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BROKEN CABLE REPLACEMENT PROCEDURE
1. PREPARATION
1.1 Collapse tower to where mast is retracted, then pivot tower to horizontal position.
1.2 Remove the tower from the trailer and place it on a work surface such as two saw horses.
2. REMOVING TOP CABLE AND TOP MAST SECTION
2.1 Tie middle section and large section together by wrapping band, cable, chain, or rope around the
sheave brackets on these two sections. This insures that the middle section stays inside the large
section during removal of the small section.
2.2 Remove or lock the telescope lock pin open. This is the pin that locks the three sections together
during travel.
2.3 Drill out the aluminum pop rivets holding the plastic guides at the top of the middle section. Using
a screwdriver, remove these guides.
2.4 Remove the clevis pin anchoring the cable to the top of the middle section and remove the clevis
pin and the sheave from the middle section.
2.5 Pass the free end of the cable through the sheave slot between the middle and small section, and out
of the top of the tower. Pull the cable and the small section completely out of the middle section
together. Be sure to keep the cable tight; if slack accumulates it is most difficult to remove.
2.6 Unfasten the cable by removing the bolt at the base of the small section.
3. REINSTALLING THE SMALL SECTION
3.1 Fasten new cable to the base of the small section.
3.2 Reversing the procedure described in steps 2.1 through 2.5, reinstall the small section.
3.3 Reinstall the plastic guides with new pop rivets. New plastic guides should be used, but the old
guides can be used if their mounting position is shifted to the point where new holes can be drilled
in the tower section to provide a good fit when installing new pop rivets.
4. REMOVING THE LOWER CABLE AND MIDDLE TOWER SECTION
4.1 Remove or lock open the telescope lock pin if not previously done in step 2.2.
4.2 Drill out the aluminum pop rivets holding the plastic guides at the top of the large section. Using a
screwdriver, remove these guides.
4.3 Remove the cable from winch drum.
4.4 Remove the sheave clevis pin and the sheave from the top of the large section.
4.5 If the old cable is not frayed between the winch and the bottom mast pulley, attach a flexible “fish
wire” or “snake” (wire, rope cord, etc.) to the end of the cable to be used to thread the new cable
through the lower tower and pulleys. This can be done by “untwisting” the cable and inserting the
wire or cord into the middle of the cable and thus letting the cable twist back tightly around the fish
wire. If the old cable is frayed, cut off the frayed portion and proceed as above and then remove
tower and cable as instructed in section 4.6.
