Lincoln Electric IM615 K1614-2,-3 MAGNUM 250 NR GUN & CABLE - Manual (Page 15)

D-1 MAINTENANCE D-1
REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR MAGNUM LINERS
NOTE: The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been cut
for a particular gun, it should not be installed in anoth-
er gun, unless it can meet the liner cut off length
requirement. Liners are shipped with the jacket of the
liner extended the proper amount.
a. Remove the nozzle insulator.
b. Remove the gas less diffuser from gun.
c. Lay gun and cable out straight on a flat surface.
For all K466 except K466-3 and K466-4 Connections:
Loosen set screw located in the brass cable con-
nector at the wire feeder end of the cable using the
same 5/64 (2.0 mm) Allen wrench. Pull liner out of
cable. (REFER TO FIGURE 1 IN INSTALLATION
FOR EACH)
For K466-3 and K466-4 CONNECTIONS:
Remove the connector cap with the wrench provid-
ed. Pull liner out of cable. If the liner is going to be
replaced with a different size liner, loosen set screw
on the connector cap and remove piece of liner
material.
d. For installation and trimming instructions for
Magnum liners see “LINER INSTALLATION” in
INSTALLATION section.
GUN TUBES AND NOZZLES
a. Replace worn contact tips as required.
b. To remove gun tube from gun, loosen socket-head
clamping screw in handle with 3/16” (4.8 mm) Allen
wrench. Remove nozzle insulator and gas less dif-
fuser.
Pull gun tube out from gun handle. To reinstall,
insert the gun tube, push in as far as possible and
retighten screws.
GUN CABLES
CABLE CLEANING
Clean cable liner after using approximately 300
pounds (136 kg) of electrode. Remove the cable from
the wire feeder and lay it out straight on the floor.
Remove the contact tip from the gun. Using an air
hose and only partial pressure, gently blow out the
cable liner from the diffuser end.
Excessive pressure at the start may cause the dirt
to form a plug.
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Flex the cable over its entire length and again blow out
the cable. Repeat this procedure until no further dirt
comes out.
CABLE REPAIR
The Magnum® 250 NR guns feature the use of
repairable cable connectors. If the cable ever gets
severely damaged. it may be cut shorter and repaired
by the user. Repair cables as follows:
GUN TUBE END REPAIR (Requires 2 S19492-2
Terminals)
a. Remove the cable liner per Removal, Installation
and Trimming Instructions.
b. Remove the gun tube per Gun Tubes and Nozzles
Section.
c. Remove three #6 screws from the gun handle, sep-
arate the two halves, and remove the cable from
the handle along with the trigger assembly.
d. Remove gun tube connector from cable by
unscrewing connector nut from gun tube connec-
tor. If the cable inner tube is difficult to remove from
the connector assembly, carefully slit it lengthwise
with a knife up to the brass connector.
e. Uncouple the strain relief by pushing its outer
housing toward the middle of the cable. Move the
strain relief and the cable boot toward the middle of
the cable, past the damaged section.
f. Cut off the damaged section of cable and strip off
the outer jacket as shown in Figure 2. Be careful
not to cut the insulation on the control wires while
stripping jacket. Strip the red and white control
leads 1/4 inch (6.4 mm) from the end and crimp a
new S19492-2 terminal to each lead.
MAGNUM® 250 NR
CAUTION