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MAGNUM PRO
CURVE HDE FCAW HYPERFILL
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 tting), 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 dif cult 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 stripping
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 colors used
are the same at both ends. The extra lead is a spare that
can be used if one of the other leads breaks.
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 tting) and
feeder end connector.
i.
Install and trim liner per Liner Installation Section.
FIGURE 4
Trigger Assembly
D-4
MAINTENANCE
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