Lincoln Electric K498, Manual

Page: 15 / 22

D-5
MAINTENANCE
D-5
and collar nut are on the cable. Slip the connector
nut over the copper strands with the threaded end
out. Orient the connector assembly so the red and
white control leads will have the straightest possi-
ble routings to the sockets on the back side of the
connector. Assemble the incoming connector to the
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 solder. Keeping the copper strands
against the shoulder, pull the connector nut over
the copper strands, engage the incoming connec-
tor threads, and tighten in place. Refer to Figure 3.
NOTE: For best results, insert a .175”/.197” (4.5-
5.0 mm) diameter rod through the connec-
tor and into core of cable approximately
5.00” (127 mm) when pushing the connec-
tor 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 assures the inner core does
not kink while assembling or tightening.
i. Solder the terminal lead assemblies from step (f) to
the control leads stripped in step (g). Insulate both
soldered connections using either heat shrink tub-
ing or electrical tape.
j. Fully insert the two control lead pins into the sock-
ets on the incoming connector. Tape the leads in
place in the necked down area of the connector.
Keeping the leads as close to the connector and
nut as possible, tape the insulated, soldered con-
nections and the spare lead to the cable in the area
between the cable jacket and connector nut. This
must be done neatly and kept as low as possible or
the cable handle will not slide over this area.
k. Install the cable clamp on the cable jacket within
1/8” (3.2 mm) from the end of the jacket and tight-
en.
l. Slide the collar nut and cable handle over the con-
nection and into place. Anchor the cable handle
with the screw removed in step (c). Slide the boot
and boot nut into place and tighten.
NOTE: If the cable handle becomes difficult to slide
over connection, try rotating it.
m. Install and trim liner per Removal, Installation and
Trimming Instructions on page D-1.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
MAGNUM 200FM
WARNING