaci n ANSI ASC Standard Z49 1 listado en la pr xima p gina para recomendaciones espec ficas 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 MAGNETI COS Son peligrosos La corriente el ctrica fluye atrav s de cualquier SN conductor causando a nivel local Campos El ctricos y Magn ticos EMF Lascorrientesen el rea decorte y soldadura crean EMF alrrededor de los cables de soldar y las maquinas Por lo tanto 1 Soldadores u Ope
31. e plomb le berylliym ou le cadmium en l absence de moyens m caniques de ventilation efficaces Ne respirez pas les vapeurs de ces mat riaux N effectuez jamais de travaux proximit d une op ration de d graissage ou de pulv risation Lor sque la chaleur ou le rayonnement de l arc entre en contact avec les vapeurs d hydrocarbure chlor ceci peut d clencher la formation de phosg ne ou d autres gazirritants tous extr mement toxiques Uneiirritation momentan e des yeux du nezoude la gorge au cours d une op ration indique que la ven tilation n est pas ad quate Cessez votre travail afin de prendre les mesures n cessaires pour am liorer la ventilation dans l aire de travail Ne poursuivez pas l op ration si le malaise persiste Consultez ANSI ASC Standard Z49 1 a la page suivante pour des recommandations sp cifiques concernant la ventilation SECTION 1 5 AVERTISSEMENT Ce produit lorsqu il est utilis dans une op ration de soudage ou de coupage d gage des vapeurs ou des gaz contenant des chimiques consid res par l tat de la Californie comme tant une cause des malformations cong nitales et dans certains cas du cancer California Health amp Safety Code 25249 5 et seq MANIPULATION DES CYLINDRES Se La manipulation d un cylindre sans gt 2 observerles pr cautions n cessaires peut produire des fissures et un chappement dangereux des gaz Une brisure soudaine du cyli
32. eee tees 20 Power Supply Description ET 20 Power Supply Installation nee 20 ESAB Central Adapter System Description 20 lastallatio SSL en nr M aa nr ae 20 Push Pull Adapter Kit Installation 21 Liner Installation Iess 24 e Beeler ie EE 24 Ken Bn RS Rennes ees ase aes ie ne 24 Dive Roll sad di 25 Swan Neck Wire and Neck Liner Guide 25 Drive Roll Pressure Adjustment ooococcccccocccocnccccncnnncncnnnncncncnnnons 25 CONSUME E 26 Gas DIS EE aaa scl cise cle aa aca Ucar eG att ASA Gath 26 Contact H Hie do 26 Contact He WE 26 Klee 26 E En e 28 General Inspection and Cleaning 28 Adapter Kit MaintenanCe cz czez vied ccecececerecadd dccececncecnczceeyeyeyenese 28 Push Pull Gun Maintenance a ves tered aves este 28 Trouble OIE A 29 Gun Body Di LR ESS GR cts Pa 34 MIG GUN PP36 Plus Push Pull MIG MAG Torch with Wire Feed Speed Control e Improved 42vdc motor for more torque and Shown with std 180 6in neck constant trouble free feeding Improved drive roll system for soft or difficult wires e Improved gas seal for long distance arc shielding e Air cooled 300A CO 280A mixed gases 60 duty cycle e Optimum torch cooling high endurance e Time saving torch neck replacement utilizes central plug system Robust construction for durability and extended torc
33. elding power connection on the power source is tight the connection on the wire feeder is tight the connection to the Adaptor block is tight and the connection of the gun to the Adaptor block is tight a Adjust the contact tip to work distance to a minimum of 3 8 for short arc welding with small diameter wires a Set the wire feed rate and voltage in accordance with good welding practices as recommended by a qualified welding engineer a Adjust the wire feed and voltage so that the arc is in accordance with good welding practice for the 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 a If the contact tip becomes worn the filler will not be in constant contact and the arc will become unsta 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 a Have the power source checked for faulty conditions such as broken wires and faulty contact 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 piece when striking the arc Try to start with as short a stick out as possible and with the welding gun as
34. enas condiciones Observe las instrucciones de operaci n del manufacturero para montar el regulador en el cilindro de gas comprimido Asegure siempre los cilindros en posici n vertical y am rrelos con una correa o cadena adecuada para asegurar el cilindro al carro transportes tablil leros paredes postes o armaz n 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 el lectrico Cuando el cilindro no est en uso mantenga la v lvula del cilindro cerrada Ponga el capote de protecci n sobre la v lvula si el regulador no est conectado Asegure y mueva los cilindros utilizando un carro o transporte adecuado Evite el manejo brusco de los defectuoso o mal mantenido puede MANTENIMIENTO DEL EQUIPO Equipo causar da o o muerte Por lo tanto SEGURIDAD 1 Siempre tenga personal cualificado para efec tuar la instalaci n diagn stico y mantenimiento del equipo No ejecute ning n trabajo el ctrico a menos que usted est cualificado 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 ning n equipo en malas condiciones 4 No abuse del equipo y sus accesorios Mantenga el equipo lej
35. eters 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 Drafts wind fans exhaust a Protect the work area from drafts with curtains or screens Drafts can easily draw away the shielding Porosity ducts etc gas from the weld pool leaving it without sufficient protection b Use tapered or bottleform nozzles when drafts are unavoidable Impurities on base metal a Remove all contaminants form the surfaces to be welded Paint mill scall rust grease and other contaminants can cause porosity in welds b Use specific wire gas mixtures for the types of impurities you are working with 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 a Fix leaks system Drafts wind fans exhaust a Protect the work piece from drafts with curtains or screens Drafts can easily draw away the shielding ducts etc gas from the weld pool leaving it without sufficient gas protection Impurities on the base metal a Remove all contamination from the surfaces to be welded Paint mill scale rust grease and other contamination can cause porosity in the weld Unsuitable joint fit up a Minimize gaps or provide backing Spatter in nozzle and on contact tip Too high or too low gas flow rate
36. everely interfering with the wire feed Replace with clean wire and keep it protected with a cover a Set the brake so that the coil immediately stops rotating as soon as welding is interrupted If the brake 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 a When the opening of the contact tip has become too badly worn the wire will no longer be in continuous electrical contact which will result in an unstable arc and an increase in spatter a Paint mill scale rust silicon scale or flux deposits from previous weld runs from an insulating layer causing an unstable arc Clean the surface to be welded a Securely attach the ground cable as close to the cable and work piece point of welding as possible on the work piece Clean the surfaces to ensure good contact b Connect ground to both working pieces to be joined Clean base metal with dedicated stainless steel wire brush when welding aluminum a Check to insure w
37. h life e 3 piece combined cable assembly for better flexibility especially for long distances e Options available to use with most ESAB 42vdc wire feeding systems with wire feed speed Shown with ext 180 9in neck option control at torch Optionally available 9 extended 180 and 45 swiveling necks for hard to reach joints Ordering Information PP36 Plus Gas Cooled Gun assemblies include standard neck 3 64 Drive roll liners HD 8mm contact tip short tip holder and 5 8 nozzie With 23 pin control plug for MA23 24 U6 U8 feeders Stocked PP36 Plus 15ft wi 180 neck 0558101453 PP36 Plus 25ft wi 180 neck 0558101455 PP36 Plus 15ft wi 45 neck 0558101454 PP36 Plus 25ft wi 45 neck 0558101456 With 10 pin control plug for older MA6 U6 U8 feeders that had Shown with std 45 Gm neck 0558004301 Push Pull module installed for Python only Request Item PP36 Plus 15ft wi 180 neck 0558101457 ES gt wm n PP36 Plus 25ft w 180 neck 0558101459 Nd PP36 Plus 15ft wi 45 neck 0558101458 PP36 Plus 25ft wi 45 neck 0558101460 With 2 pin control plug for old Mig 4HD feeders with Push Pull module installed only Request Item PP36 Plus 15ft wi 180 neck 0558101461 PP36 Plus 25ft wi 180 neck 0558101463 PP36 Plus 15ft w 45 neck 0558101462 PP36 Plus 25ft w 45 neck 0558101464 Specifications Capacity Yin neck Air cooled 300A CO 280A Mixed gases 60 duty cycle Rated using power
38. he 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 ser vice facility designated by the manufacturer READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS SECTION 1 1 0 Safety Precautions WARNING These Safety Precautions are for your protection They summarize pre cautionary information from the references listed in Additional Safety Information sec tion Before performing any installation or operating procedures be sure to read and follow the safety precau tions 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 Z processes are noisy and require ear Qe protection Thearc likethesun 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 helme
39. he 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 a Dust particles of copper drawing lubricants metal or flux and other forms of contamination rapidly 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 safety goggles when using compressed air to clean liner Insure proper safety procedures are followed to avoid possible serious eye injury a Check the length of the liner and either trim if too long or replace the liner if too short Proper feed of 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 a An unprotected coil of wire quickly collects dust and other airborne contamination If grinding is being per formed in the vicinity particles can become attached to the wire s
40. ld in 2 s 0558101472 OLDER TIP M8 SHORT ARC sold in 2 s 0558101473 OLDER TIP M6 SPRAY ARC sold in 2 s 0558101474 OLDER TIP M6 SHORT ARC sold in 2 s 2a 2b c 2d D DID Kep KOP Co O 4a 4b 4c 4d IJI I TANDARD M8 CONTACT TIPS 0558101475 ONTACT TIP 030 M8 AL sold in 5 s 0558101476 ontact Tip 035 AL sold in 5 s 0558101477 ontact Tip 040 AL sold in 5 s 0558101478 ontact Tip 3 64 AL sold in 5 s 0558101479 ontact Tip 1 16 AL sold in 5 s OJO PTIONAL M8 CONTACT TIPS 0558101480 ONTACT TIP 030 M8 CU sold in 5 s 0558101481 ontact Tip 035 CU sold in 5 s 0558101482 ontact Tip 040 CU sold in 5 s 0558101483 ontact Tip 045 CU sold in 5 s 0558101484 ontact Tip 062 CU sold in 5 s OJO OOO _ PTIONAL M6 CONTACT TIPS 0558101485 ONTACT TIP 030 M6 AL sold in 5 s 0558101486 0558101487 ontact Tip 040 AL sold in 5 s 0558101488 0558101489 0558101490 0558101491 0558101492 ontact Tip 040 CU sold in 5 s 0558101493 0558101404 0558101495 ozzle Cylindrical 20MM sold in 2 s 0558101496 0558101497 0558101498 ozzle Conical Heavy Duty 16MM 0558101499 A 0558101500 0558101501 0558101502 0558101503 0558101504 eckliner Orange 035 045 F 180 EXT 0558101505 0558101506 eckliner Blue 052 062 F 180 EXT 0558101507 eckliner Blue 052 062 F 45 EXT Qolo OF OF OF OF CH ZI ZI 2 2 ziz zizi 2 2 7 EXT ZI 212 05581015
41. loth sawdust liquid and gas fuels solvents paints and coatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hid den smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal 3 Donot weld cut or perform other hot work until the workpiece hasbeen completely cleaned sothatthere are no substances on the workpiece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire extinguishing equipment handy forinstant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use 5 Do not use equipment beyond its ratings For ex ample overloaded welding cable can overheat and create a fire hazard 6 After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could causea later fire Use fire 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 Protec tion Association Batterymarch Park Quincy MA 02269 ELECTRICAL SHOCK Contact with O live electrical parts and ground can cause severe injury or death DO NOT use AC welding currentindampareas if movement is confined or if there is danger of falling SECTION 1
42. m areas found 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 Loose power connection a Check to insure power connection on the power source is tight the connection on the wire feeder is tight the connection to the Adaptor block is tight and the connection of the gun to the Adaptor block is tight Loose Bikox connection a Remove handle assembly and Adaptor support Check to insure the Bikox connection to the swan neck is tight and the Bikox connection to the Adaptor block is tight Consumable items loose or worn a Remove nozzle from gun and inspect contact tip and contact tip holder gas diffuser for wear and tightness replace or tighten as necessary Capacity of gun being exceeded a Note complete weld parameter including welding current AMPS welding voltage wire feed speed type and size of wire type of gas and flow rate of gas and consult your local Authorized ESAB Distributor PF Damaged Bikox assembly a Visually inspect the Bikox assembly for cuts and tears Replace Bikox assembly if necessary 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 to exceed 65 psi Direction of flow reversed a Insure
43. 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 Welding gun 1 3AP1 d with pull motor Control board R and wire feed current setting W X 12V DC X1 OV X3 K CAN high X2 e wfs CAN low x4 L M REF WIRE FEED 9 A 42V AC J 1 1382 A B 42V AC 3 gt J2 1383 B 13XS24 MOTOR D1 1389 D PULL MOTOR MOTOR D2 1390 E PULL MOTOR 13XS25 13XS20 Can adapter board filter board and cable set connected to the control board of the wire feeder Adapter option with
44. ndre de la soupape ou du dispositif de surpression peut causer des bles sures graves ou mortelles Par cons quent 1 Utilisez toujours le gaz pr vu pour une op ration et le d tendeur appropri con u pour utilisation sur les cylindres de gaz comprim N utilisez jamais d adaptateur Maintenez en bon tat les tuyaux et les raccords Observez les instructions d op ration du fabricant pour assembler le d tendeur sur un cylindre de gaz comprim 2 Fixez les cylindres dans une position verticale l aide d une cha ne ou une sangle sur un chariot manuel un ch ssis de roulement un banc un mur une colonne ou un support convenable Ne fixez jamais un cylindre aun poste de travail ou toute autre dispositif faisant partie d un circuit lectrique 3 Lorsque les cylindres ne servent pas gardez les soupapes ferm es Si le d tendeur n est pas bran ch assurez vous que le bouchon de protection de la soupape est bien en place Fixez et d placez les cylindres a l aide d un chariot manuel appropri Toujours manipuler les cylindres avec soin 4 Placez les cylindres une distance appropri e de toute source de chaleur des tincelles et des flammes Ne jamais amorcer l arc sur un cylindre 5 Pour de l information suppl mentaire consultez CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders mis votre dis position par le Compressed Gas Association 1235 Jefferson Davis Highway Arlington
45. ntact 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 28 32 M6 ad M8 M6 Gei M8 For Spray Arc For Short Arc welding welding 28 34 M8 End M8 M8 M8 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 o 10 9 8 84 i E 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 recommended 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
46. nut has been tightened excessively on liner material other than steel the collet can compress the liner material causing pinching of the wire Improper liner type being used a Generally ESAB recommends the use of either Teflon or Polyamide liner for soft wires such as aluminum If in doubt as to which liner should be used in your case contact your local authorized ESAB Distributor Incorrect or worn pull motor drive roll a Check or replace as necessary Improper contact tip size a Check and replace as necessary Poor ground a Inspect ground cable for loose connections fraying and cuts Correct any problem areas found 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 Loose power connection Impurities on the base metal a Check to insure power connection on the power source is tight the connection on the wire feeder is tight the connection to the Adaptor block is tight and the connection of the gun to the Adaptor block is tight a Paint mill scale oxidation and other impurities on the base metal form an insulating layer causing an unstable arc Clean the surface to be welded 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 Coil brake applied too h
47. 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 space 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
48. os de cosas que generen calor como hornos tambi n lugares h medos como charcos de agua aceite o grasa atm sferas corrosivas y las inclemencias del tiempo 5 Mantenga todos los art culos de seguridad y coverturas del equipo en su posici n y en buenas condiciones 6 Use el equipo s lo para el prop sito que fue dise ado No modifique el equipo en ninguna manera INFORMACION ADICIONAL DE SEGURI DAD Para m s informaci n sobre las pr cticas de seguridad de los equipos de A arcoel ctrico para soldar y cortar pregunte a su suplidor por una copia de Precautions andSafe Practices for ArcWelding Cutting and Gouging Form 52 529 Las siguientes publicaciones disponibles atrav s 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 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 A ET ADVERTENCIA ADD SIGNIFICADO DE LOS SIMBOLOS Seg n usted avanzaen la lectura de este folleto Los S mbolos Sig nifican Atenci n Est Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser evadido puede resultar inmediatamente en serio da o personal o la muerte Significa el riesgo de un peligro potencial que puede res
49. ps lectriques et magn tiques peuvent causer des ennuis pour cer tains stimulateurs cardiaques 2 L exposition des champs lectriques et magn tiques peut avoir des effets n fastes inconnus pour la sant S CURIT 3 Lessoudeursdoiventsuivreles proc duressuivantes pour minimiser l exposition aux champs lectriques et magn tiques Acheminez l lectrode et les c bles de masse ensemble Fixez les l aide d une bande adh sive lorsque possible B Ne jamais enrouler la torche ou le c ble de masse autour de votre corps C Ne jamais vous placer entre la torche et les c bles de masse Acheminez tous les c bles sur le m me c t de votre corps D Branchez le cable de masse a la pi ce a traiter le plus pr s possible de la section a souder E Veillez garder la source d alimentation pour le soudage et les c bles une distance appropri e de votre corps LES VAPEURS ET LES GAZ peuvent causer un malaise oudes dommages corporels plus particuli rement dans les espaces restreints Ne re spirez pas les vapeurs et les gaz Le gaz de protection risque de causer l asphyxie Par cons quent Assurez en permanence une ventilation ad quate dans l aire de travail en maintenant une ventila tion naturelle ou l aide de moyens m canique N effectuez jamais de travaux de soudage de coupage ou de gougeage sur des mat riauxtels que l acier galvanis l acier inoxydable le cuivre le zinc l
50. radores que use marca pasos para el coraz n deber n consultar a su m dico antes de soldar El Campo Electromagn tico EMF puede interferir con algunos marca pasos SEGURIDAD 3 Los soldadores deber n usar los siguientes proced imientos 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 Aseg relos 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 s lo lado de su cuerpo D Conecte el cable de trabajo a la pieza de trabajo lo m s cercano posible al rea de la soldadura E Mantengala fuente de podery los cables de soldar lo m s lejos posible de su cuerpo HUMO Y GASES El humo y los gases pueden causar malestar o da o particularmente en espacios sin ventilaci n No inhale el humo o gases El gas de protecci n puede causar falta de ox geno Por lo tanto 1 Siempre provea ventilaci n adecuada en el rea de trabajo por medio naturalo mec nico No solde corte o ranure materiales con hierro galvanizado acero inoxidable cobre zinc plomo ber lio o cad mio a menos que provea ventilaci n mec nica positiva No respire los gases producidos por estos materiales 2 No opere cerca de lugares donde se aplique sub stancias qu micas en ae
51. res filtrants et de plaques protectrices appropri es afin de prot ger vos yeux votre visage votre cou et vos oreilles des tincelles et des rayons de l arc lors d une op ration ou lorsque vous observez une op ration Avertissez les personnes se trouvant proximit de ne pas re garder l arc et de ne pas s exposer aux rayons de l arc lectrique ou le m tal incandescent 3 Portez des gants ignifugi s crispin une chemise paisse mancheslongues des pantalons sans rebord etdeschaussures montantes afin de vous prot ger des rayons del arc des tincelles et du m tal incandescent en plus d un casque de soudeur ou casquette pour prot ger vos cheveux Il est galement recommand de porter untablierininflammable afin de vous prot ger des tincelles et de la chaleur par rayonnement 4 Les tincelles etles projections de m tal incandescent risquent de se loger dans les manches retrouss es les rebords de pantalons ou les poches Il est recom mand de garder boutonn s le col et les manches et de porter des v tements sans poches en avant 5 Prot gez toute personne se trouvant a proximit des tincelles et des rayons de l arc l aide d un rideau ou d une cloison ininflammable 6 Portez des lunettes tanches par dessus vos lunettes de s curit lors des op rations d caillage ou de meulage du laitier Les cailles de laitier incandescent peuvent tre projet es a des distances consid rables Les personnes
52. rosol El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosf geno o gas t xico y otros irritant es 3 Si moment neamente desarrolla inrritaci n de ojos nariz ogarganta mientras est operando es indicaci n de que la ventilaci n no es apropiada Pare de trabajar y tome las medidas necesarias para mejorar la ventilaci n en el rea de trabajo No contin e operando si el malestar f sico per siste 2 Exponerse a campos electromagn ticos EMF puede causar otros efectos de salud a n desconocidos Hagareferencia ala publicaci n ANSI ASC Standard 749 1 Vea la lista a continuaci n para recomen daciones espec ficas en la ventilaci n SECCION 1 5 ADVERTENCIA Este producto cuando se uti liza para soldaduras o cortes produce humos o gases los cuales contienen qu micos conocidos por el Estado de Cali fornia de causar defectos en el nacimiento oenalgunos casos Cancer California Health Safety Code 825249 5 et seq MANEJO DE CILINDROS Los cilindros si no son manejados correctamente pueden romp erse y liberar violentamente gases Rotura repentina del cilindro v lvula o v lvula de escape puede causar da o o muerte Por lo tanto Utilize el gas apropiado para el proceso y utilize un regulador dise ado para operar y reducir la presi n del cilindro de gas No utilice adapta dores Mantenga las mangueras y las conexiones en bu
53. rs 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 personnel 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 codes and regulations applicable to the installation use and maintenance of this equipment in the country state or territory of use ESAB Welding amp Cutting Products will not accept liability for the non compliance of
54. rt persists 4 Referto ANSI ASC Standard Z49 1 see listing below for specific ventilation recommendations SECTION 1 5 WARNING Thisproduct 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 amp Safety Code 25249 5 et seq CYLINDER HANDLING Cylinders BL if mishandled can rupture and vio lently release gas Sudden rupture of cylinder valve or relief device can injure or kill Therefore ec 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 fittings in good condition Follow manufacturer s operating instruc tions for mounting regulator to a compressed gas cylinder 2 Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercar riages benches walls post or racks Never secure cylinders to work tables or fixtures 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 con nected Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders 4 Locate cylinders away from heat sparks and flames Never strike an arc on a cylinder 5 Foradditional information refer to C
55. se trouvant a proximit doivent gale ment porter des lunettes tanches par dessus leur lunettes de s curit SECURITE p INCENDIES ET EXPLOSIONS La E chaleur provenant des flammes ou de l arc peut provoquer un incendie Le laitier incandescent ou les tincelles peuvent galement provoquer un incendie ou une explosion Par cons quent 1 loignez suffisamment tous les mat riaux combus tibles de l aire de travail et recouvrez les mat riaux avec un rev tement protecteur ininflammable Les mat riaux combustibles incluent le bois les v te ments la sciure le gaz et les liquides combustibles les solvants les peintures et les rev tements le papier etc 2 Les tincelles et les projections de m tal incan descent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et d clencher un incendie couvant l tage inf rieur Assurez vousquecesouverturessontbien prot g es des tincelles et du m tal incandescent 3 N ex cutez pas de soudure de coupe ou autre tra vail chaud avant d avoir compl tement nettoy la surface de la pi ce traiter de fa on ce qu il n ait aucune substance pr sente qui pourrait produire des vapeurs inflammables ou toxiques N ex cutez pas de travail chaud sur des contenants ferm s car ces derniers pourraient exploser 4 Assurez vous qu un quipement d extinction d incendie est disponible et pr t servir tel qu un tuyau d arrosage
56. so a screwdriver with a 25 Torx bit and a 2 Phillips 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 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 bot
57. stadas a continuaci n as como tambi n todo manual hoja de datos de seguridad del material calcomanias etc El no observar las Precauciones de Seguridad puede resultar en da o a la persona o muerte PROTEJASE USTED Y A LOS DEMAS Algunos procesos de soldadura corte y ranurado son ruidosos y requiren protecci n para los o dos El arco como el sol emite rayos ultravioleta UV y otras radiaciones que pueden da ar 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 AZ 1 Utilice gafas de seguridad con protecci n aloslados siempre que est en el area de trabajo aun cuando est usando careta de soldar protector para su cara u otro tipo de protecci n 2 Use una careta que tenga el filtro correcto y lente para proteger sus ojos cara cuello y oidos de las chispas y rayos del arco cuando se est operando y observando las operaciones Alerte a todas las per sonas cercanas de no mirar el arco y no exponerse alos rayos del arco el ctrico o el metal fundido 3 Use guantes de cuero a prueba de fuego camisa pesada de mangas largas pantal n 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
58. that water flow direction is into the gun through the blue water line and out of the gun through the red water line Interrupted water flow a Insure that water cooler runs for a minimum of 5 minutes after weld is completed This insures proper post weld cooling can take place through the entire gun and cableassembly Dirty coolant a Clean coolant unit after first disconnecting it from line volt age and draining old coolant fluid Consult the manufacturer of the unit for proper procedure Refill unit with fresh clean coolant fluid Poor ground a Inspect ground cable for loose connections fraying and cuts Correct any problem areas found 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 Loose power connection a Check to insure power connection on the power source is tight the connection on the wire feeder is tight the connection to the Adaptor block is tight and the connection of the gun to the Adaptor block is tight Capacity of gun being exceeded a Note complete weld parameter including welding current AMPS welding voltage wire feed speed type and size of wire type of gas and flow rate of gas and consult your local Authorized ESAB Distributor Water leaks Water cooling source not turned a The use of a water cooled MIG gun without water even for very short periods of time will
59. tom 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
60. ts face shields and goggles are also required 2 Use a face shield fitted with the correct filter 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 flameproof gauntlet type gloves heavy long sleeve shirt cuffless 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 flameproof apron may also be desirable as protec tion against radiated heat and sparks 4 Hot sparks or metal can lodge in rolled up sleeves trouser cuffs 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 flammable partition or curtains 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses SAFETY PRECAUTIONS 1 1 Safety English FIRES AND EXPLOSIONS Heat from A flames and arcs can start fires Hot i slag or sparks can also cause fires and explosions Therefore 1 Remove all combustible materials well away from the work area or cover the materials with a protec tivenon flammable covering Combustible materials include wood c
61. u tions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 A Les publications suivantes sont galement recomman d es et mises 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 SIGNIFICATION DES SYMBOLES Cesymbole utilis partout dans ce manuel signifie Attention Soyez vigilant Votre s curit est en jeu ATTE Signifie un danger imm diat La situation peut entra ner des blessures graves ou mortelles AE Signifie un danger potentiel qui peut entra ner des blessures graves ou mortelles ASSEN Signifie un danger quipeutentrainer des blessures corporelles mineures SECURITE TABLE OF CONTENTS Subject Page Disclaimer A LS LE eee ce cen cet ct cen cuter cement nal E Ly 2 ENEE EE 3 Fact Sheet and Ordering Information ssseseeseenererrerrer rreren renne 16 INtrOCUEION RE 18 Te nl E UE EE 18 User Responsibility iuris 18 Persona Nero te cuan ys SERRES Ea ee ee te tthe tat 18 AAA eT eee eee e e mer Nu 18 El ctrical SORA yt 19 Ventilation Requirements AA 19 Equipment Maintenance EE 19 Push Pull Plus Product Description cc ceceeeeee eee ee ee ee eee
62. ucir gases inflamables o vapores t xicos No trabaje dentro o fuera de contenedores o tanques cerrados Estos pueden explotar si contienen vapores inflamables 4 Tenga siempre a la mano equipo extintor de fu ego para uso instant neo como por ejemplo una manguera con agua cubeta con agua cubeta con arena o extintor port til Aseg rese que usted esta entrenado para su uso 5 Nouseel equipo fuera de su rango de operaci n Por ejemplo el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego 6 Despu s determirarlaoperacion del equipo inspec cione el area de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego mas tarde Tenga personal asignado para vigilar si es necesario 7 Para informacion adicional haga referencia a la publicaci n NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes disponible a trav s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 0 CHOQUE ELECTRICO El contacto con las partes el ctricas energizadas y tierra puede causar da o severo o muerte NO use soldadura de corri ente alterna AC en reas h medas de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo SECCION 1 Asegurese de que el chasis de la fuente de poder est conectado a tierra atrav s del sistema de electricidad primario Conecte la pieza de trabajo a un buen sistema d
63. ultar en serio da o personal o la muerte Significa el posible riesgo que puede resultar en menores da os a la persona SEGURIDAD SECTION 1 1 3 Safety French AVERTISSEMENT Ces r gles de s curit ont pour but d assurer votre protection Ils r capitulent les informations de pr caution provenant des r f rences dans la section des Informations de s curit suppl mentaires Avant de proc der l installation ou d utiliser l unit assurez vous de lire et de suivre les pr cautions de s curit ci dessous dans les manuels les fiches d information sur la s curit du mat riel et sur les tiquettes etc Tout d faut d observer ces pr cautions de s curit peut entrainer des blessures graves ou mortelles PROT GEZ VOUS Les processus de Z soudage de coupage et de gougeage QZ produisent un niveau de bruit lev et exige l emploi d une protection auditive L arc tout commelesoleil met des rayons ultraviolets en plus d autre rayons qui peuvent causer des blessures la peau et les yeux Le m tal incandescent peut causer des br lures Une formation reli e l usage des processus et de l quipement est essentielle pour pr venir les accidents Par cons quent 1 Portez des lunettes protectrices munies d crans la t raux lorsque vous tes dans l aire de travail m me si vous devez porter un casque de soudeur un cran facial ou des lunettes tanches 2 Portez un cran facial muni de ver
64. zle The shielding gas 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 Damaged kinked or leaking a Inspect and repair or replace as necessary Consult your Authorized ESAB Distributor for Genuine gas hose ESAB replacement parts Damaged or missing nozzle a Inspect and replace as necessary Consult your Authorized ESAB Distributor for Genuine ESAB insulator replacement parts 29 TROUBLE SHOOTING GUIDE GENERAL Problem Probable Cause Erratic wire feed Slipping feed rolls Clogged or worn liner Liner too long or too short Spatter on wire Coil brake incorrectly adjusted Incorrect setting of voltage and or current Unstable arc Defects in wire feed Worn contact tip Impurities on the base metal Poor contact between ground Loose power connection Stick out too long Too fast or too slow wire feed in relation to the arc voltage Too long arc Damaged contact tip Inclination of welding gun too great Faulty power source Incorrect start Poor ground contact Too long stick out short arc f Incorrect polarity Solution a Check that the feed roll size is correct for the wire size being used Increase the drive roll pressure until t

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