Table of Contents
Advertisement
Part IV Maintenance and Repair (cont.)
Section 5. Jump liner (Optional)
A. Removal
Remove nozzle, gas diffuser and neck. Remove used jump
liner from the back end of neck.
B. Service
Inspect for excessive wear and debris on the inside diameter.
Do not dip jump liner in solvents for cleaning. Jump liners
may be periodically blown out with shop air. Replace with
new jump liner when excessive wear or debris produces
poor electrode feed.
C. Installation
Insert jump liner making sure the liner stop is fully seated at
the back of the neck. Take the tapered end of the neck and
insert into end fitting of the gun handle. Install the neck. Trim
and deburr the liner past the nozzle end of the neck.
Install gas diffuser and nozzle.
Section 6. Handle
Upper Handle
Post Fasteners
Lower Handle/
Switch Assembly
Handle Screws
(250A)
A. Removal
Remove screws, post fasteners. Separate and remove handle
halves.
B. Service
Inspect for cracks, deformation of hex areas, debris, holes,
loose or missing threaded inserts, excessive wear, exterior
heat deformation, and warpage. If any of the above condi-
tions exist, replace with new handle or clean all surfaces
with mild detergent and reinstall. Test switch for continuity.
Clean any debris from trigger, if necessary, replace with new
trigger handle assembly.
C. Installation
Position cable in handle half. Pressing lead wire terminal
fully into terminals of switch. Position remaining handle half
so leads are not pinched and movement of the trigger is not
impaired. Post fasteners, and screws; torque to 10 in-lbs
(1.1 Nm)
FIGURE #2
Left Half
Handle
Screws
Right Half
Post Fasteners
(300A & 400A)
Section 7. Cable
A. Inspection
Replace the cable assembly if the following conditions are
evident on the exterior of the cable: cuts and/or abrasions in
cable jacketing exposing copper stranding, abrupt kinking
of cable causing abnormal heating in area of bend, loss of
control circuit function as verified through continuity tests,
slippage of insulating jacket exposing copper stranding, or
crushed cable.
B. Replacement
Using a replacement cable, install the terminated cable end
to the adapter block. It will be necessary to install or confirm
that the flexible strain relief and cap is in place before prepa-
ration (See Figure 3).
FIGURE #3
Cable
Cap
Spring
Primary Trigger Leads
& Spare Leads
Screw
Adapter Block
Strain Relief
(250A)
Torque the end fitting into the adapter block to 17 ft-lbs (23
Nm). Strip the appropriate control leads 1/4" (6.4 mm) and
crimp to appropriate butt connections of trigger leads. Final-
ize installation.
C. Repair
There is no authorized repair of welding cable due to product
liability. Control leads may be repaired by splicing high
temperature 18 AWG lead wire with nylon coated butt con-
nectors, or spare leads can be used.
Section 8. Liners
A. Removal
Remove nozzle and gas diffuser
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.
B. 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.
Strain Relief
(300A & 400A)
Direct Plug
Liner
Liner Lock
page 4
Advertisement
Table of Contents
