QSA Global, Inc.
40 North Avenue Burlington, MA 01803
888.272.2242
781.272.2000
qsa-global.com
Operations Manual
MAN-038 March 2019
Page 65 of 100
o’clock position of the hand grip. Apply temporary Loctite 242 (GLU031) to the first four threads of the
5/16 inch bolt. Install the 5/16 inch hex-head bolt (part number SCR219-03) and washer (WSH045) and
hand tighten using a ½ inch open-end wrench.
After assembly, verify the control crank mechanism is properly assembled by turning the crank arm. It
should spin freely. Check the operation of the brake’s plunger knob.
For reel type controls, apply Loctite 242 (GLU031) to the first four threads of the flat socket head screws.
Mount the control crank housing on the reel type frame with the two flat socket head screws (part number
SCR350) and 2 thrust plates (part number 95063).
After assembly, perform a check to ensure the control crank will turn freely. Set the brake plunger knob to
the ON position (engaged on the drive gear cover plate) and attempt to turn the handle using moderate
pressure. Do not apply excessive force. Run a section of the control cable through the control crank to
ensure the control crank operates easily without snags or resistance.
Clean the 661 safety connector assembly using a brush and solvent. Ensure the movable jaws of the
safety connector are not excessively loose or worn where they swivel in the Spirol pins (part number
PIN016). Attempt to push the pins out using the back end of a 1/8 inch drill bit or a drift punch. If they can
be moved by pushing, replace the pins. Visually look for cracked Spirol pins from both sides of the the
safety connector. Replace the Spirol pins if there is any evidence of cracked or broken pins. Examine the
connector collar for bent or loose connecting pins and excessive wear on the inner-mating surface.
Examine the face of the connector body where the control cable protrudes and verify that long-term
usage has not chamfered the area.
4.5.5 Re-assembly of the Remote Control Unit
If required, install the spring duplex strain relief assembly on the opposite end of the remote control
conduits from which it was removed. This will promote even wear of the remote control conduits.
Reposition the spring strain relief assembly by sliding it down the entire length of conduits to the opposite
end. Apply heavy-duty shrink wrap or wrap PVC tape, near the end the spring to prevent chafing of the
conduits. Reattach the remote control conduits to the safety connector assembly. Attach the EXPOSE
sheath (yellow side of the joined conduits) to the EXPOSE side of the control crank assembly.
CAUTION
Do not over-tighten these fittings.
Lay the remote control conduits out in a straight line or a wide loop. Feed the end of the control drive
cable into the conduit as far as it will go. As the control cable is being fed into the remote control conduits,
feel for any resistance that indicates damage of the remote control conduit.
Turn the control crank handle in the RETRACT direction until the end of the control cable is protruding.
Screw the safety stop spring onto the end of the control cable a minimum of two full outer helical wraps
from the end. This minimum distance is 0.250 in (6.3mm). The safety stop spring prevents the drive cable
from disengagement from the drive gear causing a loss of control to expose or retract.
Connect the RETRACT control housing (black side of the joined conduits) to the control crank housing.
Fully retract the remote control drive cable while feeling for any binding that may indicate damage to the
control housings. Perform a freedom of movement test as described part two of this section.