If you weld with an ABICOR BINZEL air-cooled MIG gun, like the MB series, you're likely welding with the ultra-lightweight and durable BIKOX® cable. Like all cables, they can become damaged from wear and tear in and around the production plant, and might need a little tender loving care to get them back to working in the optimal manner.
Repairing your cable can be done in 7 simple steps, and we're going walk through them all right here. Note this is limited to our MB 15, 24, and 36 Series cables.
Step 1: Liner Removal
First make sure you identify the damage and begin to cut the cable below the damaged area. Before cutting, make sure the cable liner been removed from the cable.
Step 2: Cut the Jacket
If the BIKOX cable has a second outer jacket, cut the jacket back 6 1/2" (165 mm). Very carefully slitthe cable down another 5 1/2" (140 mm) on both sides of the cable.
Step 3: Separate Trigger Leads
Separate the trigger leads from the cable as shown in the below image. Cut the cable cleanly 7/8" (22 mm) above the wires.
Step 4: Separate the Strands
Separate the rubber and copper strands of the BIKOX cable. After separating them, measre 9/16" (14 mm) down from the end of the inner core and cut the core. Make sure that the cut is straight and burr-free.
Step 5: Threading the Adapter
Thread a BIKOX cable adapter fitting by turning it in a clockwise motion into the inner core. Make sure that the fitting is fully seated. Do not over-tighten the fitting.
Step 6: Re-wrap the Cable
Take the copper strands and evenly spread the strands around the adaptor fitting. Using electrical tape, wrap the tape around the stripped area to holdthe copper strands into place.
Step 7: Clamp and Complete the Repair
Place a clamp into the hand tool, centering the clamp between the two ridges of the fitting. Tighten the nut with a 1/2" ratchet until the clamp is tightened.
Bend the clamping tool back and forth to snap off any excess band. Cover the area with electrical tape, then crimp the appropriate wire connectors onto the trigger leads.
Note that on cables with more than two leads, any two leads can be used provided the same ones are used at both ends of the cable.
Have a question or want to add to the blog post through your own experience? Leave a comment below!
Want to just replace the cable altogther? Contact our Product Specialists here.