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D-3
Wire Feeder End Repair (Requires 2 S19492-1
Terminals)
a. Remove the cable liner per Removal, Installation,
and Trimming Instructions in this section.
b. Remove the feeder end connector, molded gas
plug (or barbed fitting), cable handle nut, plastic
tailpiece and connector cover (see Figure D.4).
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 inch 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 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 D.1. 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.
MAINTENANCE
FIGURE D.4
MAGNUM® & MAGNUM® PRO CURVE 200 GUNS
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 tube until the copper strands
are butted against the incoming connector shoul-
der. Keeping the copper strands against the shoulder,
pull the connector nut over the copper strands,
engage the incoming connector threads, and tight-
en in place. Refer to Figure D.2.
NOTE: For best results, insert a .175/.197 inch (4.5-
5.0 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, and remove the rod from the core. This proce-
dure ensures the inner core does not kink while
assembling or tightening.
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 Figure D.4.
h. Replace the molded gas plug (or barbed fitting)
and feeder end connector.
i. Install and trim liner per Liner Installation in this
section.
WARNING
ELECTRIC SHOCK CAN KILL.
• Do not touch electrically live parts
such as output terminals or internal
wiring.
D-3
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