Quick Disconnect Plug; Shielding Gas Connection; Remote Control Connection - Lincoln Electric V160-S Service Manual

AA-7
QUICK DISCONNECT PLUG (FOR STICK ELEC-
TRODE CABLE)
A quick disconnect system is used for the welding
cable connections. The stick electrode cable will need
to have a plug attached.
1. Cut off welding cable lug, if present.
2. Remove .75 in. (19mm) of welding cable insulation.
3. Slide rubber boot onto cable end. The boot end
may be trimmed to match the cable diameter. Use
soap or other nonpetroleum-based lubricant to help
slide the boot over the cable, if needed.
WELDING CABLE
.75 in.
4. Cut 45-50% of the copper strands back 1/4" (6
19 mm
mm).
WELDING CABLE
5. Fold copper strands over cut strands and insert into
ferrule.
WELDING CABLE
6. Slide the copper ferrule into the brass plug.
7. Tighten set screw to collapse copper tube. Screw
must apply pressure against welding cable. The top
of the set screw will be well below the surface of the
brass plug after tightening.
COPPER TUBE
8. Slide rubber boot over brass plug. The rubber boot
must be positioned to completely cover all electrical
surfaces after the plug is locked into the receptacle.
INSTALLATION

SHIELDING GAS CONNECTION

Obtain the necessary inert shielding gas. Connect the
cylinder of gas with a pressure regulator and flow
gage. Install a gas hose between the regulator and gas
inlet (located on the rear of the welder). The gas inlet
has a 5/16-18 right hand female thread; CGA #032.
BOOT
•Keep cylinder away from areas where it could
be damaged.
TRIM, IF REQ'D
TO FIT OVER CABLE
•Never allow the torch to touch the cylinder.
•Keep cylinder away from live electrical cir-
cuits.
___________________________________________

REMOTE CONTROL CONNECTION

.25 in.
6 mm
A remote control receptacle is provided on the lower
center case front of the welder for connecting a remote
control to the machine. Refer to the Optional
Accessories section of this manual for available
COPPER FERRULE
remote controls.
The following items can be connected to the 6 pin
socket on the front panel:
.50 in. max
12 mm max.
• Remote control potentiometer (K857) for Stick weld-
ing.
• Remote Foot Amptrol (K870), Hand Amptrol (K963-3).
• Arc Start Switch (K814).
SET SCREW
BRASS PLUG
V160-S & -T
WARNING
CYLINDER could explode
if damaged.
•Keep cylinder upright
chained to a support.
AA-7
and