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D-2
LINER REMOVAL AND REPLACEMENT
CAUTION
NOTE: Changing the liner for a different wire size
requires replacement of the gas diffuser per Table D.1
to properly secure the different liner.
LINER REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR MAGNUM 250L
NOTE: The variation in cable lengths prevents the
interchangeability of liners between guns. Once a liner
has been cut for a particular gun, it should not be
installed in another gun unless it can meet the liner
cutoff length requirement. Liners are shipped with the
jacket of the liner extended the proper amount.
Replacement Size Stencilled Gas Diffuser Gas Diffuser
Diameter of
Liner Part
Electrodes Used
Number
.025-.030" Steel
M16087-2
(0.6-0.8 mm)
.035-.045" Steel
M16087-1
(0.9-1.2 mm)
3/64" Aluminum
M17714-1
(1.2 mm)
1. Remove the gas nozzle and nozzle insulator, if
used, to locate the set screw in the gas diffuser
which is used to hold the old liner in place. Loosen
the set screw with a 5/64" (2.0 mm) Allen wrench.
2. Remove the gas diffuser from the gun tube.
3. Lay the gun and cable out straight on a flat surface.
Loosen the set screw located in the brass connec-
tor at the feeder end of the cable and pull the liner
out of the cable.
4. Insert a new untrimmed liner into the connector
end of the cable. Be sure the liner bushing is sten-
cilled appropriately for the wire size bing used.
5. Fully seat the liner bushing into the connector.
tighten the set screw on the brass cable connector.
the gas diffuser, at this time, should not be
installed onto the end of the gun tube.
6. With the gas diffusor still removed from the gun
tube, be sure the cable is straight, and then trim
the liner to the length shown in Figure D.1.
Remove any burrs from the end of the liner.
MAINTENANCE
TABLE D.1
Fixed
Nozzle
on End of
Part No.
Liner Bushing (and Stencil) (and Stencil)
.030 (0.8 mm)
S19418-3
.045 (1.2 mm)
S19418-3
3/64" (1.2 mm)
S19418-3
PM 255
7. Screw the gas diffuser onto the end of the gun tube
and securely tighten. Be sure the gas diffuser is
correct for the liner being used. (See table and dif-
fuser stencil.)
8. Tighten the set screw in the side of the gas diffuser
against the cable liner using a 5/64" (2.0 mm) Allen
wrench.
CAUTION
This screw should only be gently tightened.
Overtightening will split or collapse the liner and
cause poor wire feeding.
SET SCREW
BRASS CABLE CONNECTOR
Adjustable
Nozzle
Part No.
S19418-2
S19418-1
S19418-1
GUN HANDLE
DISASSEMBLY
The internal parts of the gun handle may be inspected
or serviced if necessary.
The gun handle consists of two halves that are held
together with a collar on each end. To open up the
handle, turn the collars approximately 60 degrees
counterclockwise (the same direction as removing a
right hand thread) until the collar reaches a stop. Then
pull the collar off the gun handle. If the collars are diffi-
cult to turn, position the gun handle against a corner,
place a screwdriver against the tab on the collar and
give the screwdriver a sharp blow to turn the collar
past an internal locking rib.
D-2
FIG D.1
1-1/4"
(31.8mm)
LINER
TRIM
LENGTH
SET SCREW
GAS DIFFUSER
NOZZLE INSULATOR (IF USED)
GAS NOZZLE
Counterclockwise
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