How to: Replace the Mast Cable

MAST CABLING REPLACEMENT STEP-BY-STEP

V2, V3 MOBILE MOUNTING STRUCTURE - MAST

OVERVIEW: This document outlines the procedure to replace frayed, rusted, or worn cables in the mast. 

TOOLS NEEDED

  • Drill with Phillips head bit
  • Drill extension
  • Thin Fish Tape 8’+
  • ¾ socket wrench
  • 9/16 socket wrench
  • 9/16 combination wrench
  • 7/16 socket wrench
  • 7/16 combination wrench
  • ⅜ socket wrench
  • Large Crescent wrench
  • Channel Lock Pliers or Vice Grip
  • Allen Wrench set
  • Loc-Tite
  • Electrical tape
  • Wire strippers
  • Butt connectors 
  • Needle nose pliers
  • Gloves
  • Container(s) to hold nuts/bolts
  • Multimeter
  • Cable mount drill jig

PARTS NEEDED

  • 105636 SS Mast Cable Kit

SAFETY RULES

Before operating or working with an LVT Live Unit, consult Liveview’s safety guidelines. Failure to completely understand proper safety procedures when dealing with a LiveUnit may result in improper use which increases the likelihood of accidents.  To review LVT’s safety guidelines online or to print, please go here:

LVT Safety Guidelines

WARNING:

ALWAYS wear gloves while working with the sub-assembly masts. Masts are galvanized steel and can splinter.

PROCESS

NOTE: This guide is meant to be used in conjunction with the Mast Cabling Replacement Video.

PREP MOUNTING STRUCTURE 

  1. Move solar panels up and out of the way of the mast, with panels facing toward the back of the mounting structure.
  2. Check the control box and ensure both switches are in the OFF position.

REMOVE MAST SCREWS AND BOLTS 

  1. Remove all screws and bolts along the sub-assembly masts.
    1. Use a Phillips head, ¾ socket, 7/16 socket, crescent, and Allen wrenches. 
    2. There is no specific order to remove the screws and bolts from the masts.
  2. Remove pulley cable loop bolts. 
  3. Remove pulleys from the pulley housings and remove pulley from main mast.
  4. Remove pulley cable channel bolts. 
  5. Ensure all bolts and screws have been removed from all parts of the sub-assembly masts.

DISASSEMBLE POWER CABLE 

  1. In the power box, attach the camera power cable to other cables with electrical tape to prevent accidental retraction by the cable reel. 
  2. At the top of the mast, right before the tapered rubber grommet, cut the top power plug cable. Set cut power plug cable aside.
  3. Push power cable through tapered grommet until it is out of the hole and falls down the masts.
    1. Use needle nose pliers to push the cable into the top mast if needed.

PULL SUB-ASSEMBLIES APART 

  1. Pull center 2” sub-assembly out and set aside. 
  2. From the battery box, pull the power cable fully out of the assemblies.
  3. Repeat with 3” and 4” sub-assemblies.
    1. Sometimes the plastic mast spacers get stuck. DO NOT place fingers near the spacers to dislodge! Allow the mast to fall back down and pull it out again.
  4. Before removing the 5” sub-assembly, loosen the white bolt on the main mast with a crescent wrench, using 3-4 full turns.
  5. Remove the 5” sub-assembly.
    1. If the largest mast does not come out, loosen the bolt more.

DETACH & REPLACE MAST CABLES 

  1. Set the mast section across the mounting structure’s extended leg and tongue. 
  2. Separate the bolt and nut using a 9/16 combination wrench on the inside and channel pliers/vice grip on the bolt. 
  3. Remove the old cables and replace with the new cables.
    1. Each cable is labeled  “4”, “3”, or “2”. These correspond to the width of the mast each belongs to. (so “4” goes to the 4-inch mast, etc.) 
    2. V2 NOTE: Trim plastic mast spacers on V2 Masts (circled in red).
    3. Use jig to drill out cable mount holes on 5” mast..
    4. Attach cable mount on 5” mast. Torque 80 in-lbs.
    5. Feed new cable through the cable mount.
  4. Add Loc-Tite to the screw. 
  5. Secure cable with nut and screw. Ensure nut is tight and cable is aligned with mast cable channel.
  6. Repeat for all other mast cables that need replacing.

REASSEMBLE SUB-ASSEMBLY MASTS

  1. Start with the 5” sub-assembly and insert into the main mast with cable facing the winch. Line sub-assembly cable up with the pulley housing of the main mast. 
    1. Ensure cable is running up the mast channel, or it will get pinched and damaged.
  2. Repeat for each mast, ensuring mast cable lines up with the pulley housing of the previous mast. 
    1. Pulley housings should NOT line up with one another but should line up to the cable attachment arm of the previously inserted sub-assembly.

REATTACH PULLEYS AND MAST CABLE BOLTS 

  1. Insert pulleys. Loop the mast cable OVER the pulley before attaching. 
    1. Ensure the cable is not pinched behind a pulley channel.
    2. Use washer with the nut.
  2. Tighten pulley bolt using 5/32 Allen wrench and socket until firm, but ensure pulley rotates freely.
  3. Center cable loop inside cable attachment arm and secure with bolt and nut.
  4. Attach bolt and nut to top of pulley housing. 
    1. Ensure cable runs under this bolt.
  5. Repeat for all pulleys. 
  6. Tighten bolts using socket and crescent wrenches. 

REATTACH SCREWS 

  1. Screw all other bolts and screws into the sub-assemblies using Phillips head, sockets, and drill.
  2. Retighten the large bolt on the front of the main mast. Do not over tighten or sub-assembly will squeak loudly while extending up or down.

DETACH & REPLACE WINCH CABLE (28:13)

  1. Unscrew the two nuts on the cable lock, located on the back of the winch. Use 7/16 socket and drill. 
  2. Pull old cable out, using pliers if needed. 
  3. Wrap new cable as shown below around the winch wheel.
  4. Screw both nuts and bolts back onto the cable lock with 7/16 socket and combination wrenches, ensuring a tight fit. 

TESTING CABLES AND PULLEYS 

  1. Once all cables and screws are securely attached, crank winch counterclockwise until sub-assemblies fully extend to the top. 
  2. Ensure the winch brake works. If not, call LiveView tech support (888-588-9408).
  3. Lower sub-assemblies all the way again. 

ATTACH THE POWER CABLE 

  1. Unscrew the flange on the tapered grommet at the top of the center sub-assembly mast.
  2. Push fish tape through the inner tapered grommet in the topmost mast. 
    1. If needed, use small end of a large wrench to push the wire down from the top of the center sub-assembly mast.
  3. Run fish tape down through the masts to the base roller. 
    1. This section is accessible through the battery boxes. 
  4. Pull fish tape UNDER the boat roller in the mast base.
  5. Securely attach the power cable to the fish tape using electrical tape so the wire tapers to the power cable.
  6. Retract the fish tape.
  7. Wiggle the cable in a circular motion while pulling the wrapped wire/cable section through the tapered grommet. 
    1. DO NOT pull or jerk to get it through. It will most likely break. 
  8. Detach power cable from fish tape.
  9. Check that the teeth of the inner tapered grommet don’t overlap. If so, separate before continuing. 
  10. Screw on the outer tapered grommet until tight.

SPLICING THE POWER CABLE  

  1. Remove 1” of sheathing from the power cable and the power plug cable.
  2. Strip ¼” off the 3 wires in the cables. 
  3. Pinch and twist wires to fit in the connectors. 
  4. Use butt connectors to connect each color. 
    1. Crimp butt connectors when wires are in. 
  5. Wrap connectors and cable in electrical tape.

SYSTEM TESTING & WRAPPING UP 

  1. Detach power cable from other cables in the battery box.
  2. Run the mast up all the way and back down, ensuring the power cable does not pull or break.
  3. Unlock the control box and flip switches to ON position. 
  4. Use a multimeter to test the power plug connection. 
    1. Insert negative into #3 hole, and positive into #1 hole. 
    2. Reading should be 26.8, unless batteries are completely drained.
  5. Turn the control box switches to OFF position prior to reattaching the Live Unit.
  6. Rotate solar panels to face south.