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D-1
LINER REMOVAL AND REPLACEMENT
NOTICE: The variation in cable lengths prevents the inter-
changeability of liners. Once a liner has been cut for a partic-
ular 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.
Removal, Installation and Trimming Instruction for K497
& K2950 (with K466 Connector Kit installed)
a. For gun and cables using a K466-1, K466-2 or K466-5
connector kit, locate and loosen two set screws which are
used to hold the old liner in place with a 5/64 inch (2.0
mm) Allen wrench (provided with the connector kit). One
set screw is located in the connector at the wire feeder
end. The gas nozzle and nozzle insulator must be
removed to gain access to the second set screw which is
located in the gas diffuser. Note: Set screw is not
found on K2950.
b. For gun and cables using a K466-3 or K466-4 connector
kit, remove the connector cap with the wrench provided in
the kit. Loosen the set screw located the gas diffuser with
the Allen wrench provided in the connector kit. The gas
nozzle and nozzle insulator must be removed to gain
access to the diffuser.
c. Remove the gas diffuser from the gun tube.
d. Lay the gun cable on a flat surface with the cable straight
and pull the liner out of the cable from the cable connec-
tor end.
e. Install the new liner per Liner 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. To remove gun tube from gun, loosen socket-head
clamping screw in handle with 3/16 inch (4.8 mm) Allen
wrench. Remove gas nozzle and nozzle insulator and
also loosen small set screw in the diffuser using 5/64 inch
(2.0 mm) Allen wrench. Set Screw not found on K2950.
NOTE: Small set screw in the diffuser must be loosened,
otherwise liner could be damaged when attempting to
remove gun tube.
Pull gun tube out from gun handle. To reinstall, insert the
gun tube, push in as far as possible and retighten screws.
GUN CAbLES
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.
MAINTENANCE
MAGNUM® & MAGNUM® PRO CURVE 200 GUNS
CAUTION
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 Cleaning
The MAGNUM® & MAGNUM® PRO CURVE 200 gun
features 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 fol-
lows:
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
in this section.
c. Remove three #6 screws from the gun handle, sep-
arate 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 D.1. Be careful
not to cut the insulation on the control wires while
stripping jacket. Strip the red and white control
leads 1/4 inch (6.4mm) from the end and crimp a
new S19492-2 terminal to each lead.
FIGURE D.1
D-1
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