Lincoln Electric IM790 manual GUN and Cable Maintenance, For Magnum 100L GUN

D-2 MAINTENANCE D-2

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 flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow out the cable liner from the gas diffuser end.

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 con- tact tip. To install a new tip, choose the correct size contact 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

diffuser for gas shielded processes. For the Innershield® process, the gasless nozzle should be screwed 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 proper relationship between the gun tube and the cable connector. Replace the gun handle, trigger and dif- fuser. Replace the gas nozzle or gasless nozzle.

CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM

		Contact Tip	Cable Liner	Drive Roll
Components shipped with		KP2039-1B1	KP1937-3	KP665-035
SP-175 Plus		.025” (0.6mm)	.030-.035”	2 Smooth grooves
		S19726-2&-3(Loose)	(0.8-0.9 mm)	Small .023-.025” (Stenciled .025)
		.030” & .035”		Large .030-.035” (Stenciled .030-.035)
K549-1 .035 (0.9mm)		KP2039-3B1	KP1937-3	Use Large groove of KP665-035
Innershield Welding Kit		.035” (0.9mm)	.035 (0.9mm)
K549-4 .045 (1.2mm)		KP2039-4B1	KP1937-1	KP1881-3 Knurled .035-.045
Innershield Welding Kit		.045” (1.2mm)	.045” (1.2mm)
				S24220 Drive Roll	THESE PARTS
					} NOT SOLD
	K663-2 .035 (0.9mm)	KP2078-1B1	KP1959-1	S24219 Idle Roll
	Aluminum Welding Kit* •	.035A (0.9mm)	.035” (0.9mm)		SEPARATELY
KP666-035C				KP1881-2
				2 Knurled grooves for .035” (0.9mm)

•If .030 Solid wire feeding is desired obtain an KP2039-2B1 Contact Tip, an KP1937-2 Cable Liner and an M15448 Drive Roll (Smaller Groove).

*It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failure to do so may result in contaminated welds when welding aluminum.

SP-175 PLUS