MAINTENANCE |
CABLE REPAIR
The Magnum® 300 FM and Magnum® 400 FM guns feature the use of repairable cable connectors. If the cable ever gets severely damaged, it may be cut short- er and repaired by the user. Repair cables as follows:
Gun Tube End Repair (K478 and K479) (Requires 2
a)Remove the cable liner per “Removal Instructions for Magnum® Liners”.
b)Remove the gun tube per “Gun Tubes and Nozzles“.
c)Remove three #6 screws from the gun handle, sep- arate the two halves, and remove the cable from the handle along with the trigger assembly.
d)Remove the gun tube connector from the cable by unscrewing the connector nut from the gun tube 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.
e)Uncouple the strain relief by pushing its outer hous- ing toward the middle of the cable. Move the strain relief and the cable boot toward the middle of the cable, past the damaged section.
f)Cut off the damaged section of the cable and strip off the outer jacket as shown in Figure E.2. Be care- ful not to cut the insulation on the control wires while stripping the jacket. Strip the red and white control leads 1/4 inch (6.4 mm) from the end and crimp a new
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.
g)Check that the cable boot and both halves of the strain relief are on the cable. Slip the connector nut over the copper strands with the thread end out. Orient the gun tube connector so the machined flat is on the same side of the cable as the red and white control leads. Assemble the gun tube connec- tor to the cable by forcing the steel tube of the con- nector into the inside diameter of the cable inner tube until the copper strands are butted against the gun tube connector shoulder. Keeping the copper strands against the shoulder, pull the connector nut over the copper strands, engage the gun tube con- nector threads, and tighten in place. Refer to Figure E.3.
NOTE: For best results, insert a rod through the connector and into the core of the cable approxi- mately 5.00” (127 mm) when pushing the connector tube into the cable core tube. A .219”/.240”
mm) diameter rod is required for 300 and 400 amp cables. 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.
h)Pull the
j)Position the cable boot and the strain relief on the cable so it fits in the cable handle cavity and lock the strain relief in place by pushing the two halves together.
k)Assemble the cable in the left side of the gun han- dle. Assemble the trigger into the proper handle cavity. Assemble the right side of the gun handle and tighten the three screws that hold the handle together. Refer to Figure E.4.
l)Install the gun tube per “Gun Tubes and Nozzles“.
m)Install and trim the liner per “Liner Installation and Trimming Instructions”.
Wire Feeder End Repair (K478 and K479 FM Models Only)
a)Remove the cable liner per “Removal, Installation and Trimming Instructions for Magnum® Liners”.
b)Loosen the boot nut. Slide the boot nut and boot toward the middle of the cable past the damaged section.
c)Rotate the collar nut until the screw anchoring the cable handle is visible. Remove the screw and save it.
d)Slide the cable handle, collar nut and strain relief housing toward the middle of the cable past the damaged section. On older cables remove and save the cable clamp that was used in place of the strain relief.
NOTE: If sliding the cable handle becomes difficult, try rotating it 180°.
MAGNUM®