Lincoln Electric IM646-A manual Liner Installation and Trimming Instructions

A-5 INSTALLATION A-5

LINER INSTALLATION AND TRIMMING INSTRUCTIONS

Installation of (KP44 and KP44N liner series)

a.Lay the gun and cable straight on a flat surface.

b.Make sure that the set screw in the connector end is backed out so as not to damage liner or liner bushing. Remove and save the gas nozzle, nozzle insulator, and gas diffuser from the end of the gun tube assembly.

c.Insert a new untrimmed liner into the connector end of the cable. Be sure the liner bushing is sten- ciled appropriately for the wire size being used.

NOTE: For KP44N and KP45N liner series. Before fully seating the liner bushing, it will be nec- essary to trim the linerʼs inner tube flush with the liner bushing using a sharp blade. After trimming, remove any burrs from inner tube and insure that the opening is fully open.

d.Before installing the gas diffuser, fully seat the liner bushing in the connector and:

For all K466 connector kits except K466-3 and K466-4, tighten the set screw in the cable connec- tor.

or

For K466-3 and K466-4, screw in the connector cap provided in the kit until it seats on the face of the bushing. Then insert the appropriate piece of liner material into the connector cap and tighten the set screw. Three pieces of liner material are includ- ed in these connector kits to help guide the elec- trode through the connector cap. The piece with the smallest inner diameter is designed for .045” (1.2 mm) maximum diameter electrode. The next largest diameter is for 1/16” (1.6 mm) maximum diameter electrode. The largest diameter piece of liner material is for 5/64” (2.0 mm) maximum diam- eter electrode.

e.Be sure the cable is straight and then trim the liner to the length shown in Figure B.1 (a gauge is included on the wrench provided with the connec- tion kit for gauging the cut-off length on 300 and 400 amp gun tubes). Remove any burrs from the end of the liner.

f.Screw the gas diffuser onto the end of the gun tube and tighten with the wrench provided.

g.Tighten the set screw in the side of the gas diffuser against the cable liner using the Allen wrench pro- vided.

CAUTION

This screw should only be gently tightened. Overtightening will split or collapse the liner and cause poor wire feeding.

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h. Replace the nozzle insulator and gas nozzle.

INSTALLATION OF KP1958 SERIES LINERS FOR FEEDING ALUMINUM ELECTRODE

1.Lay the gun out straight on a flat surface and remove the gas nozzle.

A.For all K466 except K466-3 and K466-4 connec- tions, back out the set screw in the connector end with a 5/64 (2.0 mm) Allen wrench.

B.For all K466-3 and K466-4 connections: Remove the connector cap.

C.Back out the set screw in the diffuser for guns that have a set screw in the diffuser.

2.Remove the liner and insert a new untrimmed liner into the connector end of the cable. Check that the coils of the spring liner can be seen through the holes in the gas diffuser.

A.For all K466-3 and K466-4 connections: If the liner is going to be replaced with a different size liner, loosen the set screw on the connector cap and replace the liner material with the correct size.

3.Mark the liner 3/16" (5 mm) from the end of the liner guide or connector. Pull the liner partially out and cut off the liner at the mark using a sharp knife.

4.Screw the brass liner nipple onto the liner and fully seat the liner busing into the liner guide or the con- nector.

A.For connector kits, except K466-3 and K466-4, tighten the set screw in the cable connector.

B.For K466-3 and K466-4, screw in the connector cap.

5.For guns with a diffuser set screw, tighten the set screw in the side of the gas diffuser against the cable liner using the Allen wrench provided.

CAUTION

This screw should only be gently tightened. Overtightening will split or collapse the liner and cause poor wire feeding.

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6. Replace the nozzle insulator and gas nozzle.

MAGNUM® 400 DUAL PROCEDURE GUNS