Bernard Liners SPEC L-1.2 - Manual (Page 2)

©2008 Bernard Printed in U.S.A.
Available Liners
Replacement Instructions and Service
Remove Existing Liner
Turn off power. Remove nozzle, tip, gas diffuser and insulator cap
(guns with jump liner remove neck). Lay cable straight. Grasp liner
lock which protrudes from power pin (some direct plugs may require
removal of additional components to access the liner lock) and remove
from cable assembly.
Install Replacement Liner
Insert liner into power pin with cable laying straight. Continue until liner
lock is fully seated into power pin. A twisting motion may be necessary
to seat O-ring (some direct plugs may require installation of additional
components to secure liner).
Making sure cable is straight, trim liner at the nozzle of the neck as
follows:
• DS-1 and D-1 Centerfire™ gas diffusers (used with Centerfire™
series tips) = between 5/8" and 3/4"
• 4235 and 4635 gas diffusers (used with 1500 series tips) = 3/8"
• 4335 and 4435 gas diffusers (used with 7400 or 4200 series
tips) = 1-3/8"
• D118Q gas diffusers (used with Quik Tips™) = 7/8"
• D114Q gas diffusers (used with Quik Tips™) = 3/4"
File the cut end of liner to eliminate burrs and reinstall
insulator cap, gas diffuser, tip and nozzle.
When using Jump Liner: Trim and deburr liner with
1/4” (6.4 mm) extending beyond the gun handle and
reinstall neck.
Service
Inspect for excessive wear and debris on the inside
diameter. Do not dip liner in solvents for cleaning. Liner
may be periodically blown out with shop air. Replace
with new liner when excessive wear or debris produces
poor electrode feed.
" 4 / 1
" 1
0
" 2 / 1
" 4 / 3
" 4 / 1 - 1
" 2 / 1 - 1
Standard Liners
Wire Size Gun Amperage Direct Plug 10' (3.05 m) 15' (4.57 m) 25' (7.62 m)
.023" - .030"
(.6 mm - .8 mm)
150A - 600A All except Tweco 4, L-Tec *N/A 43015 43025
Tweco 4, L-Tec *N/A **43015T **43025T
.035" - .045"
(.9 mm - 1.2 mm)
150A All except Tweco 4, L-Tec 43110 43115 43125
Tweco 4, L-Tec *N/A **43115T **43125T
200A - 600A All except Tweco 4, L-Tec 44110 44115 44125
Tweco 4, L-Tec *N/A **44115T **44125T
.045" - 1/16"
(1.2 mm - 1.6 mm)
200A - 600A All except Tweco 4, L-Tec 44210 44215 44225
Tweco 4, L-Tec *N/A **44215T **44225T
5/64"
(2.0 mm)
200A - 400A All except Tweco 4, L-Tec *N/A 1920356 1920357
Tweco 4, L-Tec *N/A
**†1920296 **†1920298
500A - 600A All except Tweco 4, L-Tec *N/A 44315 44325
Tweco 4, L-Tec *N/A **44315T **44325T
3/32"
(2.4 mm)
500A - 600A All except Tweco 4, L-Tec *N/A 45415 45425
400A Clean-Air All except Tweco 4, L-Tec *N/A
†1920175 †1920177
7/64"
(2.8 mm)
600A
Air-Cooled Only
All except Tweco 4, L-Tec *N/A 45615 45625
1/8"
(3.2 mm)
600A
Air-Cooled Only
All except Tweco 4, L-Tec *N/A 46715 46725
Aluminum / Soft Wire Liners
Wire Size Gun Amperage Direct Plug 10' (3.05 m) 15' (4.57 m) 25' (7.62 m)
.035"
(.9 mm)
150A - 600A
Nylon
All except Tweco 4, L-Tec *N/A 43015X N/A
Tweco 4, L-Tec *N/A **43015XT
200A - 600A
Steel Coil
All except Tweco 4, L-Tec *N/A 1920343 N/A
Tweco 4, L-Tec *N/A **1920346
3/64"
(1.2 mm)
200A - 600A
Nylon
All except Tweco 4, L-Tec *N/A 43115X N/A
Tweco 4, L-Tec *N/A **43115XT
200A - 600A
Steel Coil
All except Tweco 4, L-Tec *N/A 1920344 1920350
Tweco 4, L-Tec *N/A **1920347 N/A
1/16"
(1.6 mm)
200A - 600A
Nylon
All except Tweco 4, L-Tec *N/A 44215X N/A
Tweco 4, L-Tec *N/A **44215XT
200A - 600A
Steel Coil
All except Tweco 4, L-Tec *N/A 1920345 1920351
Tweco 4, L-Tec *N/A **1920348 N/A
*10' (3.05 m) liner not available. Order 15' (4.57 m) liner and trim to size.
†Liners without outer jacket.
**For use only with Bernard guns with Tweco 4 or L-Tec direct plugs manufactured prior to 2008.