Gun Cables - Lincoln Electric K479-13 Operator's Manual

FAST MATE GUNS SERIES

GUN CABLES

See Figure D.3, D.4 & D.5
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.
Excessive pressure at the start may cause the dirt to form a plug.
Flex the cable over its entire length and again blow out the cable.
Repeat this procedure until no further dirt comes out.
CABLE REPAIR
The gun features the use of repairable cable connectors. If the
cable ever gets severely damage, 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 on page D-1.
b. Remove the gun tube per Gun Tubes and Nozzles Section of
pages D-1 and D2.
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 stripping 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 three control leads. Any two control
leads can be used, provided the two colors used are
the same at both ends. The extra lead is 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 tighten in place. Refer to Figure 3.
NOTE: For best results, insert a .175"/.197" (4.5-5.0 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.
i. Position the cable boot and strain relief on the cable so it fits
in cable handle cavity and lock the strain relief in place by
pushing the two halves together.
j. Assemble cable in left side of gun handle. Assemble trigger
into the proper handle cavity. Assemble right side of gun
handle and tighten the three screws that hold the handle
together. Refer to Figure 4.
k. Install gun tube per Gun Tubes and Nozzles Section on page
D-1.
l. Install and trim liner per Removal, Installation and Trimming
Instructions on page D-1.
GUN TUBE END CABLE REPAIR K1723 (Requires 2
#S19492-2 terminals)
a. Remove the cable liner per previous instructions.
b. Remove the gun tube per previous instructions.
c. Remove the #6 screws from the gun handle, separate the two
halves, and remove the cable from the handle along with the
trigger assembly for the K575 guns. Before removing the
trigger assembly, carefully note trigger lead wiring as it will
be important to reconnect these properly. For the K1723 also
remove the rocker switch.
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. For K575 models Cut off damaged section of cable and strip
off the outer jacket 2.15 inches back. Be careful not to cut the
insulation on the control wires while stripping jacket. Pull
control leads back and trim the exposed copper and inner
tube back .50 inch. Strip all four control leads .125 inch back
and crimp a new S8053-169 terminal to each lead. Apply
heat shrink tubing or electrical tape to terminals to prevent
electrical contact with other terminals. (See Figure E.2).
g. Cut off damaged section of cable and strip off the outer jacket
1.65 inches back. Be careful not to cut the insulation on the
control wires while stripping jacket. Strip all four control leads
.25 inch back and crimp a new S19492-2 terminal to both the
black lead and the white lead. Remove the leads connected to
the red and blue control leads from the cutoff cable and
solder these leads to the blue and red leads of the newly
trimmed cable. Insulate connections with heat shrink tubing
or tape. (See Figure E.3).
D-3
MAINTENANCE