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head rush technologies TRUBLUE SPEED AUTO BELAY Service Manual

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SERVICE MANUAL
TRUBLUE SPEED AUTO BELAY
Model: TBSD150-20

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Summary of Contents for head rush technologies TRUBLUE SPEED AUTO BELAY

  • Page 1 SERVICE MANUAL TRUBLUE SPEED AUTO BELAY Model: TBSD150-20...
  • Page 2 TABLE OF CONTENTS 1. INTRODUCTION 2. SAFETY 3. PARTS LIST 4. PART IDENTIFICATION 4.1 Retraction Spring Side 4.1.2 Retraction Springs 4.1.3 Webbing Assemblies 4.1.4 Drum Leads 4.1.5 Lightweight Webbing Retention Pin 4.2 Gear Side 4.2.2 Lightweight Magnet Drum 4.2.3 Lightweight Magnet Plate 4.2.4 Lightweight Drum Gear Screw 4.2.5 TRUBLUE Speed / TRUBLUE XL Rotor 4.2.6 TRUBLUE Speed / TRUBLUE XL Reaction Spring Sub-Assembly...
  • Page 3 10.6 Lightweight Drum Gear Replacement 10.7 Lightweight Magnet Plate Replacement 10.8 Rotor Replacement 10.9 Reaction Spring Replacement 10.10 Starlock Replacement 10.11 Damaged Magnet 10.12 Shaft Damage / Magnet Drum Replacement 10.13 Core is Not Centered 10.14 Central Plate Replacement 10.15 Removing Stuck Spring Drum Inner Screws 10.16 Removing Stuck Shackle Pin 10.17 Removing Stuck Drum Gear Screw 10.18 Removing Stuck Housing Bolt...
  • Page 4 WARNING: This document and all content incorporated within is confidential and intended solely for the use of Head Rush Technologies Authorized Service Centers . This document is for internal use only and shall not be disseminated or distributed to any party outside of the Authorized Service Center. All parties are hereby notified that disclosing, copying, distributing, or taking any alternative action in regards to the content of this document is strictly prohibited;...
  • Page 5 2. SAFETY While servicing devices manufactured by Head Rush Technologies, there are many safety concerns that you must be aware of to mitigate risk. Work deliberately, wear safety glasses, and be aware of conditions and of those around you. Many key safety concerns, though not all, are listed below: ƒ...
  • Page 6 3. PARTS LIST ABBREVIATIONS USED Head Rush Technologies One Way Idler TRUBLUE Speed TBSD Plastic Spring Drum Stainless Steel Diameter Ø Serial Number PARTS SHARED BETWEEN TBSD 12.5M AND TBSD 16M ITEM QUANTITY PART NAME PART NUMBER Pem Stud - Retraction Spring...
  • Page 7 SHARED BETWEEN TBSD 12.5M AND TBSD 16M ITEM QUANTITY PART NAME PART NUMBER Nozzle Insert Housing - Single Piece 11094 Gear - Drum - Lightweight - TRUBLUE SPEED 11206 Screw - Drum Gear - Lightweight - TRUBLUE SPEED 11218 Label - Central Plate Serial Number - TRUBLUE Speed 11221 Side Cover Sub-Assembly - TRUBLUE Speed 11695...
  • Page 8 4. PART IDENTIFICATION 4.1 Retraction Spring Side 26 - PN: 10408 22 - PN: 10404 9 - PN: 10385 14 - PN: 10390 21 - PN: 10402 15 - PN: 10391 33 - PN: 10941 27 - PN: 10412 13 - PN: 10389 24 - PN: 10406 60 - 67 WEBBING 42 - PN: 11094...
  • Page 9 26 - PN: 10408 34 - PN: 11150 9 - PN: 10385 35 - PN: 11151 35 - PN: 11151 40 - PN: 11772 20 - PN: 10401 16 - PN: 10395 26 - PN: 10408 9 - PN: 10385 49 - PN: 11767 36 - PN: 11222 40 - PN: 11772...
  • Page 10 4.1.2 RETRACTION SPRINGS RETRACTION SPRING BAND COLOR DYE COLOR SUBASSEMBLY TRUBLUE SPEED 12.5M Gold 12132 TRUBLUE SPEED 16M Silver Yellow 12129 TRUBLUE SPEED 12.5M RETRACTION SPRING TRUBLUE SPEED 16M RETRACTION SPRING 12240-04 www.headrushtech.com +1-720-565-6885...
  • Page 11 4.1.3 WEBBING ASSEMBLIES TRUBLUE Speed 12.5 m Webbing Assembly - Shown with Aluminum Carabiner - PN: 11247 Single Piece Nozzle Bar Tacks Carabiner Hand Grip TRUBLUE Speed 16m Webbing Assembly - Shown with Aluminum Carabiner - PN: 11248 Single Piece Nozzle Bar Tacks Carabiner...
  • Page 12 4.1.4 DRUM LEADS Short Webbing Loop (SWL) - Used in TRUBLUE and TRUBLUE Speed 12.5m - PN: 10394 Long Webbing Spacer (LWS) - Used in TRUBLUE Speed 16m - PN: 11777 12240-04 www.headrushtech.com +1-720-565-6885...
  • Page 13 4.1.5 LIGHTWEIGHT WEBBING RETENTION PIN - PN: 11222 36mm 12240-04 www.headrushtech.com +1-720-565-6885...
  • Page 14 4.2 Gear Side 50 - PN: 12307 26 - PN: 10408 9 - 10385 43 - PN: 11206 14 - PN: 10390 21 - PN: 10402 12 - PN: 10388 44 - PN: 11218 8 - PN: 10289 19 - PN: 10400 13 - PN: 10389 20 - PN: 10401 60 - 67 WEBBING...
  • Page 15 9 - PN: 10385 43 - PN: 11206 50 - PN: 12307 8 - PN: 10289 23 - PN: 10405 49 - PN: 11767 40 - PN: 11772 26 - PN: 10408 16 - PN: 10395 4.2.2 LIGHTWEIGHT MAGNET DRUM - PN: 11767 4 Posts 12240-04 www.headrushtech.com...
  • Page 16 4.2.3 LIGHTWEIGHT MAGNET PLATE - PN: 12307 4mm Thick 4.2.4 LIGHTWEIGHT DRUM GEAR SCREW - PN: 11218 Square Head Yellow Patch 12240-04 www.headrushtech.com +1-720-565-6885...
  • Page 17 4.2.5 TRUBLUE SPEED / TRUBLUE XL ROTOR - PN: 10289 39 - PN:11771 29 - PN: 10416 4.2.6 TRUBLUE SPEED / TRUBLUE XL REACTION SPRING SUB-ASSEMBLY - PN: 11771 4.2.7 ONE WAY IDLER ASSEMBLY - PN: 11769 38 - PN: 11216 Bulge Large Idler Gear...
  • Page 18 The One Way Idler of the TRUBLUE Speed design sticks out of the device further than on non-Speed TRUBLUE devices. A TRUBLUE Speed device will therefore not clamp into a normal Head Rush Technologies Service Bench. Authorized Service Centers may choose to either modify existing Service Benches or pur- chase a new revision of the Service Center Bench Fixture from Head Rush Technologies.
  • Page 19 5. RECERTIFICATION 5.1 Tools & Consumables Required GENERIC TOOLS CONSUMABLES HEX KEYS Snap Ring Pliers Shell Gadus V460d 2 (For Gears / OWI) 6 mm Flathead Screwdriver (Medium Thickness) Isopropyl Alcohol In Spray Bottle 4 mm Soft Head Hammer Liquid Wrench Dry Lubricant 3 mm Ball Peen Hammer 3M Clear Transfer Tape...
  • Page 20 5.3 HRT Specific Tools Required QUANTITY PART NAME PART NUMBER Service Center Bench Fixture See Note Below Support Bearing Jaw Puller Assembly – One Way Idler 11913 Support Bearing Magnetic Puller Assembly – One Way Idler 11928 Inspection Tool Assembly – One Way Idler 11962 Pick Tool 12388...
  • Page 21 5.5 Service Procedure 5.5.1. CHECK DEVICE INTO SHOP Ensure that the device received is a TRUBLUE Speed Device by checking for a “TBSD” serial number label, a One Way Idler Assembly, and a webbing with a long hand grip. Identify whether the device is a 12.5m or 16m device by comparing the webbing and webbing hand grip colors to the pictures provided in 4.
  • Page 22 5.5.3 RETRACTION SPRING AND WEBBING SERVICE a. Spring Side Disassembly Inspect the Security Housing Bolt on each side of the device. If either Security Housing Bolt shows signs of tampering, contact Head Rush Technologies and do not disassemble the device. Check that the Shaft Nut on the Gear Side of the device is torqued to 47 Nm (18 mm socket).
  • Page 23 Remove the Spring Side Shaft Nut (18 mm socket). Discard the Shaft Nut if it shows damage or corrosion. Use the Security Bolt Key to remove the Security Housing Bolt. Use a 6mm hex key to remove the four Housing Bolts. Discard any bolts that show damage or corrosion.
  • Page 24 Remove the Isolation Insert and discard if it shows severe damage, cracking, or cuts. The Isolation Insert should bend easily but feel firm in compression. Remove the Housing Insert. If the Housing Insert is difficult to remove, use a gear puller to facilitate removal.
  • Page 25 Secure the device to the service bench with the bench arm. Expel any foreign debris from the internal components of the device using compressed air and a toothbrush. Pull out webbing from the device until reaching the Drum Lead. Ensure that the Drum Lead is the correct type (Short Webbing Loop for 12.5m TRUBLUE Speed / Long Webbing Spacer for 16m TRUBLUE Speed).
  • Page 26 Measure the gap between the two Webbing Guide Plates using the Gap Probe. Slide the Gap Probe into the gap; do not forcefully insert the Gap Probe. Ensure the Gap Probe is not resting on the bottom Housing, this will give an incorrect measurement. Rotate the PSD Assembly counterclockwise, and probe four different locations approximately 90 degrees from the last measurement;...
  • Page 27 The Pass and Fail criteria are as follows: If the Gap Probe cannot be inserted be- tween the two Webbing Guide Plates, the unit fails at that location. This must be noted in the Recertification Checklist (Fail – too narrow), and contact Head Rush Technolo- gies in Lousiville, Colorado, U.S.A.
  • Page 28 Ensure that the Webbing Guide Band Clips are securely in place. If any clips are missing, replace the clips and check the interior of the device, especially the magnets, for the missing component. Gently bend any sections of the Guide Band that sit outside of the webbing spool toward the center of the device until they stay within the tapered section of the Webbing Guide Plates.
  • Page 29 Unscrew the PSD Cover Plate Screws (T08 torx) with a hand on top of the Cover Plate. Remove the cover plate, being sure that the Retraction Spring does not release. Inspect the PSD Assembly, looking for cracks or damage, especially near the inner screws and PEM stud hole.
  • Page 30 Check the PSD lid for a number written in paint pen. If the number is “4” or greater, then the Retraction Spring must be replaced. Refer to 10.1 Retraction Spring Replacement. Use isopropyl alcohol and a rag to erase all numbers from the PSD Cover Plate after Retraction Spring Replacement.
  • Page 31 b. 16m TRUBLUE Speed Only Carefully lift the center arbor of the Retraction Spring off of the Shaft. Keep a hand on top of the Retraction Spring during this process to ensure that it does not move. Keep a hand on top of the Retraction Spring. Set the center arbor of the Retraction Spring down next to the Shaft.
  • Page 32 Inspect the entire length of the Long Webbing Spacer. Ensure that the Long Webbing Spacer slides between the Webbing Guide Plates easily. Ensure that the entire length, including bar tack ends, is not damaged or cut. If damage or resistance is detected, refer to 10.3 Drum Lead Damage.
  • Page 33 Unscrew the PSD Cover Plate Screws (T08 torx) with a hand on top of the Cover Plate. Remove the cover plate, being sure that the Retraction Spring does not release. Carefully place the center arbor of the Retraction Spring onto the Shaft. Ensure that the tab on the center arbor of the Retraction Spring aligns with the slot on the Shaft.
  • Page 34 c. 12.5m TRUBLUE Speed Only Install the PSD Cover Plate, and install the PSD Cover Plate Screws. If a PSD Screw hole is damaged, rotate the Cover Plate to use a different screw hole set. Check the Revision of the PSD marked with colored paint on the side of the PSD.
  • Page 35 d. All TRUBLUE Speed Devices Carabiner Inspect the following points of the Webbing Bartacks Handgrip Assembly for damage. Discard the Webbing Assembly if damage is found or if any points fail the replacement criteria listed in the Operator Manual. Note that some webbings may not include a carabiner.
  • Page 36 Inspect the remainder of the Webbing Assembly for: damage, cuts, abrasion, discoloration, heat or friction damage (indicated by hard or shiny areas), knotting or twisting, and mold. Refer to replacement criteria in the Operator Manual. For webbing that passes but shows signs of future issues, reuse the webbing and fill out a Recertification Webbing Report.
  • Page 37 Spring Side Assembly During re-assembly of the device, replace any components that were discarded with new components supplied by Head Rush Technologies. Install the PSD Cover Plate Spacer around the Shaft. Wind the PSD Assembly in a counter-clockwise direction until reaching a stop; do NOT force past the stop.
  • Page 38 Join a 7.5m Test Webbing Assembly with 2-Part Test Nozzle pre-attached to the Drum Lead using the same Shackle and the used Shackle Pin (2.5mm hex key). Ensure the shoulder of the Shackle Pin is tight to the body of the Shackle. A properly installed Webbing should match the picture to the right.
  • Page 39 Ensure the Isolation Insert is fully seated on the Housing Insert. Install the Housing. Ensure that the nozzle housing is in its proper position. Ensure that the Housing is installed square with the Housing Insert so that the Isolation Insert does not bulge. Ensure that the Isolation Insert is not bulging or depressed;...
  • Page 40 First install the Housing Bolts (6 mm hex key), and then the Security Bolt (Security Bolt key); torque them to 18 Nm in the star pattern shown in the picture. Do not over-torque. Proceed to 5.5.4 Transmission and Brake Service. 5.5.4 TRANSMISSION AND BRAKE SERVICE a.
  • Page 41 Remove the Housing, using a pry bar if necessary. Discard the Housing if it shows cracking, severe deformation, or sharp points around the Nozzle. Expel any foreign debris from the Housing using compressed air and a toothbrush, particularly around the Nozzle and Roller. Remove the Isolation Insert and discard if it shows severe damage, cracking, or cuts.
  • Page 42 Clean the One Way Idler Assembly, the Drum Gear and Rotor Gear teeth with isopropyl alcohol and a toothbrush. Inspect the gear teeth, ensure that they are free of foreign debris and that no teeth are damaged. If gear teeth are damaged, refer to 10.6 Lightweight Drum Gear Replacement...
  • Page 43 11. Any pitting and/or shelf imperfections found on any of the gears, such as the examples shown on the right, requires a replacement of the entire gear train pursuant to TSB 0018. Inspect the Drum Gear closely for visible wear. The gear teeth should not contain any indentation on the contact surfaces.
  • Page 44 Look at the surface of each Magnet, ensuring that the Magnet is not cracked or chipped. Clean any foreign debris from the Magnets. If a magnet is 10.11 Damaged Magnet. damaged, refer to Inspect the Rotor Assembly. Ensure there is no corrosion on the Rotor.
  • Page 45 Inspect three Rotor Arms, ensuring they are not severely scraped or gouged on the perimeter, top, or bottom surfaces, and that they are centered between the Magnets. If the Rotor Arms are damaged or 10.8 Rotor Replacement. The images below show examples of Rotor contacting the Magnets, refer to Arms that are severely scraped or gouged.
  • Page 46 b. One Way Idler Inspection Inspect the One Way Idler Gear for visible wear. The gear teeth should not contain any indentation on the contact surfaces. If the gear teeth appear to be worn, discard the OWI Assembly. Excessive operational noise or sticking on retraction are also signs of potential gear wear.
  • Page 47 Use Retaining Ring Pliers to remove the Small Retaining Ring above the Small Support Bearing on the OWI Assembly. Discard the retaining ring. Move the Magnetic Bearing Puller over the Small Support Bearing until the bearing slides upward toward the magnet. Remove the Small Support Bearing by lifting the Magnetic Bearing Puller away from the assembly.
  • Page 48 Ensure that the screw and wing nut on the puller are retracted. Insert the puller into the Small Support Bearing until it bottoms. The tips of the jaws should touch the lip in the bearing that normally holds the top seal.
  • Page 49 Ensure that the pin protruding from the OWI Inspection Tool is not bent or broken. Line the pin up with one of the star-shaped lobes within the OWI cavity. Insert the OWI Inspection Tool into the OWI cavity. A red ring should be visible between the OWI and the Inspection Tool.
  • Page 50 Move the pin on the OWI Inspection Tool to the next lobe of the star-shaped cavity and test again. If the OWI Small Gear continues to rotate past 1 full turn for any of the 3 lobes, discard the OWI Assembly.
  • Page 51 Reinstall the Small Support Bearing into the OWI cavity. If the Jaw Puller was used or if the bearing was damaged, use a new bearing. The bearing should slide in by hand. If significant force is required to install the bearing, try a different bearing or discard the OWI Assembly.
  • Page 52 Gear Side Assembly 1. During re-assembly of the device, replace any components that were discarded with new components sup- plied by Head Rush Technologies. Ensure the Drum Gear screws (4 mm hex key) are torqued to 15 Nm. Torque the screws in a cross pattern as shown in the figure.
  • Page 53 Install the One Way Idler Assembly onto the Shaft. Visually inspect the clearance between the Large Idler Gear and Drum Gear. Spin the One Way Idler Assembly 1/3 of a turn and inspect the clearance again. If the gears touch in either place, the Shaft may need to be replaced due to deformation.
  • Page 54 Install the Housing. Keep the Nozzle Housing held outside of the device to ease Core Inspection. Ensure that the Housing is square to the OWI Assembly during installation, or the Isolation Insert may bulge. Ensure that the Isolation Insert is not bulging or depressed;...
  • Page 55 Put the device on its side with the Roller on the bottom and pull out webbing from the device. Inspect the location of the Webbing on the Roller, ensuring that the Webbing is centered on the Roller. Ensure the Webbing Guide Plates are located evenly between the Housings.
  • Page 56 6. DESCENT TESTING Descent Testing of the TRUBLUE Speed is intended to ensure proper braking operation of the device after service is conducted. The following test should be conducted using only a 7.5m Test Webbing installed in the device. A complete test consists of one descent with a 10 kilogram (kg) mass, one descent with a 75 kg mass, and one descent with a 150 kg mass.
  • Page 57 DESCENT TEST SPECIFICATIONS With Weight Retracted With Weight Extended GROUND 12240-04 www.headrushtech.com +1-720-565-6885...
  • Page 58 7. RETRACTION TESTING Retraction Testing of the TRUBLUE Speed is intended to ensure proper retraction operation of the device after service is conducted. The following test should be conducted using only a 7.5m Test Webbing installed in the device. A complete test consists of 5 retractions of the webbing from an extension distance of 4.2m. The webbing should have no resistance during retraction except for the weight of a lightweight tag line.
  • Page 59 RETRACTION TEST SPECIFICATIONS Webbing Extended Webbing Retracted Fully 12240-04 www.headrushtech.com +1-720-565-6885...
  • Page 60 8. WEBBING INSTALLATION Bring the device back to the work bench and secure it with the bench arm. Remove the Nozzle Clip. Pull out the Test Webbing until reaching the Drum Lead. The Nozzle halves will pop out of the device. Pin the Drum Lead to the workbench.
  • Page 61 A properly installed Webbing should match the picture to the right. Note the position of the Shackle: the SWL/LWS is on the curve of the Shackle, and the French Twist of the Webbing is on the Shackle Pin. Allow the Webbing to feed back into the device, pulling tension at regular intervals.
  • Page 62 Proceed to Labeling. 12240-04 www.headrushtech.com +1-720-565-6885...
  • Page 63 Re-install the Side Covers. The device is now ready to be repackaged in authorized Head Rush Technologies packaging (box and packag- ing material) and returned to the Customer. Ensure that the device is packaged in a TRUBLUE Speed specific box with the One Way Idler Assembly / Side Cover with Bulge facing UP, and that the packaging foam is on top.
  • Page 64 WEBBING DATE OF MANUFACTURE 12240-04 www.headrushtech.com +1-720-565-6885...
  • Page 65 10. ADVANCED SERVICE PROCEDURES 10.1 Retraction Spring Replacement DISASSEMBLY 1. Remove the Retraction Spring Safety Nut from the Retraction Spring. 2. Remove the Retraction Spring. 3. If the Retraction Spring arbor is difficult to re- move, lift up the outer coils of the Retraction Spring.
  • Page 66 4. Slowly lift the center and outer coils; if the center coils are too far above or below the outer coils, the Spring may release. 5. Keep a hand on the outer coils and remove the Spring from the Spring Drum. 6.
  • Page 67 ASSEMBLY Install the Retraction Spring, ensuring that the Spring spirals outward from the Shaft in a counter-clockwise direction. Install the PEM Nut (8mm socket) and torque to 2.5Nm. 5.5.3 Retraction Spring And Webbing Service. Proceed with the remaining steps of 10.2 Spring Drum Replacement DISASSEMBLY Start with Disassembly of...
  • Page 68 Remove the PSD. Rock the PSD back and forth if it is difficult to remove. Securing the device with the bench arm is also helpful. ASSEMBLY Install the PSD around the Shaft on the Magnet Drum, and install the three Inner PSD Screws (T10 torx) and torque to 2.5Nm.
  • Page 69 If the Webbing Retention Pin is difficult to remove, insert a flathead screwdriver behind the Pin, and tap the flathead behind the Pin until the Pin is able to be moved back and forth and removed. This may damage the Drum Lead. ASSEMBLY Install the Drum Lead around the Magnet Drum center, seating the Webbing Retention Pin with...
  • Page 70 10.4 Guide Band Replacement DISASSEMBLY Start with Disassembly of 10.2 Spring Drum Replacement if extra working space is desired. Replacement of the Guide Band without Spring Drum removal is permitted. Pry off the Webbing Guide Band Clips with a flathead screwdriver. Remove the Webbing Guide Band and any adhesive that remains on the Central Plate.
  • Page 71 Remove the covers from the adhesive tape on the Guide Band, and lay the Band flat against the Webbing Guide Plate. Press the adhesive tape against the center of the Center Plate bosses. Install Webbing Guide Band Clips, ensuring the Clips are fully seated with a flathead screwdriver.
  • Page 72 10.5 Guide Plate Replacement DISASSEMBLY Start with Disassembly of 10.3 Drum Lead Damage and Dissassembly of 10.4 Guide Band Replacement. Insert a flathead screwdriver between the Webbing Guide Plate and the Magnet Drum. Pry upwards at regular intervals around the Webbing Guide Plate to remove it.
  • Page 73 Install a Webbing Guide Plate on the Magnet Drum, ensuring the Webbing Guide Plate is centered on the Drum. Proceed with Assembly of 10.4 Guide Band Replacement and Assembly of 10.3 Drum Lead Damage, using the original components if not damaged. 10.6 Lightweight Drum Gear Replacement DISASSEMBLY Remove the Lightweight Drum Gear Screws...
  • Page 74 ASSEMBLY Ensure that four Lightweight Magnet Plate Spacers remain present on top of the Lightweight Magnet Plate. NOTE Devices that come without spaceers DO NOT need spacers installed. Place the Lightweight Drum Gear on top of the Magnet Plate pins. Rotate the Lightweight Drum Gear so that the screw holes are aligned with the holes in the Magnet Drum.
  • Page 75 10.7 Lightweight Magnet Plate Replacement DISASSEMBLY Start with Disassembly of 10.6 Lightweight Drum Gear Replacement. Use a gloved hand to pull upward on the Lightweight Magnet Plate between the posts of the Magnet Drum. The Lightweight Magnet Plate should tilt upward until it is resting on two posts of the Magnet Drum.
  • Page 76 Carefully lower the Lightweight Magnet Plate toward the other two Magnet Drum Posts and release your hand, allowing the Lightweight Magnet Plate to snap into Place. Use caution in performing this step as hands can get stuck between the Magnet Plate and other components unexpectedly! Proceed with Assembly of 10.6 Lightweight Drum Gear...
  • Page 77 ASSEMBLY Ensure the Shaft Bearing Spacer is installed and that the small side of the taper is oriented upwards. Slide the Rotor onto the Shaft. Ensure the Shaft Housing Spacer is installed and that the small side of the taper is oriented downards.
  • Page 78 10.9 Reaction Spring Replacement Refer to page 6 for replacement part numbers. STARLOCK REMOVAL Start with Disassembly of 10.8 Rotor Replacement. If a damaged Reaction Spring is discovered during Recertification, all of the Reaction Springs on the Rotor must be replaced. Remove the Rotor from the device.
  • Page 79 Pry upwards with the screwdriver to remove the Starlock. Repeat Steps 3 and 4, removing all of the Starlocks and Reaction Springs from the Rotor. Proceed with 10.10 Starlock Replacement. 10.10 Starlock Replacement Start with Disassembly of 10.8 Rotor Replacement if not already performed.
  • Page 80 Attach the ends of a new Reaction Spring on the Pins. Needle nose pliers may be required to pull them onto the Pins. If replacing only a Starlock with no Reaction Spring damage, this step may be skipped. Place a Starlock on the end of the Star Lock Pressing Tool.
  • Page 81 10.11 Damaged Magnet Start with Disassembly of 10.7 Lightweight Magnet Plate Replacement if replacing a magnet on the Magnet Plate. Start with Disassembly of 10.8 Rotor Replacement if replacing a magnet on the Magnet Drum. Heat the Magnet to loosen the glue and facilitate removal.
  • Page 82 Remove the remaining glue with a rotary sanding tool (e.g. air tool with Scotchbrite pad, dremel with abrasive accessory). Do not remove excessive yellow plating from the Magnet Drum! The Magnets must be installed in the correct position. Use the following pictures and a magnet polarity tester to ensure correctness.
  • Page 83 Apply a Loctite 7387 Activator to each prepared magnet location on the Magnet Drum. Apply a pea-sized drop of Loctite 331 Adhesive to each prepared magnet location on the Magnet Drum. Install a Magnet onto each prepared magnet location on the Magnet Drum. Ensure that polarity of each Magnet is correct according to the polarity chart.
  • Page 84 10.12 Shaft Damage / Magnet Drum Replacement DISASSEMBLY Start with Disassembly of 10.4 Guide Band Replacement. Remove the Intermediate Subassembly from the device and clamp the Shaft into a soft-jawed vice. Reference 5.5.4 Transmission and Brake Service to remove the One Way Idler Subassembly. Complete Disassembly of 10.8 Rotor Replacement with the Intermediate Subassembly in the vise.
  • Page 85 ASSEMBLY Slide the Lightweight Magnet Drum onto the Shaft. Ensure the Shaft Bearing Spacer is installed and that the small side of the taper is oriented upwards. Proceed with Assembly of 10.8 Rotor Replacement, using the original components if not damaged. Reference 5.5.4 Transmission and Brake Service to re-install the One Way Idler Subassembly.
  • Page 86 10.13 Core is Not Centered If, after service, the Core is not centered in the Housing, the Housing Inserts are likely at fault. The location of the Core is defined by a number of components, specifically how the Housing Insert fits into the Isolation Insert which fits into the Housing;...
  • Page 87 Polish the edge with the Scotch Brite Pad. Ensure there are no remaining sharp edges. Attach the Isolation Insert, ensuring that the bottom edge of the Isolation Insert is nearly flush with the bottom face of the Housing Insert. Fit the assembled Inserts into the Housing, ensuring that the Housing Insert is flush with the Housing.
  • Page 88 10.14 Central Plate Replacement This process can be performed with the device oriented either Spring Side up or Gear Side up. Removal of drum components is not necessary unless extra working space is desired. Lay down a used PSD. Place the device on top of Detach the Webbing Guide Band and Clips from Central Plate.
  • Page 89 Remove the Central Plate and Guide Band. Place the Webbing Guide Band in-between the Webbing Guide Plates. Slide a new Central Plate over the Spring Drum and onto the lower Housing. Screw the Housing into the Central Plate (do not torque).
  • Page 90 10.15 Removing Stuck Spring Drum Inner Screws These Screws can become stripped and difficult to remove. Using a rotary tool with a cutting wheel, cut a notch in the head of each stuck Screw. Heat up the Screw with a heat gun for approximately 20 seconds to loosen the Loctite.
  • Page 91 10.17 Removing Stuck Drum Gear Screw Grab the head of the Lightweight Drum Gear Screw with channel lock pliers. Twist the screw counter-clockwise to remove. Vise grips may be used instead. Continue Service from the referencing segment. 10.18 Removing Stuck Housing Bolt Housing Bolts can become stuck or difficult to remove due to a variety of issues: over torqued;...
  • Page 92 10.19 Shaft Nut Won’t Tighten If the Shaft Nut will not tighten on one side alone, then both Shaft Nuts may need to be torqued to 47Nm simultaneously with two torque wrenches. Continue Service from the referencing segment. 10.20 Device Received with Damage A device that is received with noticeable damage, and/or does not pass the Incoming Test may have several issues: broken Plastic Spring Drum (PSD), broken Retraction Spring, webbing stack-up, damaged Webbing, damaged Webbing Roller, broken Guide Band, foreign material in gear teeth, broken Reaction Spring, Housing...
  • Page 93 Loosen the Shaft Nut, but do not completely remove it. Loosen the Housing Bolts, but do not completely remove all of them. Only remove the Housing Bolt below the main mounting hole of the Center Plate, as this will be inaccessible once the bench arm is down.
  • Page 94 Wrap the PSD with strong tape (e.g. electrical tape, duct tape) to give the PSD additional structural stability. Pull the webbing out from the device, and pin down the Drum Lead. Remove the Shackle Pin and Shackle. Allow the Retraction Spring to slowly unwind. Keep gloved hands on the sides of the PSD to control the speed of the PSD.
  • Page 95 Slowly lift up the PSD Cover Plate, slide a hand on top of the Retraction Spring, and then fully remove the PSD Cover Plate. Ensure the Retraction Spring will not move before removing hand; if uncertain, continue keeping hand on top of Retraction Spring.
  • Page 96 1699 Cherry Street, Suite C, Louisville, CO 80027 USA +1-720-565-6885 www.headrushtech.com info@headrushtech.com June 2024...

This manual is also suitable for:

Tbsd150-20