Cable Reel 0951, 200, 300, 400, 228BH Series Service Manual
Contents
1. SPRING TENSION Do not connect working end of cable until the reel is properly pretensioned Hazards or CAUTION ae unsafe practices MAY result in minor personal injury or product or property damage Failure to test for adeguate spring revolutions can cause spring damage Hazards or CAUTION god unsafe practices MAY result in minor personal injury or product or property damage NOTE A minimum 2 pre tension turns is required Additional turns can added as long as one unused spring turn remains when cable is completely extended If entire cable cannot be pulled out decrease spring tension until full one turn remains Reels shipped with cable end attachments handlamps plugs etc are pre tensioned at factory All other reels require pretensioning turns to spool assembly before connecting free end of working cable Set spring tension by turning fully wrapped reel through a specific number of revolutions or turns Number of pretension turns depends on application and desired tension A minimum of 2 set up turns is needed for most applications Additional tension may be added by repeating above process After tension is set connect cable free end Failure to pretension reel may result in insufficient tension to retract and may shorten spring life mea SE PE an SM3120 13E Page 2 of 7 Aero Motive Company Jul 01 SERVICE BULB REPLACEMENT model 228BH A CAUTION Always check for shorts and continuity before tur2. inch pipe thread opening has been provided at the bottom of the enclosure in base for connecting standard water tight cable connectors or conduit fitting fittings not supplied Individual power connections are made to the collector ring bus wires inside the junction box enclosure in base using commercially available twist on wire connectors or compression splices 85 amp OV Ss 3Phase Wire Color Number Wire Color Number SAFETY INTERNAL GROUNDING Standard reels are not grounded internally with the exception of reels built to CSA standards and the model 228BH Internal grounding must be accomplished by running a jumper wire from the brush assembly to the grounding screw provided and attaching the collector ring ground bus to the bolt 3 provided in the junction box enclosure on back of base 5 See main illustration and diagram OPERATION RATCHET LOCK All models are supplied with a ratchet lock that works in any position If ratchet lock is not required constant tension move spring clip and spring to adjacent cable guide screw 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
3. 51 xx 2060 2080 2065 208S M34370004 1 Main shaft 0951 xx 2100 2120 9 C47040141 1 O ring 10 M13020029 1 Name plate 11 M14240007 1 Junction box gasket 12 M04540004 1 Junction box cover 13 C03500253 6 Screw pan head M6x16mm 14 H41220074 1 Spring pocket assembly 0951 04 H41220075 1 Spring pocket assembly 0951 05 H41220076 1 Spring pocket assembly 0951 06 H41220078 1 Spring pocket assembly 0951 08 H41220079 1 Spring pocket assembly 0951 09 15 C60610121 1 Extension spring 16 MO4730007 1 Cable guide 17 M24060125 4 Roller shaft 18 M86700006 4 Roller 19 C03500253 4 Screw pan head M6x16mm 20 C03500255 2 Screw pan head M6x20mm 21 M53350002 1 Spring clip 22 C15070225 1 Screw shoulder M8x10x16 23 M86750002 1 Ratchet pawl 24 M70780007 1 Cable clamp 25 C01070517 2 Flat washer M5 26 C03500233 2 Screw pan head M5x16 0951xxxxxxxx1 380 539 C03500235 2 Screw pan head M5x20 0951xxxxxxxx2 540 699 SM3120 13E Page 6 of 7 O Aero Motive Company Jul 01 C03500237 2 Screw pan head M5x25 0951XXXXXXXX3 00 925 H35460014 1 Screw pan head M5 0951xxxxxxxx4 no cable 27 1 Drum gasket Included in Drum Kits below 28 R61210586 6 inch Wire green 10 ground only 29 00041P0126 2 Terminal ground only AWG 16 and 14 00041PO127 2 Terminal ground only AWG 10 and 12 30 6050500000 AR Brush assembly guantity one per 9th digit 6155000000 AR Brush assembly silver quantity one per 9t
4. Cable Reel 0951 200 300 400 228BH Series Service Manual AERO MOTIVE COMPANY w 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 CAUTION Hazards or unsafe practices which MAY result in minor personal injury or product or 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 Naa in personal injury or death Instruct operators in the safe proper use and maintenance of the reel Keep this manual for CAUTION f A ae future reference 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 including base up base down or wall mounted Here are general mounting requirements Main shaft must be horizontal Centerline of th
5. e spool assembly must be on line with the cable run e When mounted overhead in base up position add a secondary chain bracket or other safety device to prevent reel from falling in case the mounting bolts are removed or become loosened from vibration 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 A ua ZXZl2ll rr eT a EE EE ds al SM3120 13E Page 1 of 7 O Aero Motive Company Jul 01 WIRING NOTE On model 228BH and CSA listed reels in Canada the green wire has been grounded to the frame of the reel and cannot be used as a power conductor A convenient one
6. emove screw shaft retainer 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 replace with new part To reassemble reverse the above procedure making sure the dimple in the shaft retainer is toward the main shaft COLLECTOR RING REPLACMENT Disconnect and lock out all power to reel before servicing collector ring assembly Hazards WARNING A wA or unsafe practices COULD result in severe personal injury or death Check continuity and replace all covers before turning on electrical power Hazards or unsafe practices MAY result in minor personal injury or product or property damage Check placement of brush holder assemblies to make sure terminal locations are centered between the protruding lobes on the inner and outer drums Hazards or unsafe practices COULD result in severe personal injury or death NOTE Check position of cable entry in relationship to studs marked by X in figure Replace subsequent brush assemblies in clockwise rotation To service the collector ring assembly remove junction box cover and disconnect bus wires in junction box Remove cover if required and outer drum half Unclip brush assembly from brush studs and remove Notice position of brush assembly Remove all brush assemblies from collector ring Loosen collector ring set screw amp slide collector ring off ma
7. h digit 31 4 Screw Included in Drum Kits below 32 1 Outer drum half Included in Drum Kits below 33 5856700021 1 Collector ring subassembly 0951 xx 2030 5856700022 1 Collector ring subassembly 0951 xx 2040 5856700023 1 Collector ring subassembly 0951 xx 2060 5856700024 1 Collector ring subassembly 0951 xx 2080 5856700009 1 Collector ring subassembly 0951 xx 2100 5856700011 1 Collector ring subassembly 0951 xx 2120 H96420102 1 Collector ring subassembly 0951 xx 203S H96420103 1 Collector ring subassembly 0951 xx 204S H96420105 1 Collector ring subassembly 0951 xx 206S H96420107 1 Collector ring subassembly 0951 xx 208S 34 1 Inner drum half Included in Drum Kits below 35 M86550002 1 Cable seal 36 M37810027 1 Seal cover 37 C03500201 4 Screw cheese head M4x12mm 38 see chart AR Cable 39 5876200000 1 Cover 0951 xx 2060 2080 206S 208S 5876100000 1 Cover 0951 xx 2100 2120 40 4350600000 1 Gasket 0951 xx 2060 2080 2100 2120 206S 208S Kit A H05010001 AR Hand lamp kit 228H and terminal Kit B PB2A AR Pivot base optional Kit C H05040001 AR Drum Kit 3 4 8 5 Cond Includes Reference Numbers 27 31 32 amp 34 H05040002 AR Drum Kit 6 amp 8 Cond Includes Reference Numbers 27 31 32 amp 34 H05040003 AR Drum Kit 10 amp 12 Cond Includes Reference Numbers 27 31 32 amp 34 KIT D H05040013 AR Clamp Kit Stainless Steel Includes Reference Numbers 6 amp 7 KIT E H26340009 1 Rol
8. in shaft To reassemble reverse above procedure The last brush assembly one closest to steel hub on collector ring must be assembled on brush studs indicated by the X in the figure BELOW T SO S mbbR T X rr S SM3120 13E Page 3 of 7 O Aero Motive Company Jul 01 Incorrect Correct Brush terminals are Terminals properly to close to drum lobe Ground centered between Drum drum lobes Lobe WORKING CABLE REPLACEMENTIINSTALLATION Disconnect and lock out all power to reel before servicing Hazards or unsafe practices WARNING I A COULD result in severe personal injury or death CAUTION Check continuity and replace all covers before turning on electrical power Hazards or unsafe practices MAY result in minor personal injury or product or property damage 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 The procedure below applies to both new installations and for replacement of working cable To install replace cable loosen seal cover and cable seal Remove cover if required and outer drum half Loosen or remove cable clamp amp individual conductors of working cable from brush assemblies Pull working cable through opening of in
9. ler Guide Kit Reference Numbers 16 17 18 19 amp 20 Above parts are all painted Yellow Aero Motive Company W A Woodhead Industries Inc Sul PO Box 2678 Kalamazoo MI 49003 2678 616 337 7700 bsidiary AKAPP Electro Industrie W A Woodhead Industries Inc Subsidiary Nijverheidsweg 14 Box 54 NL 3771 ME Barneveld NL 3771 AB Barneveld Woodhead Connectivity LTD Woodhead Asia PTE LTD W A Woodhead Industries Inc Subsidiary 401 Commonwealth Drive 04 04 Haw Par Technocentre Singapore 0314 Woodhead Canada LTD W A Woodhead Industries Inc Subsidiary Factory No 9 Rassau Industrial Estate Ebbw Vale Gwent NP3 5SD W A Woodhead Industries Inc Subsidiary 1090 Brevik Place Mississauga Ontario L4W 3Y5 Canada 800 999 8559 FAX 800 333 6119 www aeromotive com SM3120 13D Holland 31 34 241 4022 FAX 31 34 249 2384 www akapp com United Kingdom 0495 35 0436 FAX 0495 35 0877 sales wdhd co uk Page 7 of 7 65 261 6533 FAX 65 479 3588 sales wasia com sg 905 624 6518 FAX 905 624 9151 www woodhead ca Aero Motive Company Jul 01
10. ner drum amp remove seal cover amp cable seal from old working cable Place seal cover and cable seal over replacement cable To reassemble reverse the above procedure Be sure to connect working cable conductors to the proper brush assembly A ss a a ira dida a aa GD SM3120 13E Page 4 of 7 O Aero Motive Company Jul 01 REPLACEMENT PARTS 00129 BMP 2 5 fe JZZ 26 O O EI CIE SM3120 13E Page 5 of 7 Aero Motive Company Jul 01 POW R MITE REEL REFERENCE CHART FOR REELS WITH CABLE INCLUDED Pow R Pow R Matic Mite Model No Model 0951 Cable No Ft Size OD 413B 0621200C4 R62120151 16 12 358C 0420300C2 R62110117 435D 0620300C3 R62110120 383D 0420300C3 R62110120 444D 0620400C3 R62110121 385D 0420300C3 R62110120 443E 0620400C4 R62110124 462E 0620600C5 R62120237 Reference Number Part Number Qty Description 1 C03500231 1 Screw pan head M5x12mm C03500231 1 Screw pan head m5x12mm 0951 xx 2060 2080 2100 2120 2065 208S 2 M41100003 1 Shaft retainer 3 C03510130 2 Bolt hex head M5x10mm 4 00041PO127 1 Terminal 0951 xxxx 3 4 6 8 ground 00041P0126 1 Terminal 0951 xxxx 10 12 ground 5 M04160004 1 Base 6 3 Clamp Included in Clamp Kit D below 7 3 Bolt hex head M6 Included in Clamp Kit D below 8 M34370002 1 Main shaft 0951 xx 2030 2040 203S 204S M34370003 1 Main shaft 09
11. ning on electrical power Hazards or unsafe practices MAY result in minor personal injury or product or property damage Remove guard on hand lamp by removing screws on base of guard NOTE Use a 75 watt or smaller bulb A rough service bulb is recommended MAINSPRING Always disconnect electrical power before dismantling any part of the reel Fuse size A WARNING must not be greater than maximum amperage capacity of cable Remove all spring tension before attempting any service Hazards or unsafe practices COULD result in severe personal injury or death WARNING To prevent personal injury death or property damage handle all springs with care Use suitable protective gloves for spring handling Hazards or unsafe practices COULD result in severe personal injury or death WARNING To prevent personal injury death or property damage hold center of spring down as the hub is pulled out If the center is allowed to rise up the spring may escape from its container Hazards or unsafe practices COULD result in severe personal injury or death NOTE ltis recommended to replace all springs since unbroken springs of same age will likely need replacement very soon as well Failure to do this will result in much more frequent maintenance If reel will not develop tension or retract cable spring pocket assembly may need to be replaced Remove junction box cover Disconnect line input wires from collector ring bus wires R
Download Pdf Manuals
Related Search