Kemppi Flexlite GC Welding Torch - Wire Liner Installation and Replacement Guide

Section 3.3: Installation and Replacement of the Wire Liner

This guide details the procedure for replacing the wire liner in Kemppi Flexlite GC MIG welding torches. It is important to note that this specific instruction does not apply to the Flexlite GC 223GMM welding torch. For guidance on the Flexlite GC 223GMM, please refer to the MinarcMig Evo device manual.

Flexlite GC MIG welding torches are supplied with a wire liner already installed. The wire liner is a consumable component that naturally wears out over time and requires periodic replacement. It is also recommended to replace the liner whenever there is a change in the type or diameter of the electrode wire being used. Both spiral and DL Chili type liners are compatible with these torches.

Important Pre-procedure Note: Before commencing the wire liner replacement, ensure that the electrode wire is removed from the torch assembly.

Required Tools

The following tools are typically required for this procedure:

• Pliers
• Wire cutters
• File
• Screwdriver (for cap removal/installation)

Removing and Inserting the Wire Liner

1. Straighten the welding torch cable to facilitate easier manipulation.

2. Unscrew and remove the cap, sleeve nut, and the inner ring of the wire liner from the torch cable, specifically from the side connected to the wire feeder.

   Diagram Description: A hand is shown unscrewing a cap, a nut, and an inner ring from the end of a welding torch cable.

3. If you are replacing the wire liner with a new one, carefully remove the old liner from the cable. If you intend to reuse the old liner later, handle it with care to prevent any damage during removal.

   Diagram Description: A hand is shown gently pulling an old wire liner out of a welding torch cable.

4. Insert the new wire liner into the torch cable until it reaches and stops at the end of the torch neck. Ensure that the contact tip and its adapter are correctly in place. If they are not, the liner may not seat properly at the neck end. For the GC 323G model specifically, only the contact tip adapter is required at this stage.

   Diagram Description: A hand is shown inserting a new wire liner into the end of a welding torch cable. Arrows indicate the direction of insertion. A close-up shows the torch neck with the contact tip and adapter, highlighting where the liner should stop.

5. Information: To ensure the wire liner is correctly positioned, you may need to temporarily detach the welding torch's contact tip. For more detailed information regarding the contact tip, please consult the "Device Construction" section on page 4 and the "Torch Assembly" section on page 7 of the manual.

Steel Spiral Liner: Cutting the Wire Liner and Fitting the Sleeve

1. Cut off the sleeve nut that is attached to the end of the wire liner.

   Diagram Description: A hand is shown using pliers to cut off a nut attached to the end of a wire liner.

2. Slide the sleeve nut (provided with the new liner), without the cap and inner ring, onto the wire liner. Tighten it lightly as a temporary measure.

   Diagram Description: A sleeve nut is shown being slid onto a wire liner. The cap and inner ring are shown separately.

3. Cut the wire liner so that it is flush with the end of the sleeve nut. Use pliers to trim any excess material from the steel spiral liner.

   Diagram Description: A wire liner is shown being cut flush with the end of a sleeve nut. Pliers are indicated for trimming excess material.

4. Remove the sleeve nut.

   Diagram Description: A hand is shown removing a sleeve nut from the wire liner.

5. For steel spiral liners only: File the end of the wire liner to ensure it is smooth and free of burrs.

   Diagram Description: A file is shown being used to smooth the end of a steel spiral wire liner.

6. Warning: Ensure there are no sharp edges or uneven surfaces left that could potentially damage the electrode wire. First, install the inner ring, followed by the sleeve nut and cap onto the liner. Tighten the sleeve and the nut securely.

   Diagram Description: A diagram illustrates the assembly sequence: an inner ring, a sleeve nut, and a cap are shown being fitted onto the liner. A wrench is depicted tightening the nut.

DL Chili Liner: Cutting the Wire Liner and Fitting the Sleeve

1. Slide the sleeve nut (provided with the liner) along with the inner ring onto the wire liner and tighten it.

   Diagram Description: A sleeve nut and an inner ring are shown being inserted onto a DL Chili wire liner.

2. Cut the wire liner so that it is flush with the end of the sleeve nut. Trim any excess DL Chili liner material with a utility knife.

   Diagram Description: A DL Chili wire liner is shown being cut flush with the end of a sleeve nut. A utility knife is indicated for trimming excess material.

3. First, install the inner ring, then the sleeve nut and cap onto the liner. Tighten the sleeve and the nut securely.

   Diagram Description: Similar to the steel spiral section, this diagram shows the assembly sequence: an inner ring, a sleeve nut, and a cap are fitted onto the liner, with a wrench tightening the nut.