Thermal Arc POWERMASTER 400SP, Service Manual

Page: 33 / 110

POWERMASTER 400SP, 500SP AUTOMATION
Octobe r 30, 2008 3-11
3.08 Installing A New Wire Conduit
1. Be su r e the MIG gun cable is a rr anged in a st r aight
line, f r ee f r om twists, when installing o r r emoving
a wi r e conduit. Remove the old conduit by fi r st r e-
moving the MIG gun nozzle, contact tip, insulato r
and gas diffuse r . Then loosen Allen sc r ews in the
conducto r tube and connecto r plug and pull the
old wi r e conduit out of the cable assembly f r om
the connecto r plug end.
2. To install a new conduit, fi r st inspect the o- r ing
gas seal on the conduit fo r cuts o r damage. Sta r t
f r om the connecto r plug end of the assembly and
begin pushing the conduit th r ough the connecto r
plug, cable assembly and into the gun. If the con-
duit should lodge along the way, gently whip o
r
wo r k the cable assembly to aid fo r wa r d movement.
When the conduit stop meets the end of the con-
necto
r plug and the new r aw end extends th r ough
the end of the conducto r tube on the welding gun,
tighten the Allen sc r ew in the connecto r plug onto
the conduit to p r event its backwa r d movement.
NOTE
When the conduit is fully inse r ted into the
cable assembly and the conduit stop is
fi
r mly against the Connecto r Plug, the
“ r aw end” of the conduit will p r ot r ude out
of the open end of the gun conducto r
tube. T r im the conduit as shown below.
The t r immed end which seats in the Gas
Diffuse r must be filed and r eamed smooth
on the inside and outside r adii so wi r e
feed will not be obst r ucted.
3. Replace Gas Diffuse r , Contact Tip, Insulato r and
Nozzle.
4. Tighten the Allen sc r ew in the conducto r tube.
CAUTION
Do not ove r tighten the conducto r tube
sc r ew as this action will r esult in the
disto r tion of the conduit and will lead to
wi r e feedability p r oblems.
CONDUCTOR TUBE
CONDUIT LINER
CONDUIT LINER
1 1/16"
(27mm)
Art # A-07921
REMOVE
CON
S UMABLE S
ALLEN S CREW
O-RING S
ALLEN S CREW
CONNECTOR PLUG