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.
- 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
- Electrical tape
- Wire strippers
- Butt connectors
- Needle nose pliers
- Container(s) to hold nuts/bolts
- Cable mount drill jig
- 105636 SS Mast Cable Kit
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:
ALWAYS wear gloves while working with the sub-assembly masts. Masts are galvanized steel and can splinter.
NOTE: This guide is meant to be used in conjunction with the Mast Cabling Replacement Video.
PREP MOUNTING STRUCTURE
- Move solar panels up and out of the way of the mast, with panels facing toward the back of the mounting structure.
- Check the control box and ensure both switches are in the OFF position.
REMOVE MAST SCREWS AND BOLTS
- Uninstall all screws and bolts along the sub-assembly masts.
- Use a Phillips head, ¾ socket, 7/16 socket, crescent, and Allen wrenches.
- There is no specific order to uninstall the screws and bolts from the masts.
- Uninstall pulley cable loop bolts.
- Remove pulleys from the pulley housings and remove pulley from main mast.
- Remove pulley cable channel bolts.
- Ensure all bolts and screws have been removed from all parts of the sub-assembly masts.
DISASSEMBLE POWER CABLE
- In the power box, attach the camera power cable to other cables with electrical tape to prevent accidental retraction by the cable reel.
- At the top of the mast, right before the tapered rubber grommet, cut the top power plug cable. Set cut power plug cable aside.
- Push power cable through tapered grommet until it is out of the hole and falls down the masts.
- Use needle nose pliers to push the cable into the top mast if needed.
PULL SUB-ASSEMBLIES APART
- Pull center 2” sub-assembly out and set aside.
- From the battery box, pull the power cable fully out of the assemblies.
- Repeat with 3” and 4” sub-assemblies.
- 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.
- Before removing the 5” sub-assembly, loosen the white bolt on the main mast with a crescent wrench, using 3-4 full turns.
- Remove the 5” sub-assembly.
- If the largest mast does not come out, loosen the bolt more.
DETACH & REPLACE MAST CABLES
- Set the mast section across the mounting structure’s extended leg and tongue.
- Separate the bolt and nut using a 9/16 combination wrench on the inside and channel pliers/vice grip on the bolt.
- Remove the old cables and replace with the new cables.
- 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.)
- V2 NOTE: Trim plastic mast spacers on V2 Masts (circled in red).
- Use jig to drill out cable mount holes on 5” mast..
- Install cable mount on 5” mast. Torque 80 in-lbs.
- Feed new cable through the cable mount.
- Add Loc-Tite to the screw.
- Secure cable with nut and screw. Ensure nut is tight and cable is aligned with mast cable channel.
- Repeat for all other mast cables that need replacing.
REASSEMBLE SUB-ASSEMBLY MASTS
- 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.
- Ensure cable is running up the mast channel, or it will get pinched and damaged.
- Repeat for each mast, ensuring mast cable lines up with the pulley housing of the previous mast.
- 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
- Reinstall pulleys. Loop the mast cable OVER the pulley before reinstalling.
- Ensure the cable is not pinched behind a pulley channel.
- Use washer with the nut.
- Tighten pulley bolt using 5/32 Allen wrench and socket until firm, but ensure pulley rotates freely.
- Center cable loop inside cable attachment arm and secure with bolt and nut.
- Attach bolt and nut to top of pulley housing.
- Ensure cable runs under this bolt.
- Repeat for all pulleys.
- Tighten bolts using socket and crescent wrenches.
- Screw all other bolts and screws into the sub-assemblies using Phillips head, sockets, and drill.
- 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)
- Unscrew the two nuts on the cable lock, located on the back of the winch. Use 7/16 socket and drill.
- Pull old cable out, using pliers if needed.
- Wrap new cable as shown below around the winch wheel.
- 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
- Once all cables and screws are securely attached, crank winch counterclockwise until sub-assemblies fully extend to the top.
- Ensure the winch brake works. If not, call LiveView tech support (888-588-9408).
- Lower sub-assemblies all the way again.
REINSTALL THE POWER CABLE
- Unscrew the flange on the tapered grommet at the top of the center sub-assembly mast.
- Push fish tape through the inner tapered grommet in the topmost mast.
- If needed, use small end of a large wrench to push the wire down from the top of the center sub-assembly mast.
- Run fish tape down through the masts to the base roller.
- This section is accessible through the battery boxes.
- Pull fish tape UNDER the boat roller in the mast base.
- Securely attach the power cable to the fish tape using electrical tape so the wire tapers to the power cable.
- Retract the fish tape.
- Wiggle the cable in a circular motion while pulling the wrapped wire/cable section through the tapered grommet.
- DO NOT pull or jerk to get it through. It will most likely break.
- Detach power cable from fish tape.
- Check that the teeth of the inner tapered grommet don’t overlap. If so, separate before continuing.
- Screw on the outer tapered grommet until tight.
SPLICING THE POWER CABLE
- Remove 1” of sheathing from the power cable and the power plug cable.
- Strip ¼” off the 3 wires in the cables.
- Pinch and twist wires to fit in the connectors.
- Use butt connectors to connect each color.
- Crimp butt connectors when wires are in.
- Wrap connectors and cable in electrical tape.
SYSTEM TESTING & WRAPPING UP
- Detach power cable from other cables in the battery box.
- Run the mast up all the way and back down, ensuring the power cable does not pull or break.
- Unlock the control box and flip switches to ON position.
- Use a multimeter to test the power plug connection.
- Insert negative into #3 hole, and positive into #1 hole.
- Reading should be 26.8, unless batteries are completely drained.
- Turn the control box switches to OFF position prior to reattaching the Live Unit.
- Rotate solar panels to face south.