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GUN AND CABLE
MAINTENANCE
FOR MAGNUM™ 100L GUN
Gun Cable Cleaning
Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of
CAUTION
Excessive pressure at the start may cause the dirt to form a plug.
Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out.
Contact Tips, Nozzles, and Gun Tubes
1.Dirt can accumulate in the contact tip hole and restrict wire feeding. After each spool of wire is used, remove the contact tip and clean it by push- ing a short piece of wire through the tip repeatedly. Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip.
2.Replace worn contact tips as required. A variable or “hunting” arc is a typical symptom of a worn contact tip. To install a new tip, choose the correct size con- tact tip for the electrode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser.
3.Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required.
4.Be sure the gas nozzle is fully screwed onto the dif-
fuser for gas shielded processes. For the Innershield® process, the gasless nozzle should screw onto the diffuser.
5.To remove gun tube from gun, remove gas nozzle or gasless nozzle and remove diffuser from gun tube. Remove both collars from each end of the gun handle and separate the handle halves. Loosen the locking nut holding the gun tube in place against the gun end cable connector. Unscrew gun tube from cable connector. To install gun tube, screw the locking nut on the gun tube as far as possible. Then screw the gun tube into the cable connector until it bottoms. Then unscrew (no more than one turn) the gun tube until its axis is perpendicular to the flat sides of the cable connec- tor and pointed in the direction of the trigger. Tighten the locking nut so as to maintain the prop- er relationship between the gun tube and the cable connector. Replace the gun handle, trigger and dif- fuser. Replace the gas nozzle or gasless nozzle.
OVERLOAD PROTECTION
Output Overload
The Compact Wire Welders are equipped with a circuit breaker and a thermostat which protects the machine from damage if maximum output is exceeded. The cir- cuit breaker button will extend out when tripped. The circuit breaker must be manually reset.
Thermal Protection
The Compact Wire Welders have a rated output duty cycle as defined in the Technical Specification pages. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a rea- sonable operating temperature. This is an automatic function of the machine and does not require user intervention. The fan continues to run during cooling.
Electronic Wire Drive Motor Protection
The Compact Wire Welders have