I would like to repair the unit but I've got six wires & two screens with no idea where they terminate within the unit. Harold Dale has posted info on a similar repair (how to repair the jack lead) and says it would be much more difficult to repair the headset cable. I want to give it a go rather than ditching the unit but can't without wiring info. Can anyone help?
Usually red is right and green is left leaving copper as ground. All manufacturers have their own color scheme so another way to do it is obtain some alligator test leads. You will need 3 in this case. Clip the clips to the replacement plug ( the leads come in different colors if you need to avoid confusion ) Then clip the other ends of the leads to the head phone wiring connections. The wiring usually goes into the left headphone first from the plug and is soldered to a pad. From the pad there will be wires that go through the headband to the right headphone. By comparing the colors of the wires you should be able to trace them. Whatever colors go to the right headphone will be right signal and ground. The remaining wires will be left signal and ground. The ground wire will be common to both left and right headphones. I mentioned the test leads so that you can plug the replacement plug into a stereo signal source such as a headphone out on your stereo amp and using a low volume setting, try different combinations until you get the right one. You can pan the signal left and right on the amp. This is in case you don't have a volt ohm meter. The meter makes the tracing a lot easier. There is a video here that also might help:http://www.metacafe.com/watch/1045725/how_to_solder_how_to_repair_headphones/ Let me know how you make out. It all sounds complicated but the worse you can do is wire your phones out of phase. Unless you are using high volumes to test them you shouldn't hurt them otherwise.
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Thanks