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CW Series CORD REEL Service Manual
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1. disconnect could cause serious injury death or property damage Hazards or unsafe practices COULD result in severe personal injury or death RATCHET amp SPRING ASSEMBLY When reassembling ratchet and spring assembly be sure arrow on ratchet plate aligns with CAUTION ae alignment in drum Hazards or unsafe practices MAY result in minor personal injury or product or property damage NOTE If reel will not develop tension on retract cable ratchet and spring assembly may need to be replaced To remove cover remove bottom screws retaining ring and guide Remove inspect and replace ratchet and spring assembly as necessary to removing nuts Reverse procedure to reassemble Remainder of reel may be disassembled with stand tools and parts replaced as required WORKING CABLE INSULATOR RING ASSEMBLY amp BRUSH REPLACEMENT NOTE Check continuity before connecting power When reel is equipped with hand lamp or fluorescent lamp remove lamp from cable see hand lamp replacement instructions EEE E O O ee ee eee ae SM311703 A Page 2 of 6 ONov 01 Unplug reel and remove tension as described in Operations Spring Tension Remove screws and retaining ring from cover Remove cover and carefully slide insulator and ring assembly out of drum Disconnect wire from power cable Remove working cable wires from brush holder and slide brush holder from hub Slide working cable out through cable guide from housing Replace
2. in any position and needs no adjustment If ratchet is not desired constant tension remove ratchet spring ratchet lever and lever shaft This will eliminate locking action GUIDE MOUNTING POSITIONS A T TWO WAY PAYOUT A Moun GUIDE REMOVED CEILING MOUNT FLOOR OR BENCH CABLE GUIDE The cable guide may be set at any position around cable drum Guide must be set so cable pays off reel in a straight line without bends Remove guide from reel for two way cable payout SPRING TENSION Do not connect working end of cable until the reel is properly pretensioned Hazards or CAUTION unsafe practices MAY result in minor personal injury or product or property damage Failure to test for adequate spring revolutions can cause spring damage Hazards or CAUTION unsafe practices MAY result in minor personal injury or product or property damage NOTE Adjust tension before or after installation of reel Pull cable out to determine if more or less tension is desired Place wrench on end of main shaft over flat While holding wrench firmly pull pin on housing until it allows shaft to rotate Turn shaft counter clockwise to decrease tension and clockwise to increase tension Re engage pin when desired tension has been set Pull cable out completely to insure enough spring revolutions remain for operating If entire cable assembly cannot be pulled out decrease spring tension until it can SERVICE A WARNING Unplug power Failure to
3. old working cable with new cable and reassemble to brush holder Be sure to rewire in the same order as removed See diagram Reassemble brushholder to hub and rewire insulator and ring assembly Be sure to rewire in the same order as removed See diagram Reassemble the slide insulator and ring assembly to hub See power cord replacement procedure below if a fluorescent lamp is being installed Replace cover assembly Reverse above procedure to reassemble HAND LAMP REPLACEMENT Remove guard bulb and the screws from sides of handle Remove cable stop assembly bumper spring ball and cable wiring Wire up cable to replacement handle black to gold screw white to silver screw and green to green screw Reverse steps above to reassemble FLUORESCENT HAND LAMP 13W REPLACEMENT WARNING The power cord transformer must be installed if the 13W fluorescent hand lamp is to be used Failure to install this cord will result in hazards or unsafe practices which COULD result in severe personal injury or death Check continuity before reconnecting power Hazards or unsafe practices MAY result in CAUTION ee minor personal injury or product or property damage Remove defective hand lamp from reel and cord set See illustration below Remove nut plastic washer and rubber strain relief from lamp handle and slide back onto cord Remove screws from side of handle that secure the tube Pull tube lamp and lamp connector from h
4. 2 5785500000 2 Clamp assembly 13 00160P0077 2 Lock nut 10 24 14 01137P0062 4 Screw 6 x 3 8 pan phil SF tap 15 0004700001 1 Ball stop CW53 H 16 C89440002 1 Hand lamp with outlet CW53 H C89440005 1 Hand lamp Insulated no outlet CW53 FE H81420038 1 Hand lamp 13W Florescent oval CW53 13W Transformer lead in incl C89480118 1 Hand lamp 13W Florescent round CW53 13G Transformer lead in incl 17 00230P0103 1 Self lock pin 18 C39810210 1 Clamp 5 16 dia C39810211 1 Clamp 3 8 dia 19 00160P0077 1 Lock nut 10 24 20 00152P0006 1 cond Nut 8 32 brass 21 00103P0035 1 cond Washer 8 22 5786700000 1 cond Brush 23 00160P0077 3 Lock nut 10 24 24 00600P0010 3 Spring 25 5786600000 1 Brush holder 26 00002P0901 1 cond Screw 8 32 x 7 16 27 5785900000 1 Insulator and ring assembly CW43 CW53 5786000000 1 Insulator and ring assembly CW34 CW44 28 5787000000 1 Spacer 29 5785600000 1 Cover stand 30 00006P0104 4 Screw 10 24 x 3 8 31 00580P0045 1 Retaining ring 32 00002P0901 1 Screw 8 32 x 7 16 33 5937800000 1 Cable power supply CW44 M10720099 1 Cable power supply 14 3 CW53 CW43 5937700000 1 Cable power supply CW34 See 16 1 CW53 13S or CW53 13G supply cord comes with item 16 H80230012 1 CWC53 H80230013 1 CWC43 34 00916P0004 1 Strain relief 35 H81310003 1 ground wire as required 36 00103P0035 1 Washer 8 37 00152P0006 1 Nut 8 32 brass 38 5786500001 1 Hub bearing 39 5786200000 1 Washe
5. CW Series CORD REEL Service Manual AERO MOTIVE 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 CAUTION Hazards or unsafe practices which MAY result in minor personal injury or product or 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 property damage INSTALLATION Failure to read understand and follow these instructions creates hazards that COULD result WARNING hae in personal injury or death Instruct operators in the safe proper use and maintenance of the reel Keep this manual for CAUTION ae future reference Hazards or unsafe practices MAY result in minor personal injury or product or property damage MOUNTING Reel may be mounted in any position that allows main shaft to be horizontal Reel should be mounted with centerline of drum in line with cable run WIRING On all models the green wire has been grounded to frame of reel and cannot
6. andle Pull cord wire leads from lamp connector To assemble new hand lamp 13 W fluorescent onto reel and cord set strip black and white wires from cord to size 18 and tin ends Remove green wire as close to outer jacket as possible Press replacement lamp into connector until firmly retained Push stripped and tinned wire leads into quick connect wiring holes in bottom of connector Slide replacement lamp into protective cover tube so end of the lamp is seated in tube end Slide tube and lamp assembly into handle while pulling cord back through until tube and lamp are seated Lubricate with soap if necessary Secure tube with screws in sides of handle Replace nut plastic washer and rubber strain relief onto lamp handle Green cut off arf ss ss q F Green Cover Tube a 4 Red SA Handle Black Connector REPLACEMENT PARTS eee SM311703 A Page 3 of 6 ONov 01 00002 BMP OPTIONAL AUTOMATIC SWITCH LU eee SM311703 A Page 4 of 6 ONov 01 Reference Number Part Number Qty Description 1 00030P0115 1 Screw 1 4 20 x 1 2 2 00101P0030 1 Lock washer 1 4 3 00126P0050 1 Washer 1 4 4 00580P0045 1 Retaining ring 5 4737800000 1 Washer 6 57844000YE 1 Cover assembly Includes items 5 57 58 59 1 2 62 63 7 00160P0077 6 Lock nut 10 24 8 5784600006 1 Ratchet and spring assembly 9 1405800002 1 Hub spring release 10 57812000YE 1 Guide 11 5781400000 1 Nose guide 1
7. are parts Aero Motive Company WwW A Woodhead Industries Inc Subsidiary PO Box 2678 Kalamazoo MI 49003 2678 616 337 7700 800 999 8559 FAX 800 333 6119 SM311703 A AKAPP Electro Industrie WwW A Woodhead Industries Inc Subsidiary Nijverheidsweg 14 Box 54 NL 3771 ME Barneveld NL 3771 AB Barneveld Holland 011 31 3420 14022 FAX 011 31 3420 92384 Aero Motive UK Limited WwW A Woodhead Industries Inc Subsidiary Rassau Industrial Estate Ebbw Vale Gwent NP3 5SD United Kingdom 0495 350436 FAX 0495 350877 Page 6 of 6 Woodhead Asia PTE LTD WwW A Woodhead Industries Inc Subsidiary 401 Commonwealth Drive 04 04 Haw Par Technocentre Singapore 0314 65 479 6533 FAX 65 479 3588 Woodhead Canada LTD WwW A Woodhead Industries Inc Subsidiary 1090 Brevik Place Mississauga Ontario L4W 3Y5 Canada 905 624 6518 FAX 905 624 9151 Nov 01
8. be used as a CAUTION ri power conductor Hazards or unsafe practices MAY result in minor personal injury or product or property damage All internal wiring has been completed at factory Models equipped with a handle and bulb guard are completely wired and ready for installation AUTOMATIC SWITCH OPTIONAL 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 SECONDARY SUPPORT CHAIN A DANGER A secondary safety cable or chain is to be attached to all reels mounted overhead to prevent reel from falling Immediate hazards WILL result in severe personal injury or death 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 on reel Attach other end of secondary support chain or cable to a support component other than that which supports the reel The chain or cable should be as short as possible allowing reel to drop no more than 6 to 12 inches if the primary connection is released A secondary support is offered as an accessory item SM311703 A Page 1 of 6 ONov 01 OPERATION RATCHET LOCK All models are equipped with a ratchet lock which works with reel mounted
9. r 40 00580P0045 1 Retaining ring 41 5781500000 1 Main shaft 42 00160P0077 2 Lock nut 10 24 43 5782300000 1 Guide 44 0202400001 1 Spring 45 0202500001 1 Bumper SM311703 A Page 5 of 6 Nov 01 46 0200600000 1 Pin mounting bracket opt 47 57808000YE 1 Swivel opt use RE YE Sl 48 02009000YE 1 Mounting bracket opt Use RE YE Sl 49 00228P0010 1 Cotter pin opt 50 3036500000 1 Washer opt 51 57877000YE 1 Plate swivel opt Use RE YE SI 52 C11050300 4 Screw Whizlock 1 4 20x1 2 54 57807000YE 1 Base plate Use RE YE Sl 55 5789000000 1 Cable working CW53 5789300000 1 Cable working CW44 5789500000 1 Cable working CW43 5789800000 1 Cable working CW34 56 5787500000 1 Drum assembly CW53 CW53 H CW43 CW44 CW34 57 5784300000 1 Shaft lever 58 5772700000 1 Spring ratchet 59 5785000000 1 Pin 60 C22430230 4 Nut Whizlock 1 4 20 61 5784100000 1 Lever ratchet 62 00103P0020 1 Lock washer 6 63 00151P0015 1 Nut 6 32 64 00576P0041 1 Retaining ring 750 dia 65 01026P0012 1 Automatic switch optional 67 00002P0105 3 Screw round head 8 32x5 8 optional 68 00103P0035 3 Washer lock int tooth 8 optional 69 00151P0085 3 Nut hex 8 32 optional 83 0009500000 1 Clamp Assy OPTIONAL KITS A 6302700000 AR Slip ring 3 cond includes 20 21 22 24 25 26 B 6302900000 AR Slip ring kit 4 cond includes 20 21 22 24 25 26 C 6238800000 AR Cable safety opt on 6 for CW53 S H Recommended sp
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