945 Series Cord Reel Service Manual - Aero
Contents
1. cable retract slightly until lock engages To release lock pull cable out slightly OVERHANG Overhang will reduce active cable travel Adjust ball stop by loosening cable clamp and slide ball stop along cable until light hangs at desired length when cord is fully retracted Tighten cable clamp SERVICE Disconnect power or unplug supply cord before attempting any service Hazards or unsafe practices COULD result in severe personal injury or death A WARNING Remove all spring tension before attempting any service Secure broken spring by A WARNING welding or wire wrapping in four 4 locations equally spaced Hazards or unsafe practices COULD result in severe personal injury or death O ESS inane SM311403B Page 2 of 6 AMCO Jan 03 MAIN SPRING REPLACEMENT Spring is dangerous Always wear gloves Before removing broken spring weld coils A WARNING together at four 4 locations or wrap securely with wire Hazards or unsafe practices COULD result in severe personal injury or death WORKING CABLE REPLACEMENT Unplug reel and remove ALL tension as described in TENSION ADJUSTMENT section Remove screw from main shaft amp complete cover Remove shaft retaining ring and pull tension pin down then slide complete drum assembly and shaft out of housing Remove spacer from shaft and remove shaft Remove nuts from cover then remove cover Carefully remove main spring from spool Replace new main spring in drum Be2. lead in cable Replace brush assembly and lead wire in same order as disassembly Reverse the above procedure to reassemble Be sure to replace springs between plate and cover RATCHET LOCK REPLACEMENT SM311403B Unplug reel and remove ALL tension as described in TENSION ADJUSTMENT section Remove screw from main shaft amp pull off cover Remove shaft retaining ring and pull tension pin down then slide complete drum assembly and shaft out of housing Remove retaining ring and unclip spring of ratchet lock from housing Reverse the above procedure to reassemble Page 3 of 6 AMCO Jan 03 HAND LAMP REPLACEMENT amp INSTALLATION Check reel for proper continuity polarity and grounding before connecting power Hazards or unsafe practices COULD result in severe personal injury or death A WARNING Disconnect power or unplug supply cord Hazards or unsafe practices COULD result A WARNING oy in severe personal injury or death Incandescent Remove guard and bulb Remove screws from sides of handle Remove cable stop assembly bumper spring ball and cable wiring Strip wire as needed and wire cable to replacement handle black to brass screw white to silver screw and green to green screw Reverse the above procedure to reassemble Power Cord or Transform Assembly Remove bolt to open reel cover Remove the wires that connect the power cord transformer assembly wires to the brush plate Attach the lugs on the new cord
3. transformer assembly wires to the brush assembly Reassemble the reel 13W Florescent Disassemble new hand Green lamp Strip the black and white wires from N the cord and tin ends Cut and remove the a pa green wire as close to the outer jacket as possible Press replacement lamp into connector until firmly retained Push Nut stripped and tinned wire leads into quick connect wiring holes in bottom of Strain Relief Green White Lamp connector Slide replacement lamp into 7 protective tube so that the end of the lamp Washer sandie Black Connector is seated in the end of the tube Slide tube Cover Tube and lamp assembly into the handle while pulling cord until tube and lamp are seated Secure tube with screws in sides of handle Replace nut plastic washer and rubber strain relief onto lamp handle SL _ _ _ _ _ _ _ _ _ _ EEEE _ _ _ _ _ _ LLL Sst ana SM311403B Page 4 of 6 AMCO Jan 03 REPLACEMENT PARTS Kit r 49 48 42 47 41 AS a KIT D TENSION oN BNO i A OPTIONAL AUTOMATIC A SWITCH Ref No Part No Qty Description 1 AM00580P0050 1 Retaining ring 500 shaft 2 KitC AMH22520007 akis Housing amp lock Assembly included 3 27 28 37 38 39 40 41 42 48 49 3 AM01137P0060 6 Screw self tap 8 x 3 8 4 AM3127400000 1 Bushing 5 AM0208500000 1 Cover pl
4. 945 SERIES SERVICE MANUAL Daniel Woodhead Company Ww A Woodhead Industries Inc Subsidiary IMPORTANT SAFETY INSTRUCTIONS Please read this manual carefully and follow its instructions Improper use or failure to follow these instructions could result in serious injury death or property damage Operators should be instructed in the safe and proper use and maintenance of this product Keep this manual for future reference The following safety precautions call attention to potentially dangerous conditions A DANGER Immediate hazards which WILL result in severe personal injury or death A WARNING Hazards or unsafe practices which COULD result in severe personal injury or death A CAUTION Hazards or unsafe practices which MAY result in minor personal injury or product or property damage NOTE Instruct operators in the safe proper use and maintenance Keep this manual for future reference INSTALLATION A WARNING Failure to read understand or follow these instructions could lead to hazards or unsafe practices COULD result in severe personal injury or death A CAUTION Instruct operators in the safe proper use and maintenance of this product Hazards or unsafe practices MAY result in minor personal injury or product or property damage NOTE Fuse protection should be used and must not be greater than maximum reel amperage rating MOUNTING Reel may be mounted on ceiling wall or in an
5. If with incandescent hand lamp 36 AMM10720062 81 Working cable 37 AM0333900000 1 Cable guide 38 AMO0580P0020 1 Retaining ring 187 shaft 39 AMO0207800000 1 Knob lock pin 40 AM0207600000 1 Bushing lock pin 41 AM0207500000 1 Spring 42 AM0207700000 1 Lock pin tension 43 AM00152P0006 3 Nut 8 32 44 AM5786700000 3 Brush 45 AM00041P0050 2 Terminal 46 AM01149P0050 A R Wire green 47 KitD AM01026P0012 A R Automatic switch optional 48 AMO0200600000 1 Pin 49 AMO2009000YE 1 Swivel mounting bracket 50 AMC01010222 1 Washer 51 AMO00228P0010 1 Cotter Pin 52 AMO0981300000 1 Washer 53 AM3123400000 1 Washer Kit A AMH92110001 A R Brush plate assembly inc 15 16 17 43 44 Kit B AMH92110002 A R Slip ring and cable assembly inc 14 36 Recommended spare parts Daniel Woodhead Company Woodhead Canada LTD WwW A Woodhead Industries Inc Subsidiary 1090 Brevik Place Mississauga Ontario L4W 3Y5 Canada 905 624 1079 FAX 905 624 9151 www woodhead ca Ww A Woodhead Industries Inc Subsidiary 3411 Woodhead Drive Northbrook IL 60062 888 996 6343 Fax 847 272 8133 www danielwoodhead com wetechsup domino danielwoodhead com SM311403B Page 6 of 6 AMCO Jan 03
6. ate assembly 6 AM0207400000 1 Main shaft 7 AM0208000346 1 Main spring 8 AM00701P0010 1 Grommet 3 8 cable 1 2 hole 9 AM00002P0202 2 Screw round head 6 32 x 1 2 10 AM0004800000 1 Cable clamp 11 AM0330600000 1 Drum assembly 12 AM00103P0020 1 Lock washer 13 AM00151P0015 1 Nut 6 32 14 AMH96310001 1 Slip ring assembly 15 AMM84780004 1 Brush plate BESSA SM311403B Page 5 of 6 AMCO Jan 03 Ref No Part No Qty Description 16 AM00103P0035 3 Lock washer int Th 8 17 AMO00002P0901 3 Screw brass 8 32 x 7 16 18 AM0303400000 1 Cover 19 AMO00916P0003 1 Strain relief 625 DIA Hole 20 AM6234600003 1 Lead in cable without transformer Contact Factory Lead in cable 945 3SWFL 21 AM0207100000 1 Screw main shaft 22 AM00002P0101 5 Screw 8 32 x 5 16 23 AM00103P0035 6 Washer 8 24 AM00151P0085 5 Nut 8 32 25 AM00600P0010 2 Spring 26 AMM82310002 2 Pin aligning 27 AM00580P0030 1 Retaining ring 375 shaft 28 AM0967400000 1 Kit Spring 1083HONS Hand lamp Florescent 945 3SWFL 1086 3 Hand lamp Florescent transformer in handle 945 3 86 106S 1 Hand lamp handle and guard 962 30 106US Hand lamp handle and guard 963 118 Hand lamp handle and guard 964SW 3000 1 Dual Outlet Box 5 15 966 1547 Single Outlet 5 15 945 1547 31 AMO009500000 1 Cable stop assembly 32 AM0202500001 1 Bumper 33 AM0202400001 1 Spring 34 AMO0004700001 1 Ball 35 AM00047P0001 3 Terminal
7. leted at factory Reels equipped with handle and guard are ready for installation OPTIONAL AUTOMATIC SWITCH When cable is retracted into reel ball stop will trigger switch to shut off power To install remove screws from cable guide place switch over guide and replace screws Plug cord from reel into switch Then plug cord from switch into power source Kit D ADJUSTMENT TENSION ADJUSTMENT To prevent spring damage test for proper spring revolutions Hazards or unsafe A caution i nage a practices MAY result in minor personal injury or product or property damage NOTE Tension adjustment can be performed before or after installation of reel amp can be can be adjusted after all electrical connections are made To adjust tension hold the main shaft by placing a wrench on the flats provided on the protruding end of shaft Hold wrench firmly while pulling out on the lock pin knob and turn the shaft with wrench clockwise to increase tension or counterclockwise to decrease tension After adjusting tension carefully pull the cable all the way out to be sure the spring does not bottom out before the cable is fully extended PULL TO RATCHET LOCK NOTE Ratchet lock may be disengaged for constant tension WRENCH Engage lock release lever by turning lock release knob counterclockwise while pulling cable in and out slightly Ratchet lock can engage about every 6 of cable travel Pull cable to desired location and let
8. sure spring hook engages on lip of drum Reverse the above procedure to reassemble Be sure shaft engages hook on spring when reassembling See Illustrations below Unplug reel and remove ALL tension as described in TENSION ADJUSTMENT section Remove screw from main shaft amp pull off cover Remove shaft retaining ring and pull tension pin down then slide complete drum assembly and shaft out of housing Carefully slide slip ring assembly out of drum and disconnect wires from slip ring ass y Unwind cable and then loosen drum clamp Remove cable with grommet Slide cable out through cable guide from housing When equipped with hand lamp or fluorescent lamp remove from cable see hand Lamp replacement instructions below Replace old cable with new cab le and reassemble by reversing the above procedure SLIP RING amp BRUSH REPLACEMENT A WARNING Check reel for proper continuity polarity and grounding before connecting power Hazards or unsafe practices COULD result in severe personal injury or death Remove tension as described in ADJUSTMENT Remove screw from main shaft amp remove cover Slide slip ring from shaft and remove wiring Rewire and replace slip ring by reversing the procedure Remove brush plate Be sure to rewire in the same order as before Remove ground screw and terminal from lead in cable Then remove screws and brush plate with springs and pins Remove brushes by removing screw and hardware with leads from
9. y position as long as main shaft of reel is horizontal When possible mount reel within two feet of an electrical outlet For locations of more than two feet use a three conductor extension cord with wire size equal to or larger than on reel Use mounting bracket as a template for location of 1 4 screw holes Template dimensions are 3 11 16 by 7 8 center to center SECONDARY SAFETY CABLE A secondary safety cable or chain is to be attached to reels mounted overhead to A DANGER prevent reel from falling Immediate hazards WILL result in severe personal injury or death SM311403B A 3 16 hole is provided on the base of reel to permit installation of a secondary support chain All reels mounted over head should have a secondary support chain to protect personnel in case of structure or mounting component failure Attach one end of secondary support chain or cable to secondary support point and the other to a support component other than that which supports the reel Chain or cable should be as short as possible allowing reel to drop no more than 6 to 12 inches if primary connection is released Supports are offered as an accessory item Page 1 of 6 AMCO Jan 03 WIRING Do not disconnect green wire the green wire has been grounded to the frame on all A WARNING models and cannot be used as a power conductor Hazards or unsafe practices COULD result in severe personal injury or death All internal wiring has been comp
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