Lincoln Electric K497, K2950 manual Maintenance, Liner Removal and Replacement, To form a plug

D-1	MAINTENANCE		D-1
LINER REMOVAL AND REPLACEMENT		CAUTION
NOTICE: The variation in cable lengths prevents the inter-		Excessive pressure at the start may cause the dirt
changeability of liners. Once a liner has been cut for a partic-
		to form a plug.
ular gun, it should not be installed in another gun, unless it
can meet the liner cut off length requirement. Liners are		Flex the cable over its entire length and again blow
shipped with the jacket of the liner extended the proper
		out the cable. Repeat this procedure until no further
amount.
		dirt comes out.
Removal, Installation and Trimming Instruction for K497		Cable Cleaning
& K2950 (with K466 Connector Kit installed)		The MAGNUM® & MAGNUM® PRO CURVE 200 gun
a. For gun and cables using a K466-1, K466-2 or K466-5		features the use of repairable cable connectors. If the
		cable ever gets severely damaged, it may be cut
connector kit, locate and loosen two set screws which are
		shorter and repaired by the user. Repair cables as fol-
used to hold the old liner in place with a 5/64 inch (2.0
		lows:
mm) Allen wrench (provided with the connector kit). One
set screw is located in the connector at the wire feeder		Gun Tube End Repair (Requires 2 S19492-2
end. The gas nozzle and nozzle insulator must be		Terminals)
removed to gain access to the second set screw which is
		a. Remove the cable liner per Removal, Installation
located in the gas diffuser. Note: Set screw is not
found on K2950.		and Trimming Instructions on page D-1.
b. For gun and cables using a K466-3 or K466-4 connector		b. Remove the gun tube per Gun Tubes and Nozzles
		in this section.
kit, remove the connector cap with the wrench provided in
the kit. Loosen the set screw located the gas diffuser with		c. Remove three #6 screws from the gun handle, sep-
the Allen wrench provided in the connector kit. The gas		arate the two halves, and remove the cable from
nozzle and nozzle insulator must be removed to gain		the handle along with the trigger assembly.
access to the diffuser.		d. Remove gun tube connector from cable by
c. Remove the gas diffuser from the gun tube.		unscrewing connector nut from gun tube connector.
		If the cable inner tube is difficult to remove from the
d. Lay the gun cable on a flat surface with the cable straight		connector assembly, carefully slit it lengthwise with
and pull the liner out of the cable from the cable connec-		a knife up to the brass connector.
tor end.		e. Uncouple the strain relief by pushing its outer
e. Install the new liner per Liner Installation Section.		housing toward the middle of the cable. Move the
GUN TUbES AND NOzzLES		strain relief and the cable boot toward the middle of
		the cable, past the damaged section.
a. Replace worn contact tips as required.		f. Cut off the damaged section of cable and strip off
		the outer jacket as shown in Figure D.1. Be careful
b. Remove spatter from inside of gas nozzle and from tip
		not to cut the insulation on the control wires while
after each 10 minutes of arc time or as required.
		stripping jacket. Strip the red and white control
c. To remove gun tube from gun, loosen socket-head		leads 1/4 inch (6.4mm) from the end and crimp a
clamping screw in handle with 3/16 inch (4.8 mm) Allen		new S19492-2 terminal to each lead.

wrench. Remove gas nozzle and nozzle insulator and

also loosen small set screw in the diffuser using 5/64 inch (2.0 mm) Allen wrench. Set Screw not found on K2950.

NOTE: Small set screw in the diffuser must be loosened, otherwise liner could be damaged when attempting to remove gun tube.

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 gas diffuser end.

FIGURE D.1

MAGNUM® & MAGNUM® PRO CURVE 200 GUNS