980, 990 & 997 Series Cord Reels Service Manual
Contents
1. 4 AM10720117 14 4 x30 SJTOW 47 1 G Ball Stop Parts 48 60 61 17 2 C Washer 3 8 x 5 64 flat 18 1 C Yoke mounting 19 1 C Yoke Repair Part Kits 20 2 C Pin cotter 3 32 x 1 A 1 AH05040014 Drum Kit 21 1 A Ring conductor 1 inner B 1 AH05040015 Brush Kit 22 1 A Ring conductor 2 C 1 AH05040016 Swinging Mount Kit 23 1 A Ring conductor 3 outer D 1 AH05040017 Ratchet Lock Kit 26 1 Stand E 1 AH05040018 Spring Kit 27 1 D Spring ratchet pawl F 1 AH36220002 Automatic Switch Kit 28 2 Retainer push on shaft G 1 AH05010025 Ball Stop Kit 29 1 Guide cord 30 1 Arm guide SM3114 10B Page 4 of 4 AMCO Nov 012. 980 990 amp 997 Series Cord Reels 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 Hazards or unsafe practices which MAY result in minor personal injury or product or CAUTION property damage INSTALLATION A CAUTION Operators should be instructed in the safe and proper use and maintenance of this product Keep this manual for future references Improper use or failure to follow these instructions could result in serious injury death or WARNING property damage A WARNING This equipment should only be installed adjusted amp serviced by a qualified electrician in accordance with the National Electric Code and any applicable local codes Mounting Wall or ceiling mount so that shaft is horizontal When wall mounting ensure large end of keyho
3. le holding brush terminals with needle nose pliers Do not pull wires Remove brushes by removing screw from terminal amp pulling brush straight out Install new brushes by reversing steps SM3114 10B Page 2 of 4 AMCO Nov 01 Ratchet Kit Replacement Cam Disconnect reel from line Remove wire inlet housing by removing 3 screws from front Remove screw amp washer in center of cam loosen screw on support bracket and rotate bracket off pivot pin Install cam by reversing steps Note To ensure proper interface with ratchet cam finger must be positioned between two 90deg apart ratchet fingers as per picture Install lock washer screw and tighten After reinstallation of new ratchet amp cam system test for proper operation wp Place finger from cam between fingers on ratchet shown below Ratchet_ amp Spring Disconnect reel from line Release all spring tension Remove spring housing assembly by removing 3 screws pull housing straight off drum assembly Remove retainer ring on shaft removing plastic bearing and slide drum off shaft Remove screw and washer holding ratchet and ratchet spring Reverse steps to install new ratchet Spring legs should be positioned between two outer fingers of cam amp installed between two stops one plastic one steel on guide arm base assembly Install screws and washers It is likely that cam will need repositioning Remove 3 screws from inlet housing and check po
4. les are facing down Centerline of drum should be in line and perpendicular to intended cable payout Secure reel to mounting surface using 3 8 hardware suitable for specific mounting surface or structure Secondary Safety Cable Attach a secondary safety cable or chain to all reels mounted overhead to prevent reel A DANGER from fallin Immediate hazards WILL result in severe personal injury or death For all overhead mounting attach a secured secondary safety cable to hole provided on stand Wiring Do not disconnect green wire green wire is grounded to frame on all models and cannot A WARNING be used as a power conductor Hazards or unsafe practices COULD result in severe personal injury or death All internal wiring is completed at factory P is D SR NY J Reels equipped with handle and guard are ready for installation Optional Automatic Switch If specified reels come with switch to turn on power when cable is extended and ratchet lock engaged See parts kits if switch needs to be added If switch is not wanted remove it and Auto Fi connect lead in wires directly to brushes Switch SM3114 10B Page 1 of 4 AMCO Nov 01 ADJUSTMENT Ratchet Lock All models are equipped with a ratchet lock system If ratchet is not desired remove wire inlet housing by removing 3 screws on face disengage ratchet if engaged by rotating drum rotate cam counterclockwise until stop 9 00 from base and complete in
5. rom line Remove all spring tension Remove spring housing assembly by removing 3 screws from front amp pulling housing straight off drum assembly Install new assembly by reversing steps NOTE Internal hex of spring hub must line up with hex shaft to complete installation and must be installed in proper direction to engage spring hook Working Cord Replacement Disconnect reel from line Remove all spring tension Remove spring housing assembly by removing 3 screws from front amp pulling housing straight off drum assembly Payout all cord from drum Remove ball stop system from cord Remove cord from drum by disconnecting 3 conductors from ring terminals on inside of drum Grip connectors amp pull straight out while holding ring terminals with needle nose pliers Do not pull wires Install new working cord by reversing steps Lead in Cord Replacement Disconnect reel from line Remove wire inlet housing by removing 3 screws from front Remove strain relief bracket from terminal block Remove lead in cord by disconnecting 3 conductors from brush terminals Grip connectors amp pull straight out while holding brush terminals with needle nose pliers Do not pull wires Install new lead in cord by reversing steps Brush Replacement Disconnect reel from line Remove wire inlet housing by removing 3 screws from front Disconnect lead in cord by removing 3 conductors from brush terminals Grip connectors amp pull straight out whi
6. sition of Cam as per above instruction REPLACEMENT PARTS Spring rests on stop from stand Other end on ratchet finger SM3114 10B Page 3 of 4 AMCO Nov 01 Ref Qty Part No or Kit Description Ref Qty Part No or Kit Description 1 6 Screw M4 x 30mm PHMS 31 2 D Screw M4 x 8mm PHMS 2 1 E Housing spring 32 1 D Washer 8 x 3 64 thick 3 1 E Spring main 33 1 D Pawl ratchet 4 1 E Plate spring seat AM10720100 Cord grounded lead in 16 3 5 1 E Plate spring cover AM10720114 16 4 6 1 E Hub spring 36 1 AM10720107 14 3 7 2 E Retainer E ring flat 5 8 shaft AM10720116 14 4 8 1 A Flange drum outer AM10720108 12 3 9 2 A Bearing 37 4 Screw M5 x10mm PHMS 10 1 Shaft main 38 1 Screw M5 x 10mm green 12 20 Screw 8 x PH thrd rolling 39 1 Block terminal 13 1 A Flange drum inner 40 1 D Cam ratchet pawl 14 1 A Drum 41 x F Switch miniature 15A 125V 15 3 Clamp strain relief 42 i F Screw 4 x 5 8 BHMS AM10720109 Cord 16 3 x51 SITOW 43 0 Circuit Breaker 250V AH88000001 16 3 x 51 w triplex outlet 44 3 B Assy brush AM10720110 14 3 x46 STOW 45 1 Seal foam 16 1 AM10720111 12 3 x36 SJITOW 46 1 Housing wire inlet hub AM10720115 16 4 x50 SUTOW 57 2 D Washer lock M
7. stallation screw at end of cam arm Replace housing Cable Guide Payout Orientation The cable guide may be oriented in either of two positions 90 degrees apart To change orientation remove wire inlet housing by removing 3 screws on face remove two mounting screws completely from arm loosen two remaining mounting screws and rotate guide arm slowly to position Reinstall two screws and tighten all four screws Replace housing Spring Tension A CAUTION Failure to test for adequate spring revolutions can cause spring damage Hazards or unsafe practices MAY result in minor personal injury or product or property damage Adjust tension before or after installation of reel Increase tension by pulling out cord one revolution and while holding drum pulling cord back through guide amp wrapping around drum To decrease tension reverse procedure NOTE Reel should have at least 2 3 initial pre turns of tension and should complete the payout cycle with at least one turn remaining to ensure normal operational life SERVICE Disconnect ALL electrical power before dismantling any part of reel Remove all spring A WARNING tension before attempting any service Hazards or unsafe practices COULD result in severe personal injury or death Power Spring Replacement Do not remove spring cover from housing Hazards or unsafe practices COULD result in WARNING set severe personal injury or death Disconnect reel f
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