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PSR ACT Replacement Instructions Manual

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Rev 4 6-15-05

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Summary of Contents for PSR ACT

  • Page 1 Rev 4 6-15-05...
  • Page 5 Contents (ACT) Cable Reel Removal Page 3-7 Cable Reel Replacement 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 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 Cable Reel replacement Instructions (ACT) Disconnect the wires at the junction 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.
  • Page 9 Cable Reel replacement Instructions (ACT) CAUTION: THE CABLE REEL IS UNDER 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...
  • 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 Cable Reel replacement Instructions (ACT) The replacement reel has a coil of excess wire and a clamp on it (Fig 1). Pull the cable out through the roller-guides to the boom tip. Measure how much of the excess wire you need to re-connect the wires to the junction box for the A-2-B switch and cut off the excess wire.
  • Page 12 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...
  • Page 13 +V = +5vdc supply voltage for angle/length/ Green wire -V = Ground/Gray wire A1 = Angle output/Blue wire Zero degrees output should be +2.50vdc L1 = Length output/White wire Fully retracted boom output should be +0.250vdc +5vdc Ground Angle Length A-2-B A-2-B return...
  • Page 14 To set the angle; Fully retract the boom, and boom the machine down to zero degrees using a level or angle finder to determine zero degrees.. Look at the display to see what the angle indication is. Remove the three mounting lugs on the pc board. See next page, Tip the pc board out and loosen the three angle pot mounting screws.
  • Page 15 Angle Pot Length Pot Angle Pot screws...
  • Page 16 To set the Radius; Fully retract the boom, and lower boom to zero degrees, look at 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.
  • Page 17 Check if the length assembly is damaged internal of the cable reel by physically pulling the cable out by hand and listen for a clicking sound when pulling it out. We are checking to see if the spring package internal of the cable reel has been damaged. If no clicking noise is present, spring package should be ok.
  • Page 18 If the cable was cut close to the end of the boom, there should be enough cable left on the reel to re-connect. There shall be at least three wraps of cable left on the cable reel drum with a fully extended boom in order to use the existing cable. Otherwise the cable must be replaced.
  • Page 19 Boom at zero degrees and extend the boom out and check for the maximum boom radius on the display. Fully retract the boom and check the minimum boom radius again adjust if required until the display indicates the proper radius. The boom radius is not set.
  • Page 20 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 Lay the cable reel on the top cover on a flat surface. See below.
  • Page 22 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 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 Feed the new cable threw 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 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 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 Remove the three socket mounting lugs from the reel using a 8mm socket and place them with the cover. Remove the grounding wire from the lug.
  • Page 28 Carefully fold the pcb over to access the angle 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. 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.
  • Page 29 Remove the three socket head cap screws on the cover of the cable reel using a 8mm wrench and ground wire. Set the hardware and cover in a safe place to avoid damage. Remove the two set screws from the length gear drive located on the side of the gear using a 1.5 mm allen wrench.
  • Page 30 Carefully fold the pcb over to access the length 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. 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.
  • Page 31 Remove the wires on the existing pot at the length pot terminals with a soldering iron (40 watts max). Solder wires 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.
  • Page 32 Replace the white large gear and press it back onto the length pot shaft. 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.