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®
MAGNUM PRO
CURVE HDE 250, 350, 450 & 550
MAINTENANCE
REMOVAL, INSTALLATION AND TRIMMING GUN
LINERS
NOTICE: The variation in cable lengths prevents the interchange-
ability of liners. Once a liner has been cut for a particular gun, it
should not be installed in another gun, unless it can meet the liner
cut off length requirement. Liners are shipped with the jacket of
the liner extended the proper amount.
a. Remove the gas nozzle and nozzle insulator. Loosen the set
screw located in the side of the diffuser with 5/64" (2.0 mm)
Allen wrench (provided with the gun or connector kit).
b. Remove the gas diffuser from gun.
c. Lay gun and cable out straight on a flat surface. For all K466
except K466-3 and K466-4 Connections:
Loosen set screw located in the brass cable connector at the
wire feeder end of the cable using the same 5/64" (2.0 mm)
Allen wrench. Pull liner out of cable.
<OR>
For K466-3 CONNECTIONS:
Remove the connector cap with the wrench provided. Pull
liner out of cable. If the liner is going to be replaced with a
different size liner, loosen set screw on the connector cap
and remove piece of liner material.
d. For installation and trimming instructions for liners see "LINER
INSTALLATION" in INSTALLATION section.
GUN TUBES AND NOZZLES
a) Replace worn contact tips as required.
b) Remove spatter from inside of gas nozzle and from tip after
each 10 minutes of arc time or as required.
c) Unscrew the guntube using the gooseneck nut.
Pull gun tube out from gun handle. To reinstall, insert the gun
tube, push in as far as possible, and re-tighten the gooseneck
nut.
GUN CABLES
Cable Cleaning
Clean cable liner after using approximately 300 (136 kg) pounds 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.
Flex the cable over its entire length and again blow out the cable.
Repeat this procedure until no further dirt comes out.
CAUTION
Excessive pressure at the start may cause the dirt to form a
plug.
CABLE REPAIR
®
The MAGNUM
PRO CURVE HDE 250-350-450 & 550 guns feature
the use of repairable cable connectors. If the cable ever gets
severely damaged. it may be cut shorter and repaired by the user.
Repair cables as follows:
Gun Tube End Repair
(Requires 2 S19492-2 Terminals)
a. Remove the cable liner per Removal, Installation and
Trimming Instructions.
b. Remove the gun tube per Gun Tubes and Nozzles Section.
c. Remove three #6 screws from the gun handle, separate the
two halves, and remove the cable from the handle along with
the trigger assembly.
d. Remove gun tube connector from cable by unscrewing
connector nut from gun tube connector. If the cable inner
tube is difficult to remove from the connector assembly,
carefully slit it lengthwise with a knife up to the brass
connector.
e. Uncouple the strain relief by pushing its outer housing toward
the middle of the cable. Move the strain relief and the cable
boot toward the middle of the cable, past the damaged
section.
f. Cut off the damaged section of cable and strip off the outer
jacket as shown in Figure 2. Be careful not to cut the
insulation on the control wires while strip- ping jacket. Strip
the red and white control leads 1/4 inch (6.4 mm) from the
end and crimp a new S19492-2 terminal to each lead.
NOTE: The cable contains control leads. Any two control leads can
be used, provided the two colors used are the same at both
ends. The extra leads are a spare that can be used if one of
the other leads breaks.
g. Check that the cable boot and both halves of the strain relief
are on the cable. Slip the connector nut over the copper
strands with the thread end out. Orient gun tube connector so
machined flat is on the same side of the cable as the red and
white control leads.
Assemble gun tube connector to cable by forcing the steel
tube of the connector into the inside diameter of the cable
inner tube until the copper strands are butted against the gun
tube connector shoulder. Keeping the copper strands against
the shoulder, pull the connector nut over the copper strands,
engage the gun tube connector threads, and tight- en in
place. Refer to Figure 3.
NOTE: For best results, insert a .219"/.240" (5.6/6.1 mm)
diameter rod through the connector and into core of cable
approximately 5.00 (127 mm) when pushing the connector
tube into the cable core tube. To tighten, hold the connector
in place while turning the nut, then remove the rod from the
core. This procedure ensures the inner core does not kink
while assembling or tightening.
h. Pull the cut-off lead terminals off the trigger assembly and
connect the replacement control lead terminals.
D-1
MAINTENANCE
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