Welding Reel ERA 4000 Service Manual
Contents
1. 1 NAMEPLATE 9 C71140112 1 NUT NPT LOCKING 10 M14240007 1 JUNCTION BOX GASKET 11 M04540006 1 JUNCTION BOX COVER 12 C75620115 1 STRAIN RELIEF CONNECTOR 24 NPT 310 560 C75620116 1 STRAIN RELIEF CONNECTOR 74 NPT 500 750 13 C03500253 10 SCREW PAN HD M6 X 16MM 14 H41220076 1 SPRING POCKET ASSEMBLY 15 C60610118 1 EXTENSION SPRING 16 M04730007 1 CABLE GUIDE See kit below 17 M24060125 4 ROLLER SHAFT 18 M86700006 4 ROLLER 19 C03500255 2 SCREW PAN HD M6 X 20MM 20 M53350002 1 SPRING CLIP 21 C15070225 1 SCREW SHDR M8 X 10 X 16MM 22 M86750002 1 RATCHET PAWL 23 M70780007 1 CABLE CLAMP 24 C01070517 2 FLAT WASHER M5 25 C03500233 2 SCREW PAN HD M5 26 1 DRUM GASKET INCLUDED IN DRUM KIT BELOW 27 6168300000 1 SLIP RING ASS Y ELECTRIC WELDING REEL 28 4 SCREW INCLUDED IN DRUM KIT BELOW 29 1 OUTER DRUM HALF INCLUDED IN DRUM KIT BELOW 30 M86550002 1 CABLE SEAL 31 M37810027 1 SEAL COVER 32 C03500201 4 SCREW PAN HD M4 X 12MM 33 R60270114 50 1 CABLE ERA4150 R60270115 40 1 0 CABLE ERA4040 R60270116 40 2 0 CABLE ERA4940 R60270113 50 2 CABLE ERA4250 R60270112 50 4 CABLE ERA4450 34 1 INNER DRUM HALF INCLUDED IN DRUM KIT BELOW 35 1 SLIP RING BRACKET INCLUDED IN DRUM KIT BELOW 36 2 SCREW PAN HD M8 X 16MM INCLUDED IN DRUM KIT BELOW 37 2 WASHER SPRING LOCK M8 INCLUDED IN DRUM KIT BELOW KIT H05040006 AR DRUM KIT INCLUDES REFERENCE s 26 28 29 34 35 36 amp 37 KIT H26340009 1 Roller Guide Kit Reference Nu2. Welding Reel ERA 4000 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 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 m nor personal injury or product or CAUTION property damage NOTES Instruct operators in the safe proper use and maintenance Keep this manual for future reference INSTALLATION A WARNING Failure to read understand and follow these instructions may result in hazards or unsafe practices COULD result in severe personal injury or death CAUTION Operators need to be instructed on the safe proper use and maintenance of this product Keep this manual for future references Hazards or unsafe practices MAY result in minor personal injury or product or property damage MOUNTING The fixed base of the reel allows mounting in several different positions which the mains
3. haft remain horizontal The center line of the spool assembly must be on line with cable run When mounted overhead in base up position add a secondary chain bracket or other safety device to prevent the reel from falling in case the mounting bolts are removed or become loosened from vibration See SECONDARY SUPPORT CHAIN below 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 PIVOT BASE If optional pivot base is used reel will be self aligning to direction of cable run The four roller cable guide must be used with pivot or swivel mounts seer E E SM5810 03 D Page 1 of 6 Nov 01 WIRING A convenient 74 pipe thread opening has been provided in the junction box cover for connecting standard water tight cable connectors or conduit fitting fitting
4. lt in minor personal injury or product or property damage A Always check for shorts and continuity before turning on electrical power Hazards or CAUTION V unsafe practices MAY result in minor personal injury or product or property damage Pp WARNING v Before performing any service always disconnect and lock out all electrical power Hazards or unsafe practices COULD result in severe personal injury or death NOTE Adjust tension before or after installation of reel Do not connect working end of able until the reel is properly pretensioned To pretension reel wrap all cable onto the reel and engage ratchet even if you elect not to use the ratchet Pull cable out far enough to allow one full wrap of cable to be placed back on reel and re engage ratchet Wrap the cable that was pulled out back onto the reel This sets the tension one turn Repeat to place a total of two pretension turns on the reel Pull cable out completely to ensure enough spring revolutions remain for operating Additional tension may be added if required by repeating the above process After tension is set connect cable end Failure to pretension the reel may result in insufficient tension to retract the cable and may shorten the life of the spring SERVICE Always disconnect electrical power before dismantling any part of the reel Fuse size must not be greater than maximum amperage capacity of cable Remove all spring tension before at
5. mbers 16 17 18 19 21 KIT H05040013 1 Clamp Kit Stainless Steel Includes set of three Reference Numbers 4 amp 5 KIT PB2A AR PIVOT BASE OPTIONAL Aero Motive Company Ww A Woodhead Industries Inc Subsidiary PO Box 2678 Kalamazoo MI 49003 2678 AKAPP Electro Industrie Ww A Woodhead Industries Inc Subsidiary Nijverheidsweg 14 Box 54 NL 3771 ME Barneveld Aero Motive UK Woodhead Asia PTE LTD Woodhead Canada LTD Limited Ww A Woodhead Industries Inc Subsidiary Rassau Industrial Estate Ebbw Vale Gwent NP3 58D WwW A Woodhead Industries Inc Subsidiary 1090 Brevik Place Mississauga Ontario Ww A Woodhead Industries Inc Subsidiary 401 Commonwealth Drive 204 04 Haw Par Technocentre 616 337 7700 800 999 8559 FAX 800 333 6119 SM5810 03 D NL 3771 AB Barneveld Holland 011 31 3420 14022 FAX 011 31 3420 92384 United Kingdom 0495 350436 FAX 0495 350877 Page 5 of 5 Singapore 0314 65 479 6533 FAX 65 479 3588 LAW 3Y5 Canada 905 624 6518 FAX 905 624 9151 Nov 01
6. s not supplied To connect power supply cable to slip ring assembly remove junction box cover and outer drum half Strip cable 3 4 to 1 and tin end keeping wires in a tight bundle Remove slip ring from end of shaft Insert cable through liquid tight strain relief connector and main shaft Insert cable into slip ring and secure cable using the setscrew provided Assure cable is secure reinstall slip ring on mainshaft and tighten mainshaft set screw Before reattaching the junction box cover or outer drum half be sure to check for proper placement of junction box gasket and drum gasket Reattach junction box cover and outer drum half then secure power supply cable by tightening strain relief connector OPERATION RATCHET LOCK All models are supplied with a ratchet lock which works in any position If ratchet lock is not required constant tension remove spring clip and spring under the adjacent cable guide fastener CABLE GUIDE The cable guide position is set by rotating the spring pocket assembly Loosen the three clamps holding the spring pocket assembly in place by unscrewing the three hex head bolts Unless required do not completely remove bolts or clamps Reposition guide as required making sure clamps straddle ribs on outside diameter of spring pocket assembly and retighten hex head bolts SPRING TENSION Failure to test for adequate spring revolutions can cause damage Hazards or unsafe CAUTION Ea practices MAY resu
7. tempting any service Hazards or unsafe practices which COULD result in severe personal injury or death MAIN SPRING amp POCKET REPLACEMENT A WARNING Never under any circumstances remove the spring from its spring pocket assembly Replacement springs are assembled in a sealed assembly for safety and there is no need to remove them Serious injury or death could result from removal of spring If reel will not develop tension or retract cable spring pocket assembly may need to be replaced To replace remove junction box cover Disconnect cable slip ring Remove screw and shaft retainer Remove outer drum and main shaft from base Remove cable guide spring clip ratchet spring shoulder bolt and ratchet pawl from spring pocket assembly Remove spring pocket assembly from base and a ees SM5810 03 D Page 2 of 5 Nov 01 replace with new part To reassemble reverse the above procedure making sure the dimple in the shaft retainer is toward the main shaft See Illustrations below SLIP RING REPLACEMENT WARNING v Before performing any service always disconnect and lock out all electrical power Check all continuity and replace all covers before turning on electrical power Hazards or unsafe practices COULD result in severe personal injury or death To replace slip ring assembly remove outer drum half and loosen setscrew securing power supply cable Loosen setscrew securing main shaft The slip ring assembly will note slide off
8. the main shaft To reassemble reverse the above procedure WORKING CABLE INSTALLATION amp REPLACEMENT WARNING Before performing any service always disconnect and lock out all electrical power Check all continuity before turning on electrical power Hazards or unsafe practices COULD result in severe personal injury or death NOTE Cable seal is a bellows type seal designed to fit different size cables Pull out the bellows in one direction and cut the seal so that the through opening is at least 1 8 diameter smaller than the working cable Always cut the seal smaller than required More of the seal may be cut off if necessary To install replace cable loosen seal cover and cable seal Remove outer drum half Loosen or remove cable clamp Remove conductors of working cable from slip ring assemblies Pull working cable through opening of inner drum Remove seal cover and cable seal from old working cable Place seal cover and cable seal over replacement cable To reassemble reverse the above procedure SM5810 03 D Page 3 of 5 Nov 01 REPLACEMENT PARTS Nov 01 Page 4 of 5 SM5810 03 D Reference Part Number Number Qty Description 1 C03500231 1 SCREW PAN HD M5 X 12MM 2 M41100003 1 SHAFT RETAINER 3 M04160004 1 BASE 4 3 CLAMP Included in Clamp Kit below 5 3 SCREW HEX HD M6 X 45MM Included in Clamp Kit below 6 M34370006 1 MAIN SHAFT ELECTRICAL WELDING REEL 7 C47040141 1 O RING 8 M13020079
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