Lincoln Electric MAGNUM 450 - Manual (Page 18)

MAINTENANCE
the outer jacket as shown in (Figure D.1). Be care-
ful 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 S19492-2 terminal to each lead.
note: The cable contains four control leads. Any
two control leads can be used, provided the two col-
ors used are the same at both ends. The extra leads
are spares 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 gun tube connector so machined flat is on
the same side of the cable as the red and white con-
trol leads.
Assemble gun tube connector to cable by forcing
the steel tube of the connector into the inside diam-
eter 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 connector threads, and tight-
en in place. Refer to (Figure D.2).
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.
h. Pull the cut-off lead terminals off the trigger assem-
MAGNUM® PRO 250, 350, 450 & 550 AMP
RED WHITE INSULATION ON THE CONTROL WIRES MUST NOT BE CUT OR DAMAGED. OF CABLE JACKET. CORE TUBE MAY RETRACT TRIM CORE TUBE FLUSH WITHIN ± .125 (3.18mm) TO DIMENSION SHOWN, DO NOT SKIN SKIN WHITE AND RED LEADS ONLY .30 (7.6mm) MAXIMUM AFTER TRIMMING. THE BLUE OR THE BLACK LEAD. .16 (4.01mm) SKIN GUN END 1.000 (25.4mm) .875 (22.2mm) COPPER STRANDING 3.50 (88.9mm) 3.25 LEAD LENGTH (4 PLACES) (82.6mm)
RED
WHITE
INSULATION ON THE CONTROL WIRES MUST
NOT BE CUT OR DAMAGED.
OF CABLE JACKET. CORE TUBE MAY RETRACT
TRIM CORE TUBE FLUSH WITHIN ± .125 (3.18mm)
TO DIMENSION SHOWN, DO NOT SKIN
SKIN WHITE AND RED LEADS ONLY
.30 (7.6mm) MAXIMUM AFTER TRIMMING.
THE BLUE OR THE BLACK LEAD.
.16 (4.01mm)
SKIN
GUN END
1.000 (25.4mm)
.875 (22.2mm)
COPPER
STRANDING
3.50 (88.9mm)
3.25
LEAD LENGTH
(4 PLACES)
(82.6mm)
FIGURE D.1
D-2 D-2
CONNECTOR TUBE CABLE LINER MALE CONE ASSEMBLY, 250A - 450A POWER CABLE FEMALE NUT STRAIN RELIEF SPRINGBOOT STRAIN RELIEF HOUSING KNURLED NUT SPRING BOOT RETAINER CABLE COPPER STRANDS
CONNECTOR TUBE
CABLE LINER
MALE CONE ASSEMBLY, 250A - 450A
POWER CABLE FEMALE NUT
STRAIN RELIEF
SPRING BOOT
ST RAIN RELIEF HOUSING
KNURLED NU T
SPRING BOOT RETAINER
CABLE
COPPER STRANDS
FIGURE D.2