PSR ACT, Replacement Instructions Manual

Page 1: ...C Ca ab bl le e R Re ee el l C Ca ab bl le e A An ng gl le e L Le en ng gt th h R Re ep pl la ac ce em me en nt t I In ns st tr ru uc ct ti io on ns s Rev 4 6 15 05 ...

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Page 5: ...t Page 8 Cable Reel Layout Page 9 10 Cable Reel Angle Adjustments Page 11 12 Cable Reel Radius Adjustments Page 13 Cable Broken repair Page 14 16 Cable Replacement Page 17 23 Cable reel angle pot replacement Page 24 25 Cable reel length pot replacement Page 26 29 ...

Page 6: ...Cable Reel replacement Instructions ACT Fully retract the boom and lower it to zero degrees now turn the power off the system ...

Page 7: ...Cable Reel replacement Instructions ACT Disconnect the cable that comes from the swivel area of the machine at the cable disconnect located by the slip ring collector for the cable reel ...

Page 8: ... box for the A 2 B switch Note For cable reels with two conductor cable connect the red and gray wires for the A 2 B circuit in the boom tip junction box For cable reels with three conductor cable connect the red and green wires for the A 2 B circuit in the boom tip junction box ...

Page 9: ... TENSION DO NOT RELEASE THE CABLE AND ALLOW IT TO RETRACT ON ITS OWN DAMAGE CAN OCCUR TO THE GEAR ASSEMBLY Remove the cable clamp and rubber grommet save it for later Hold on to the cable and slowly release the cable back towards the cable reel by hand to release the tension ...

Page 10: ...Cable Reel replacement Instructions ACT Remove the four mounting bolts on the cable reel that attach it to the boom and replace the cable reel with the replacement cable reel Tighten the four bolts ...

Page 11: ...nnect the wires to the junction box for the A 2 B switch and cut off the excess wire Attach the cable clamp and rubber grommet you removed Fig 2 and connect the wires to the junction box Remove the clamp back and rubber grommet at the cable reel When completed you should have tension on the cable from the reel Fig 3 in order for the reel to wind up properly if not readjust the cable clamp to tensi...

Page 12: ...R RE EE EL L A AC CT T L La ay yo ou ut t 1 The reel is equipped with three separate terminal strips MS1 MS2 and MS3 MS1 and MS3 are used Angle Pot is located on back side of electronic Length Pot Assembly MS1 MS2 MS3 ...

Page 13: ...ay wire 4 A1 Angle output Blue wire Zero degrees output should be 2 50vdc 5 L1 Length output White wire Fully retracted boom output should be 0 250vdc 5vdc Ground 1 MS2 Not used Angle Length A 2 B return A 2 B 12vdc 1 MS3 2 1 A 2 B return pink wire 3 2 A 2 B 12vdc supply red wire 4 Yellow wire is shield to be connected to the pc board mounting lug ...

Page 14: ...xt page Tip the pc board out and loosen the three angle pot mounting screws Holding the pc board as close to vertical as possible turn the angle pot until the display indicates zero degrees Tighten the three angle pot screws and replace the mounting lugs on the pc board Do not forget to connect the shield Check the angle indication again on the display Adjust as needed until it indicates zero degr...

Page 15: ...C CA AB BL LE E R RE EE EL L A AC CT T S Se et tt ti in ng g A An ng gl le e o on n c ca al li ib br ra at te ed d u un ni it ts s Angle Pot Length Pot Angle Pot screws ...

Page 16: ... the display to see what the radius indication is Using a flat tip screw driver turn the screw on the length pot assembly until the radius indication on the display is correct Now extend the boom fully and check it then retract it again to see if it is ok Continue this procedure until the radius indication is correct MS1 L1 should be approximately 0 250vdc range 0 248vdc to 0 251vdc Length pot adj...

Page 17: ...If no clicking noise is present spring package should be ok 2 Remove the cable reel cover and physically check for any broken components Using a voltage meter put the ground lead on terminal VB ground and the positive lead on terminal VB of MS1 With power on the system it should be 5 00 vdc range of 4 96 to 5 00vdc If not check length pot for damage inside cable reel 3 Check between VB and S1 on M...

Page 18: ...econnect the cable at the tip of the boomtip The cable should have some tension on it so the cable does not droop but taunt Turn on the power of the system and using a volt meter check the length output on S1 of MS1 terminal on the terminal 6 Output needs to be 0 250vdc range 0 248 to 0 251vdc if not using a small flat tip screwdriver adjust the screw on the length pot until it is close Now look t...

Page 19: ...til the display indicates the proper radius 8 The boom radius is not set The system was already calibrated therefore we only need to adjust the length pot at the minimum radius The system should be checked at min and max radius and will indicate the proper radius in all positions of extension in feet and tenths 9 Replace the cable reel cover and tighten hardware properly Boom Radius Feet tenths Mi...

Page 20: ... AC CT T 1 1P PA AE E 0 00 0 C Ca ab bl le e R Re ep pl la ac ce em me en nt t Disconnect the cable reel connector by the slip ring collector and remove the four mounting bolts on the cable reel and remove the reel from the machine ...

Page 21: ...C CA AB BL LE E R RE EE EL L A AC CT T 1 1P PA AE E 0 00 0 C Ca ab bl le e R Re ep pl la ac ce em me en nt t Lay the cable reel on the top cover on a flat surface See below ...

Page 22: ...a ab bl le e R Re ep pl la ac ce em me en nt t Tools required for cable replacement Phillips screwdriver wire cutters heat shrink and soldering gun with small tip Remove the tension from the reel if not already done and remove the screws that hold the wiring down ...

Page 23: ...A AE E 0 00 0 C Ca ab bl le e R Re ep pl la ac ce em me en nt t Using the small wire cutters carefully remove the existing heat shrink from the wires With your soldering gun disconnect the wires Remove the cable reel cable and replace it with new ...

Page 24: ... the hole as the old cable came off and reel new cable back on reel drum Using heat shrink put it on each wire before soldering it and a larger piece on the cable reel wire There will be one small piece of heat shrink to cover each wire soldered and one larger piece to cover the entire cable once you have soldered the wires together ...

Page 25: ...T T 1 1P PA AE E 0 00 0 C Ca ab bl le e R Re ep pl la ac ce em me en nt t Once you have soldered and heat shrunk the small wires Slide the larger heat shrink over all wires and heat shrink it reconnect the cable clamps and tighten screws ...

Page 26: ...e e R Re ep pl la ac ce em me en nt t Turn the drum and put five revolutions of tension on the cable reel drum Then using the strain relief clamp it to the front of the guide Now go to page 6 and follow To page 16 use the pages for broken cable replacement for calibration ...

Page 27: ... An ng gl le e A AS SA A p po ot t r re ep pl la ac cm me en nt t 1 2 1 Remove the three socket mounting lugs from the reel using a 8mm socket and place them with the cover 2 Remove the grounding wire from the lug ...

Page 28: ...ing 2 Loosen the three screws using a small flat tip screwdriver backside of pcb and a 5mm wrench on the front side of the pcb to remove the angle pot Remove the wiring from the terminal strip Now replace the angle pot in the same orientation as the one that was removed make note of where the wires come out of the pot Connect the wiring and see page 11 for adjustment or proceed to page 26 for leng...

Page 29: ...screws from the length gear drive located on the side of the gear using a 1 5 mm allen wrench Do not replace these set screws 3 Using your hand lift the large length gear straight out from the reel and off the shaft of the length pot Do not pry on this with tools or damage will result Remove the gear and set it with the cover 1 3 A AC CT T L Le en ng gt th h p po ot t r re em mo ov va al l ...

Page 30: ...th pot on the back side of the pcb Do not let the pcb hang from the wiring which will result in damage to the A 2 B or other wiring 2 Place your hand on the pot and using a 13mm wrench loosen the length pot nut on the front side of the pcb turn it counter clockwise to loosen it and remove it and the washer Length Pot 1 2 ...

Page 31: ...back on new length pot green is output brown is ground and white is 5vdc Insert the pot back into the pcb and position it as indicated below replace washer and nut then tighten nut from the front of the pcb 3 Place your hand on the pot and using a 13mm wrench loosen the length pot nut on the front side of the pcb turn it counter clockwise to loosen it and remove it and the washer 1 ...

Page 32: ...l la ac ce em me en nt t 1 Replace the white large gear and press it back onto the length pot shaft 2 Replace the ground wire and mounting lugs Make certain the length gear assembly is meshing with the small gear drive See page 13 for adjustment 1 2 ...