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D-3
j.
Install gun tube per section entitled "Gun Tube
and Nozzles".
k. Install and trim liner per installation instructions.
Wire Feeder End Repair (Requires 2 No. S19492-1
Terminals)
a. Remove the cable liner per the Maintenance
Section.
b. Remove the feeder end connector, molded gas
plug (or barbed fitting), cable handle nut, plastic
tailpiece, and connector cover (See Figure 6).
NOTE: In order to remove the cable handle nut,
the tail of the connector cover must be depressed
and the cable handle nut rotated 1/4 turn counter-
clockwise as viewed from the feeder end.
c. Remove incoming connector from cable by
unscrewing connector nut from incoming connec-
tor. If the cable inner tube is difficult to remove
from the connector assembly, carefully slit it
lengthwise with a knife up to the brass connector.
d. Move the cable boot, cable handle, and strain
relief toward the middle of the cable past the dam-
aged section.
e. Cut off the damaged section of cable and strip off
the outer jacket as shown in Figure 3. Be careful
not to cut the insulation on the control wires while
stripping jacket. Strip the red and white control
leads 1/4" (6.4mm) from the end and crimp a new
S19492-1 terminal to each lead. Trim the inner
tube to dimensions shown.
NOTE: The cable contains four control leads. Any
two control leads can be used, provided the two
colors used are the same at both ends. The extra
leads are spares that can be used if one of the
other leads breaks.
f.
Check that the cable boot, cable handle and strain
relief are on the cable. Slip the connector nut over
the copper strands with the threaded end out.
Assemble incoming connector to cable by forcing
the steel tube of the connector into the inside
diameter of the cable inner tube until the copper
strands are butted against the incoming connector
shoulder. Keeping the copper strands against the
shoulder, pull the connector nut over the copper
strands, engage the incoming connector threads,
and tighten in place. Refer to Figure 4.
MAINTENANCE
NOTE: For best results, insert a .250" (6.4mm)
diameter rod through the connector and into core
of cable approximately 11.00" (280mm) when
pushing the connector tube into the cable core
tube. To tighten, hold the connector in place while
turning the nut, then remove the rod from the
core. This procedure assures the inner core does
not kink while assembling or tightening.
Position the plastic strain relief such that the
tapered end is 7.10" (180mm) from the incoming
connector (See Figure 6). Lock into place with
steel housing.
g. Position cable boot and cable handle on cable
and assemble replacement control wire terminals
in place on the cable handle. Insert connector
cover in place. Install tailpiece and fasten to cable
handle with cable handle nut. Refer to Figure 6.
h. Replace the molded gas plug (or barbed fitting)
and feeder end connector.
i.
Install and trim liner per installation instructions.
T A I L P I E C E
F E E D E R E N D
C O N N E C T O R
MAGNUM® 550
7 . 1 0 "
( 1 8 0 m m )
P R E S S H E R E T O
R E M O V E T H E C A B L E
G A S P L U G
H A N D L E N U T
O R
F I T I N G
C O N N E C T O R C O V E R
S T R A I N R E L I E F
C A B L E H A N D L E N U T
I N C O M I N G C O N N E C T O R
Figure 6
D-3
C A B L E
C A B L E B O O T
C A B L E H A N D L E
S T R A I N R E L I E F
H O U S I N G
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