Replacing DL Chili wire liner

Tools needed:

Removing and inserting wire liner

This same method applies to both Euro connector (GX series 3 and 5) and Kemppi connector (GX series 8) welding guns, but the visual details may vary. The method is the same also for both gas- and water-cooled welding guns.

1.

Straighten the welding gun cable pack.

2.

At the wire feeder end of the cable, remove the wire liner's sleeve nut and retainer cone.

The GX series 8 welding gun has a long sleeve nut and the series 8 GMN, WS and 608W models include also an additional sealing ring (*). Remove that also.

3.

Remove the old wire liner from the cable hose.

If you still plan to use the same wire liner later, make sure not to damage the wire liner at this stage.

4.

Feed the new wire liner into the cable hose until it stops at the gun neck end.

The standard DL Chili wire liner includes a short metal spiral section at its front end. This metal spiral end goes in first. The DL Chili wire liner for a multi-neck welding gun does not include the metal spiral section.

To ensure that the wire liner is in the correct position, temporarily remove the welding gun contact tip. For more information on the contact tip, refer to About equipment and Assembling gun. In case of a multi-neck welding gun, the wire liner does not go into the neck. With a multi-neck welding gun, the neck is to be removed (refer to Replacing wire liner for multi-neck).

For finalizing the wire liner installation, refer to (depending on your welding gun model):

Installing sleeve assembly and cutting wire liner (Euro connector: series 3 and series 5 welding guns) or

Installing sleeve assembly and cutting wire liner (Kemppi connector: series 8 welding guns).

Installing sleeve assembly and cutting wire liner (Euro connector: series 3 and series 5 welding guns)

The method is the same for both gas- and water-cooled welding guns.

1.

Insert the sleeve nut next to the wire liner for measure.

2.

Using carpet knife, cut the wire liner flush with groove in the sleeve nut end.

3.

Insert the retainer cone onto the wire liner and push in place.

4.

Place the sleeve nut on the wire liner and secure it in place. Tighten to 12 Nm torque.

Installing sleeve assembly and cutting wire liner (Kemppi connector: series 8 welding guns)

The method is the same for both gas- and water-cooled welding guns, except for the additional sealing ring with the below-mentioned models.

1.

Temporarily remove the end cap from the long sleeve nut.

2.

Insert the retainer cone and sleeve nut (without end cap) on the wire liner and secure them in place. Tighten to 12 Nm torque.

All series 8 Flexlite GX models (Kemppi connector) include a longer wire liner sleeve. The series 8 GMN, WS and 608W models include also an additional sealing ring (*):

3.

Cut the wire liner flush with the sleeve nut end. Use a carpet knife for cutting.

4.

Install the end cap. Tighten to 1 Nm torque.