D-1
MAINTENANCE
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MAGNUM® PRO 350, 450 AND 550 DUAL PROCEDURE & DUAL SCHEDULE
REMOVAL, INSTALLATION AND
TRIMMING INSTRUCTIONS FOR
MAGNUM
®
LINERS
NOTE:
The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been cut
for a particular gun, it should not be installed in anoth-
er gun, unless it can meet the liner cut off length
requirement. Liners used to feed steel wire are
shipped with the jacket of the liner extended the prop-
er amount.
a. Remove the gas nozzle and nozzle insulator.
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 con-
nector at the wire feeder end of the cable using the
same 5/64 (2.0 mm) Allen wrench. Pull liner out of
cable. (REFER TO Figure B.1 IN INSTALLATION
FOR EACH)
<OR>
For K466-3 and K466-4 CONNECTIONS:
Remove the connector cap with the wrench provid-
ed. 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
Magnum
®
liners see “LINER INSTALLATION” in
the 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” (4.8 mm) Allen
wrench. Remove gas nozzle and nozzle insulator.
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.
Excessive pressure at the start may cause the dirt
to form a plug.
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Flex the cable over its entire length and again blow
out the cable. Repeat this procedure until no further
dirt comes out.
CABLE REPAIR
CABLE REPAIR FOR MAGNUM
®
PRO DP
and DS MODELS
MAGNUM
®
PRO DP and DS cables feature the use
of repairable cable connectors. If the cable ever gets
severely damaged, it may be cut shorter and repaired
by the user.
GUN TUBE END CABLE REPAIR FOR DP
AND DS MODELS
(Requires 4 #S8053-169
Terminals for DS or 2 #S19492-2 terminals for DP)
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, sepa-
rate the two halves, and remove the cable from the
handle along with the trigger assembly for the DS
guns. Before removing the trigger assembly, care-
fully note trigger lead wiring as it will be important
to reconnect these properly. For the DP also
remove the rocker switch.
CAUTION