Product Guide: Clean Air E™ – Changing the Y Connector

Keep your Bernard® Clean Air E™ Fume Extraction MIG Gun performing at its best by replacing the Y-connector when needed. This quick guide walks you through the simple steps to ensure a secure fit and maintain optimal fume extraction efficiency. Watch now to keep your system running smoothly and your workspace cleaner.

Instructions

Separate connector halves.

Push rear hose swivel forward to slide it out of the cavity. Slide the hose assembly forward and remove the remaining Y Connector half.

Place the new rubber boot into the new Y Connector set.

Position the cable assembly in the Y Connector channel, ensuring proper alignment with rubber boot.

Pull the hose assembly back into the swivel cavity and ensure it is taut (no slack).

Confirm the hose and cable assemblies are properly seated and secure.

Align the Y Connector halves and reinstall screws.

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Product Guide: Clean Air E™ – Connecting to a Fume Extraction Unit

Properly connecting your Bernard® Clean Air E™ Fume Extraction MIG Gun to a fume extraction unit is key to maximizing performance and maintaining a cleaner work environment. In this video, we walk you through the simple steps to ensure a secure and efficient connection, helping you get the most out of your fume extraction system.

Instructions

Thread hose onto the fume port of the fume extraction unit and tighten securely.

Attach the opposite end of hose to the 1-3/4” port on the Y Connector, ensuring all connections are tight.

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Product Guide: Clean Air E™ – Replacing the Neck and Trigger

Maintaining your Bernard® Clean Air E™ Fume Extraction MIG Gun is quick and easy! Watch as we walk through the simple process of replacing the neck and trigger, ensuring your gun stays in top working condition. Designed for durability and performance, the Clean Air E™ makes maintenance hassle-free so you can focus on the job.

Instructions

Changing the Inner Neck Assembly

Remove the Shroud and Consumables: Unthread the knurled smoke shroud from the smoke tube assembly and remove the front end consumables.

Separate the Handle Halves: Remove the socket head cap screws (7/64″ hex) and keep them for later.

Remove the Smoke Tube Assembly: Slide it forward and off the inner neck assembly.

Loosen the Lock Nut: Place the neck in a vise (don’t over-tighten). Use 3/4” wrenches to loosen the lock nut on the neck.

Unthread the Neck: Once the lock nut is loose, unthread the neck from the end fitting by hand.

Replace the Neck: Add the lock nut to the new neck, thread it into the cable end fitting, and tighten by hand. Secure the neck in a vise and torque the lock nut/end fitting connection to 30 ft-lbs (40.7 Nm).

Reassemble the Handle: Position the neck and smoke tube assembly into the handle. Ensure the trigger components and vacuum slide are correctly placed, with trigger wires routed properly.

Secure the Handle Halves: Use the handle screws and torque them to 10 in-lbs (1.1 Nm).

Changing the Switch – Button Model

Separate the Handle Halves: Remove the screws completely.

Remove the Terminals: Use needle nose pliers to remove the terminals from the trigger switch.

Attach the New Trigger: Secure the terminals to the new trigger, position it in the right handle half, and ensure the wires are routed correctly.

Reassemble the Handle: Reinstall the second handle half, tighten all screws, and torque to 10 in-lbs (1.1 Nm).

Changing the Switch – Lever Model

Separate the Handle Halves: Remove the screws completely.

Remove the Switch Assembly: Use needle nose pliers to disconnect the terminals and carefully remove the lever.

Attach the New Switch: Secure the terminals to the new switch assembly, install it into the mounting cavity, and reinstall the lever.

Reassemble the Handle: Ensure all components are correctly positioned, then reinstall the second handle half, starting with the lever screw. Tighten all screws and torque to 10 in-lbs (1.1 Nm).

Changing the Vacuum Slide Switch

Separate the Handle Halves: Remove the screws completely.

Remove the Slide Switch: Carefully take it out of the channel in the handle half.

Install the New Slide Switch: Position it in the channel, ensuring it moves freely.

Reassemble the Handle: Keep the slide switch properly aligned and reinstall the screws, tightening them evenly and torquing to 10 in-lbs (1.1 Nm)

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Product Guide: Clean Air E™ – Changing Shrouds to Maximize Fume Extraction

We designed the Bernard® Clean Air E™ Fume Extraction Gun with interchangeable shrouds, giving you the flexibility to optimize fume capture for your specific welding application. Choose from a longer shroud for maximum fume extraction, a medium shroud for the perfect balance of weld access and fume capture, or a short shroud for maximum weld access while still extracting fumes.

Instructions

Simply unthread the fume shroud from the neck tube and rethread your desired shroud based on your nozzle size and welding application.

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Product Guide: Clean Air E™ – Changing Out the Hose

Need to replace the hose on your Clean Air E™ fume extraction gun? We’ve got you covered! Follow these simple steps to swap it out quickly and keep your fume extraction system performing at its best. Watch now and ensure clean, efficient welding every time.

Instructions

1. If replacing the vacuum hose assembly, remove all screws to separate the handle halves and remove the front hose swivel from its cavity.

2. Remove screw covers and two screws securing the rear handle, then slide the rear handle and strain relief backward to remove them.

3. Remove screws on the Y Connector and open to expose the cable assembly and rear hose swivel.

4. Pull the vacuum hose assembly backward to remove it from the cable assembly.

5. Slide the new vacuum hose assembly forward over the cable assembly until the front hose swivel rests in its cavity. Align the handle halves and reinstall all screws to retain hose assembly within handle.

6. With the cable straight, pull the hose and position it into the Y Connector, ensuring no slack. Tighten Y Connector screws, correctly positioning rubber boot within the Y Connector.

7. Slide rear handle and strain relief forward onto the cable assembly and secure with screws and screw covers.

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