Wire Rope Mechanical Connector

Revised 9-25-14

Tools Required.

3 ea hose clamps (slightly larger than cable diameter)

1ea 4” Electric Grinder
2ea 4” X 1/8” Grinding Disk (such as Metabo)
2ea 10” Pry Bars (Flat Head Screw Drivers)
1ea 10# Hammer
1ea Torque Wrench with 1” Drive (Capable of at least 450ft lbs.)
1ea Torque socket (1” drive x 1-1/2”)
1ea Table Vise
1ea 10” Pliers
1/2” x 1/2” key stock or square bar about 4” long
1ea Wire Wedge Tool (Included in kit)
1ea Torque Socket (Included in kit)

Assembly Instructions.

As of 3-5-14 all of our connector kits are to be used one time. We will not
ship extra wedges. We have found some connectors are damaged in the field
during the disassembly process. This would possibly cause a safety issue for
the re-use of the kit. The price will remain the same but we will include the
wedge tool and torque tool.

We suggest watching the enclosed DVD prior to reading these

instructions. These instructions over ride the DVD.
For safety we suggest clearing the rig floor of all personnel before
restringing cable.
As of 3-5-14 all connectors are designed to be used one time.

Please note the DVD mentions a, “Gap” between the connector halves.
There should be no gap once torqued.

1. Inspect old cable for any stretched or broken sections within 1 foot of
the end of the cable. If any damage is observed, then cut cable back
until there is at least 1 foot of undamaged cable.
2. Perform same inspection as outlined in step 1 on the new cable.
3. Put one cable end in vise with a minimum 10” protruding above the
vise jaws. Measurement changed to 10” due to needing more
flexibility of the 1.5” cable in order to cut outer strands.
4. Place 2ea hose clamps over the cable with 1 clamp at the vise and the
second clamp 5-1/2” from the top of the cable end. Tighten both
clamps so the cable cannot unravel.
5. Measure down from the end of the cable 4-1/2” and mark completely
around the cable.
6. Start to separate outer cable bands one at a time and cut off outer
bands at the 4-1/2” mark with a 4” grinder. Do not touch the inner
core of the main cable with the grinding disc.
7. Complete step 6 for all remaining outer bands.
8. Upon completion of step 7, grind a 45º bevel on the outer bands. This
will assist with the assembly of the bottom cable connector and allow
the connector to be driven over the outer bands to keep them from
unraveling.
9. After all outer bands have been removed; clean cable center core
with solvent to remove cable grease, clean again after center core
is separated, then slide the cable connector over the core cable with
the treaded end of the connector toward the end of the cable. Again it
is very important it is to clean all grease from the center core so
that it will hold under stress.
10.Drive the cable connector over the outer bands until a minimum of 1-
1/2” of the core is above the top of the cable connector. This can be
accomplished by using a short pipe that fits loosely over the threads so
as not to damage threads. Mark the center strand of the core cable.
Separate the cores outer bands, clean the outer bands with solvent, and
slide the wedge over the center stand with the small end of the wedge
going over the cable first. The wedge must slide over the center
core easily.
11.Then drive the wedge down with the wedge driving tool until the
wedge stops. Use a 10lb hammer to drive wedge in very tightly!
12.Measure from the top of the bottom cable connector to the top of the
cores outer strands 1-1/8”. Mark this measurement and grind off the
remaining section of cable. Do Not Grind The Center Strand!!
13.Remove Hose Clamps.
14.Remove the cable from the vise and place cable connector into the
vise. Use key stock on the machined surfaces. This will assist when
tightening the cap on to the bottom section.
 15.Put one of the removed hose clamps around the ends of the cable in
the connector to pull the strands back together above the wedge. Once
the strands are together, the clamp can again be removed
16.Screw on the cable connector cap and tighten with the special socket
adaptor and torque wrench until it reaches 300ft lbs.
17.Repeat steps 1-16 for the other end of the connector assembly.

5/8” Connector:
The wedge for this size connector does not have a hole drilled in the
center.
If the 5/8” wire rope has a center core, remove about 6” of center core.

Post use inspection

As of 3-5-14 all connectors are designed to be used one time.

Discard entire kit after one use for safety.

Please feel free to contact me if you have any questions.

We appreciate your business!

Bobby Craigue
Machine Shop
Gulf Copper & Manufacturing Corp
5700 Procter St. Ext., Port Arthur, TX 77642
Cell 409-466-1644
BCraigue@gulfcopper.com