G4 Owner’s Manual – 21d – Maintaining Your Mirage – Installing Replacement Cutaway Handle

September 22, 20170

Installing A Replacement Cutaway Handle

The cutaway handle originally delivered with your Mirage had the cable length trimmed specifically for your rig.

The overall length of the cables varies according to the harness and container size.

Mirage Systems, Inc., recommends that a qualified rigger install the replacement cutaway handle for you in accordance with the following instructions:

 

Tools Needed:

  • A ruler
  • A clean soft cloth
  • Spray silicone lubricant*
  • Sharp wire cutters
  • Matches or cigarette lighter

* A dry lubricant, such as powdered graphite, may be used if desired.  Use caution, however, since powdered graphite is messy and the stains can’t be removed from your rig.

 

Clean and lubricate the yellow cables

Before installing the yellow release cables, apply a small amount of spray silicone to a soft cloth and wipe the entire length of both cables.

Be sure to remove any excess lubricant by wiping the cables with a clean, soft cloth.

 

Position end fittings

Before installing the release cables, check to make sure that the end fittings are positioned correctly, and that the housings are “at rest”, without any tension on them.

The base of the end fitting on the long housing should be about even (+/-) with the top of the harness release ring.

 

IMPORTANT!

Make sure that there is no sand or grit on the cables when threading the cables through the release housings.

 

Install cables

Thread both cleaned and lubricated yellow release cables of the breakaway system through their respective housings and mate the hook velcro on the handle with the pile velcro located in the pocket.

The handle should be positioned close to the cable housings so that very little yellow cable is showing between the handle and the ends of the housings.

 

Mark cables for cutting

Measuring the cables from where they exit the end fittings, we recommend that you mark the cables at:

  • For non-RSL equipped rigs, 6” (both sides).
  • For RSL equipped rigs, 6.25” for the RSL side, and 5.75” for the NON-RSL side.
  • The minimum length for any cable is 5.5”, and the maximum is 6.25”.

 

Double check your marks

Before cutting, we recommend that the handle be removed from the pocket and the release cables be slowly withdrawn to check your measurements.

When the mark on the non-RSL side cable reaches the bottom edge of the hole in the end fitting, the RSL side cable should extend 1/4″ to 1/2″ past the end of its end fitting.

If not, reposition the handle in the pocket and double-check your measurements.

 

CAUTION!

If an RSL is installed, the RSL side cable MUST release last!

If an RSL is installed, verify that the exposed yellow release cable extending from the short housing is shorter than the exposed yellow cable extending from the long housing.  The left riser with the RSL attached MUST release AFTER the right riser releases when the cables are withdrawn.

 

Cut the cables

When you are satisfied that the cables are marked correctly, cut each cable at your marks with sharp wire cutters.

 

Finish the ends of the cables 

After cutting, finish the ends to cover the exposed inner steel cable.

Using a lighter or matches, warm the yellow plastic coating for 5 seconds to soften it.

Hold the end of the cable at the edge of the flame, but not in the flame.

Remove the flame and quickly pull and roll the yellow plastic coating with your fingers over the end of the exposed steel cable.

Make sure that no cable remains exposed, and that there are no burrs or snags.

Reheat very briefly if needed to shape the ends.

 

CAUTION!

Heating the cable ends too long can result in injury!  Heat only long enough to soften the yellow covering, not melt it or set it on fire!