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7. Screw the gas diffuser onto the end of the gun tube
and securely tighten. Be sure the gas diffuser is cor-
rect for the liner being used. (See table and diffuser
stencil.)
8. Tighten the set screw in the side of the gas diffuser
against the cable liner using a 5/64" (2.0 mm) Allen
wrench.
FIGURE D.1
This screw should only be gently tightened.
Overtightening will split or collapse the liner and
cause poor wire feeding.
CAUTION
MAINTENANCE
D-3 D-3
Power MIG® 215XT
LINER REMOVAL AND REPLACE-
MENT
NOTE: Changing the liner for a different wire size
requires replacement of the gas diffuser per
Table D.1 to properly secure the different liner.
LINER REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR
MAGNUM 250L
NOTE: The variation in cable lengths prevents the
interchangeability of liners between guns.
Once a liner has been cut for a particular gun,
it should not be installed in another gun unless
it can meet the liner cutoff length requirement.
Liners are shipped with the jacket of the liner
extended the proper amount.
1. Remove the gas nozzle and nozzle insulator, if
used, to locate the set screw in the gas diffuser
which is used to hold the old liner in place. Loosen
the set screw with a 5/64" (2.0 mm) Allen wrench.
2. Remove the gas diffuser from the gun tube.
3. Lay the gun and cable out straight on a flat surface.
Loosen the set screw located in the brass connec-
tor at the feeder end of the cable and pull the liner
out of the cable.
4. Insert a new untrimmed liner into the connector end
of the cable. Be sure the liner bushing is stencilled
appropriately for the wire size bing used.
5. Fully seat the liner bushing into the connector. tight-
en the set screw on the brass cable connector. the
gas diffuser, at this time, should not be installed
onto the end of the gun tube.
6. With the gas diffuser still removed from the gun
tube, be sure the cable is straight, and then trim the
liner to the length shown in Figure D.1. Remove any
burrs from the end of the liner.
Fixed Adjustable
Nozzle Nozzle
Replacement Size Stencilled Gas Diffuser Gas Diffuser
Diameter of Liner Part on End of Part No. Part No.
Electrodes Used Number Liner Bushing (and Stencil) and Stencil)
.025-.030" Steel KP1934-2 .030 (0.8 mm) KP2026-3 KP2026-2
(0.6-0.8 mm)
.035-.045" Steel KP1934-1 .045 (1.2 mm) KP2026-3 KP2026-2
(0.9-1.2 mm)
3/64" Aluminum KP1955-1 3/64" (1.2 mm) KP2026-3 KP2026-2
(1.2 mm)
TABLE D.1
SET SCREW
SET SCREW
BRASS CABLE CONNECTOR
GAS DIFFUSER
NOZZLE INSULATOR (IF USED)
GAS NOZZLE
1-1/4"
(31.8mm)
LINER
TRIM
LENGTH
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