Tweco 500SP PowerMaster Automation - Manual (Page 36)

POWERMASTER 400SP, 500SP AUTOMATION
3-12 March 16, 2007
3.11 Installing A New Wire Conduit in
the Pulsemaster PMA512S-3545
1. Be sure the MIG gun cable is arranged in a straight
line, free from twists, when installing or removing
a wire conduit. Remove the old conduit by first
removing the MIG gun nozzle, contact tip, insulator
and gas diffuser. Then loosen Allen screws in the
conductor tube and connector plug and pull the
old wire conduit out of the cable assembly from
the connector plug end.
2. To install a new conduit, first inspect the o-ring
gas seal on the conduit for cuts or damage. Start
from the connector plug end of the assembly and
begin pushing the conduit through the connector
plug, cable assembly and into the gun. If the conduit
should lodge along the way, gently whip or work
the cable assembly to aid forward movement.
When the conduit stop meets the end of the
connector plug and the new raw end extends
through the end of the conductor tube on the
welding gun, tighten the Allen screw in the
connector plug onto the conduit to prevent its
backward movement.
CONDUCTOR TUBE
CONDUIT LINER
CONDUIT LINER
1 1/16"
(27mm)
Art # A-07921
REMOVE
CONSUMABLES
ALLEN SCREW
O-RINGS
ALLEN SCREW
CONNECTOR PLUG
NOTE
When the conduit is fully inserted into the
cable assembly and the conduit stop is
firmly against the Connector Plug, the
“raw end” of the conduit will protrude out
of the open end of the gun conductor
tube. Trim the conduit as shown below.
The trimmed end which seats in the Gas
Diffuser must be filed and reamed smooth
on the inside and outside radii so wire
feed will not be obstructed.
3. Replace Gas Diffuser, Contact Tip, Insulator and
Nozzle.
4. Tighten the Allen screw in the conductor tube.
CAUTION
Do not over tighten the conductor tube
screw as this action will result in the
distortion of the conduit and will lead to
wire feedability problems.