How To: Mobile Unit Mast & Winch Cable Repair Video & Step-by-Step

MOBILE UNIT - MAST

OVERVIEW: This document outlines the process of replacing cables and repairing the cable winch.

TOOLS NEEDED

  • Drill with Phillips head bit
  • Drill extension
  • Fish wire (the skinnier, the better)
  • 3/4” socket wrench
  • 9/16” socket wrench
  • 9/16” combination wrench
  • 7/16” socket wrench
  • 7/16” combination wrench
  • 3/8” socket wrench
  • Large Crescent wrench
  • Channel Lock Pliers or Vice Grips
  • Allen Wrench set
  • Loc-Tite
  • Electrical Tape
  • Wire Strippers
  • Butt connectors
  • Needle nose pliers
  • Gloves
  • Containers to hold nuts/bolts

PARTS NEEDED

  • Replacement cables

SAFETY RULES

Before operating or working with an LVT LiveUnit, 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

MOBILE UNIT MAST AND WINCH CABLE REPAIR

PREP MOUNTING STRUCTURE 00:15-00:33

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

REMOVE MAST SCREWS AND BOLTS 00:34-06:20

  1. Using a Phillips head, 3/4” socket, 7/16” socket, and Allen wrenches, remove all screws along the sub-assembly masts (the galvanized steel mast, not white powder coated main mast). NOTE: There is no specific order to uninstall the screws and bolts from the masts.
  2. Unscrew bolts along the sub-assembly masts using socket and crescent wrench. 
  3. Remove pulley cable loop bolts.
  4. Remove pulleys from the pulley housings and remove pulley from main mast.
  5. Remove pulley cable channel bolts.
  6. Ensure all bolts and screws have been removed from all parts of the sub-assembly masts. 

DISASSEMBLE POWER CABLE 06:21-09:01

  1. In the power box, tape black power cable to other cables to prevent the interior  pulley from retracting accidentally.
  2. Use wire cutters to cut top power plug cable located right next to the tapered rubber grommet at the top of the mast. 
  3. Set cut power plug cable aside.
  4. Push power cable through tapered grommet until it is out of the hole and falls down the mast. 
  5. Use needle nose pliers to push the cable into the top mast if needed.

PULLING MASTS APART 09:02-12:09

  1. Pull the center mast out completely and set aside. 
  2. From the battery box, pull the power cable out of the masts all the way. 
  3. Repeat with each mast, from smallest to largest. NOTE: Plastic mast spacers may get stuck. Resist putting fingers near the spacers to dislodge! Allow the mast to fall back down and try pulling out again. 
  4. Before removing the largest, loosen the white bolt with a crescent wrench on the main mast using 3-4 full turns. NOTE: If the largest mast does not come out, loosen the bold more.

DETACH AND REPLACE MAST CABLES 12:10-18:39

  1. Set the mast section across the mounting structure’s extended leg and tongue. Use a 9/16” combination wrench on the inside nut and channel pliers/vice grips on the cable screw to separate. 
  2. Once apart, remove the old cable and replace with the new cable. NOTE: Each cable is labeled “5”, “4”, “3”, or “2”. These correspond to the width of the mast each cable belongs to (ie. “5” goes to the 5-inch mast, etc.).
  3. Not all cables may need to be replaced, but check each cable to ensure they are not frayed, rusty, or worn. 
  4. Before screwing the nut back on, add Loc-Tite to the screw. 
  5. Repeat steps 18-21  for all other mast cables that need replacing. 

REASSEMBLE SUB-ASSEMBLY MASTS 18:40-20:08

  1. Start with the largest mast and insert into the main mast with cable facing the winch, lining the mast cable up with the pulley housing of the main mast. NOTE: Ensure cable is running up the mast channel, or it will get pinched and damaged. 
  2. Repeat for each mast, ensuring the cable lines up with the pulley housing of the previous mast. NOTE: The pulley housings should NOT line up with one another, but should line up to the cable attachment arm of the previous mast. 

REATTACH PULLEYS AND MAST CABLE BOLTS 20:09-25:26

  1. Reinstall pulleys. Loop the mast cable OVER the pulley before reinstalling, ensuring the cable is not pinched behind a pulley channel. NOTE: Use washer with the nut. Tighten using 5/32” allen wrench and socket until firm, but ensure pulley still rotates freely.
  2. Connect cable loop to the cable attachment arm. 
  3. Attach bolt and nut to top of pulley housing. NOTE: Ensure cable runs under this bolt.
  4. Repeat steps 25-27 for all pulleys.
  5. Tighten bolts using socket and crescent wrenches.

REATTACH SCREWS 25:27-28:13

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

DETACH AND REPLACE WINCH CABLE 28:14-31:55

  1. Use the 7/16” socket and drill to unscrew the two nuts on the cable lock located on the back of the winch. 
  2. Pull old cable out, using pliers if needed. 
  3. Orient winch to allow the cable to wrap over the back of the winch first. Start with the back of the winch and wrap the new cable over and under the winch. Move counter clockwise around the winch wheel to wrap the cable. See video for more detail on orientation. 
  4. Insert the end of the new winch cable through the hole closest to the cable lock and loop cable around cable lock to feed into the cable lock from the right side. 
  5. Insert winch cable under cable lock, ensuring it sticks out past the lock by about 1”. 
  6. Screw the two nuts and bolts back onto the cable lock with 7/16” socket and combination wrenches, ensuring a tight fit. 

REINSTALL THE POWER CABLE 31:56-35:42

  1. Unscrew the flange on the tapered grommet at the top of the center sub-assembly mast. 
  2. Push the fish wire through the inner tapered grommet in the topmost mast. NOTE: If needed, use the small end of a large wrench to push the wire down from the top of the center sub-assembly mast. 
  3. Fish down through the masts to the bottom of the mast. NOTE: This section is accessible through the battery boxes.
  4. Pull the fish wire UNDER the pulley in the mast base. 
  5. Using electrical tape, securely attach the power cable to the fish wire so the wire tapers to the power cable.
  6. Retract the fish wire. 
  7. When the wrapped wire/cable section reaches the tapered grommet, wiggle the cable in a circular motion while pulling through. NOTE: DO NOT give it a hard tug to get it through, or it may break. 
  8. Detach power cable from fish wire. 
  9.  Check that the teeth of the inner tapered grommet don’t overlap.
  10. Screw on the outer tapered grommet until tight.
  11. Use butt connectors to connect each color respectively. NOTE: Crimp butt connectors when wires are inside.
  12. Wrap connectors and cable in electrical tape. 

SYSTEM TESTING AND WRAPPING UP 35:43-END

  1. Detach power cable from the 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 multi-meter 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. 
  5. Turn the control box switches to OFF position.
  6. Rotate solar panels to face south.