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test_equipment:hp_lever_switch_repair [2013/01/08 19:00] |
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+ | ====== Lever Switch Repairs On HP8552B IF Unit (and others) ====== | ||
+ | |||
+ | |||
+ | My 8552B had been damaged in transit and the SCAN MODE switch arm | ||
+ | lever broken off and missing. | ||
+ | |||
+ | A previous post asking for advice on how to fix this switch got no | ||
+ | response, so I assume that most of you have easy and cheap access to | ||
+ | spare switches and have never needed to fix a broken one. | ||
+ | But that's not the case outside the US so I had to "bite the bullet" | ||
+ | and have a go myself. | ||
+ | |||
+ | Now I know its likely that other HP gear uses the same switches, or | ||
+ | at least the mechanical parts comprising the switch's lever assembly | ||
+ | making up the switch lever, spring retainers, actuator rod | ||
+ | and switch cam, so although the actual switch bank wafers | ||
+ | themselves may be different, at least the above bit is likely to be | ||
+ | transferable. | ||
+ | |||
+ | For example my 1822A time base from my 180 CRO has 4 of these | ||
+ | switches, all 4 position, which very likely has the same internal | ||
+ | mechanics as my 8552B SCAN MODE switch, | ||
+ | but again I am not going to disable my still working and excellent 180 | ||
+ | which would be blind without its timebase and which | ||
+ | is still a rare enough beast to have to find here in West Australia. | ||
+ | |||
+ | So here is a run down on one way to fix it (Applies to VIDEO FILTER | ||
+ | and probably SCAN TRIGGER switches too) | ||
+ | |||
+ | The switch arm was broken off just before it entered the support slot | ||
+ | on the switch bracket. | ||
+ | |||
+ | To remove the entire switch assembly, then the lever sub assembly. | ||
+ | |||
+ | 1. Remove the 4 side screws holding the entire panel assembly to | ||
+ | the 8112B box. | ||
+ | Swing out the front panel assembly to expose its rear | ||
+ | wiring. | ||
+ | Now remove the front outer fascia panel You will first | ||
+ | have to unsoider 3 of the BNC sockets along the | ||
+ | right front except for the CAL OUTPUT BNC, wbich is a | ||
+ | special screened prewired thing which | ||
+ | unscrews from the front with a round nut and then just | ||
+ | pulls free. | ||
+ | |||
+ | Remove all the BNC connectors from the fascia panel as | ||
+ | they clamp a seperate mini panel to the | ||
+ | fascia with the BNC signal descriptors . You cant get | ||
+ | the fascia panel off until you first remove this one. | ||
+ | |||
+ | BEWARE ! After removing the nuts on the "Base Line | ||
+ | Clipper" and "Manual Scan" pots and pulling | ||
+ | off the plastic 'handles" on the lever switches, you | ||
+ | might think the fascia just pulls straight off . It doesn't! | ||
+ | (the three knobs can stay on, as they have large round | ||
+ | cutouts on the fascia panel which clear them, but | ||
+ | I removed mine to prevent possible damage.) | ||
+ | Three of the fascia lamps ("Scanning" and "+, X" ) are | ||
+ | still firmly attached with plastic clips which | ||
+ | also form part of the fascia panels illuminated | ||
+ | annunciators ! | ||
+ | |||
+ | If you pull the panel straight off YOU WILL BREAK THE | ||
+ | WIRES OF THE ATTACHED FILAMENT "WIRE IN" BULBS AND POSSIBLY | ||
+ | THE WIRES ON THE NEON TOO !!! | ||
+ | (I KNOW this cos thats what I did!!! ... and even after | ||
+ | looking at the manual, too!!. I had to replace two | ||
+ | of them with LEDS, but thats yet another story). | ||
+ | |||
+ | You have to lever the bulbs out of these clips FIRST | ||
+ | before you remove this panel | ||
+ | |||
+ | 2. Now remove the circlip retaining the switch rotator rod | ||
+ | which goes through the slot on both switch wafers | ||
+ | (With the switch still attached the panel it makes a | ||
+ | stable platform for removing the circlip) | ||
+ | |||
+ | 3. Now remove the two screws holding the switch bracket to | ||
+ | the front panel proper. You can now swing the switch assy | ||
+ | part out now so you can see how the switch wafers are | ||
+ | held together. Observing the arrangement of the metal | ||
+ | spacers remove the wafer attachment nuts and pull out the | ||
+ | bolts which clamp them together. | ||
+ | |||
+ | Note the position of the | ||
+ | tiny non metallic washers between the pillars and | ||
+ | wafer switchs. Its best to make a sketch of this first. | ||
+ | Carefully note the swich rotor positioning of the 2 | ||
+ | wafers and the colour coding of the wires which are adjacent each | ||
+ | other so there is no doubt as to how it goes back together | ||
+ | Add this to your sketch before disassembly. | ||
+ | |||
+ | 4. | ||
+ | Now you can remove the metal stamping , that is the bracket which | ||
+ | contains the spring, the metal cam teeth, the (broken off) | ||
+ | operators actuating lever arm and the wafer switch rotator rod. Pull | ||
+ | the switch rotator part,which includes the spring and cam up and out | ||
+ | so the actuator shaft exits the wafers slots. It may help to remove | ||
+ | the spring first. | ||
+ | |||
+ | 5. | ||
+ | You can now examine the bit you want to fix. In mine the lever | ||
+ | switch arm was broken off just before the bend | ||
+ | where its angled up to pass through the brackets guide | ||
+ | slit. My experience, looking at of the broken off end, told me | ||
+ | that it would not weld together well. The surface is | ||
+ | too granulated. It would have to be screwed together somehow. | ||
+ | |||
+ | 6. | ||
+ | WHAT NOT TO DO: I thought I would cut off the bent part with a | ||
+ | hacksaw, leaving the "wasted" flat part which the wafers rotator | ||
+ | rod is fixed to. I would drill a couple of 10BA tap size holes in | ||
+ | it, make up a new metal operators switch arm complete with double | ||
+ | bend, coat the screws threads with Loctite and screw the lot into the | ||
+ | threaded 10BA holes. | ||
+ | |||
+ | There would just be enough clearance to do it by cutting off the | ||
+ | excess bolt lengths and flush filing. | ||
+ | |||
+ | Well, you CANT simply hacksaw it off. This parts made of hardened | ||
+ | metal and you will blunt the saw blade with barely | ||
+ | a scratch showing. I tried drilling small holes with a new drill in | ||
+ | the drill press and that barely makes a dot on the surface. | ||
+ | |||
+ | |||
+ | 7. | ||
+ | WHAT TO DO: To remove the bent up angled stub ,squeeze itin a | ||
+ | vice. It breaks off neatly. | ||
+ | |||
+ | Luckily, I found the metal takes solder easily! I simply silver | ||
+ | soldered the new switch arm I had made to the remaining flat stub and | ||
+ | it held beuatifully. !! | ||
+ | (Tin both surfaces first, of course) | ||
+ | |||
+ | 8. | ||
+ | MAKING THE REPLACEMENT LEVER: Take the width and length from the | ||
+ | other lever switches and shape outa replacement in metal thin enough | ||
+ | to go through the panel slots (Note: The outer fascia slot is WIDER | ||
+ | in width than the inner front slot. Make sure the thickness of your | ||
+ | made up lever arm clears the INNER panel slot width. | ||
+ | |||
+ | Try to follow the "wasted" contour of the original as close as | ||
+ | possible when shaping the replacement. | ||
+ | |||
+ | After silver soldering dress the edges with a file to remove any | ||
+ | solder squeezed out at the edges. | ||
+ | |||
+ | Its important this lines up with the original 'waist' angle as it | ||
+ | affects the mechanical position of the switches at both end | ||
+ | positions. Again a file will correct this (no need to worry about | ||
+ | filing part of the original away !) | ||
+ | |||
+ | |||
+ | 9. | ||
+ | Reassemble: You will find it difficult (I did) to get the pillars and | ||
+ | tiny washers to go back on the wafers while ensuring the wafer slots | ||
+ | align with the rotor rod. Do the "inside" end first as its the | ||
+ | hardest to get at. | ||
+ | |||
+ | Check out to see if any of the fine wires have broken off the switch | ||
+ | wafer lugs due to your Houdini like finger exercises when | ||
+ | reassembling. You will find the sketch you made indispensable if this | ||
+ | happens. | ||
+ | |||
+ | I used a black plastic knob off a low end CRO which had similar lever | ||
+ | switches (but totally incompatible otherwise) | ||
+ | |||
+ | This didnt fit securely, having too wide a slot,. I shrunk some heat | ||
+ | shrink over the shaft end which then secuured it OK. | ||
+ | |||
+ | Watch out for bits dropping down into the panel wiring. They are hard | ||
+ | to retrieve. | ||
+ | |||
+ | I can now use my 141T and do the full calibration as HP intended. | ||
+ | |||
+ | Hope all this helps others. | ||
+ | |||
+ | JOHN BYERS | ||