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MAGNUM PRO
CURVE HDE 250, 350, 450 & 550
Wire Feeder End Repair
(REQUIRES 2 #S19492-1 TERMINALS)
a. Remove the cable liner per Removal, Installation, and
Trimming Instruction.
b. Remove the feeder end connector, molded gas plug (or
barbed fitting), cable handle nut, plastic tailpiece and
connector cover (see Figure 5).
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 counterclock- wise as viewed from the
feeder end.
c. Remove incoming connector from cable by unscrewing
connector nut from incoming connector. 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 and cable handle toward the middle of
the cable past the damaged section.
e. Cut off the damaged section of cable and strip off the outer
jacket as shown in Figure 2. Be careful not to cut the
insulation on the control wires while strip- ping jacket. Strip
the red and white control leads 1/4 inch (6.4 mm) from the
end and crimp a new S19492-1 terminal to each lead.
NOTE: The cable contains three control leads. Any two control
leads can be used, provided the two col- ors used are the
same at both ends. The extra lead is a spare that can be used
if one of the other leads breaks.
Gun Tube
FIGURE 4
Gooseneck Nut
Gun Housing
Trigger Assembly
f. Check that the cable boot and cable handle 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 3.
NOTE: For best results, insert a .219"/.240" (5.6/6.1 mm)
diameter rod through the connector and into core of cable
approximately 5.00" (127 mm) 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 ensures the inner core does not kink
while assembling or tightening.
Position the plastic strain relief such that the tapered end is
4.68 (119 mm) from the incoming connector (see Figure 5).
Lock into place with steel housing. Plastic strain relief may
overhang cable jacket a maximum of .43" (11 mm).
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
5.
h. Replace the molded gas plug (or barbed fitting) and feeder
end connector.
i.
Install and trim liner per Liner Installation Section.
Cable Assembly
D-3
MAINTENANCE
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