Hubbell SM21 User Manual

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For reels manufactured after April 16, 2001

INSTALLATION and MAINTENANCE INSTRUCTIONS

SM21 GEAR DRIVE ELECTRIC CABLE REELS

All units are provided with right hand rotation unless otherwise specified. This means that cable is pulled off spool top left or bottom right (spool rotates clockwise to wind cable) when viewing spring end of reel. See diagram on parts page.

Clock-typesprings provide power for automatic cable takeup.Spring must be pretensioned at time of installation to ensure that tension is applied to cable at all times. A tension adjustment ratchet wrench is provided with each reel.

! WARNING

Do not attempt to relieve spring tension using spanner wrench. Doing so may result in personal injury.

INSTALLATION

1.Ensure that machinery to be serviced by reel is at position closest to reel.

2.Securely mount reel in desired position using 1/2"(M12) bolts. Be sure spool is aligned with cable run.

3.Position optional cable guide, if reel is so equipped. See CABLE INSTALLATION DRAWING

4.Connect free end of cable to junction box on machine or adjust cable stop so that desired length of cable extends from reel.

5.Remove ratchet wrench and cover plate on spring housing to expose shaft and spring hub. (See Figure 1).

6.Reinstall ratchet wrench (Fig 2). Use long handled wrench to rotate arbor driver clockwise (for standard rotation). Number of 360° turns should match last digit in model number on serial plate. If model number includes an

"R", reel is reverse rotation and wrench must be rotated counterclockwise. (See EXPLANATION on parts list page.)

!

CAUTION

Do not exceed number of turns indicated on serial plate. Over-tensioningcan cause a broken spring, sheared shaft or other damage.

NOTE: On reels containing more than one spring, the hubs are connected at the factory. Therefore, by tightening the outer spring, the inside spring(s) will be tightened.

7.Remove wrench and install on other spring stack. Add pretension turns as in step 6, above. Springs on both sides must be adjusted equally. Remove wrench, replace cover plates and return wrench to stored position.

8.Remove collector cover and connect individual supply conductors to collector terminals. See ELECTRICAL CONNECTIONS diagram, on parts page.

MAINTENANCE

Periodically: A. Use compressed air to clean collector assembly and inside of collector housing. Inspect collector assembly for brush wear and pitted slip rings.

B.Inspect cable for wear and check mounting bolts and other hardware for tightness.

C.Check for broken springs by pulling about 2/3 cable off reel and observing “Broken Spring Indicators” on sides of spring canisters. See Fig. 3.

NOTE:Bearings and springs are prelubricated and require no periodic maintenance.

“IN” with 2/3

BROKEN SPRING

cable off reel–

INDICATORS

SPRING OK

 

“OUT” with 2/3 cable off reel–

SPRING BROKEN

Figure 3

! WARNING

Do not attempt to remove spring from its housing. Clocktype springs can be dangerous to handle. Removal of spring from housing could result in personal injury.

SPRING REPLACEMENT

The unique SAFETYCHANGE® spring motor consists of a spring and hub sealed within a housing. A replacement spring is supplied sealed in its housing and the old unit should be discarded completely.

1.Turn off all electric power.

2.Disconnect cable from machine junction box.

3.Relieve all spring tension following steps under SPRING DETENSIONING on last page.

4.Remove inspection cover from face of spring housing.

5.Rotate spool clockwise and observe spring shaft. Shaft should rotate clockwise and hub (with spring attached) should remain stationary.

NOTE: Do not attempt to remove spring if resistance is met or hub tends to rotate with shaft.

Continue to rotate spool and strike end of shaft several sharp blows with a lead hammer or rubber mallet until shaft rotates freely and hub remains stationary.

6.Remove (4) nuts which secure spring motor(s) to frame.

7.Slide spring motor(s) off shaft and discard.

NOTE: Onmulti-springreels, be sure to remove andsave dowel pins which connect one spring hub with another. Also

remove snap rings on shaft between spring housings. 8. Install replacement spring motor(s), pawls and pawl springs.

NOTE: Pawl springs must be located between the pawls and the deepest section of the shaft grooves. Make sure that pawls and pawl springs are inserted flush with ends of shaft and hub or they may rub against inspection cover.

 

PAWL

 

SPRING

SPOOL

 

HUB

 

 

SHAFT

 

 

(Spring not

 

 

 

shown)

 

SPRING

 

SHAFT

 

Install

 

SIDE VIEW

END VIEW

GROOVE

against flat

9.Tighten nuts (and extension bolts) securing spring housing(s) to reel frame.

10.Connect free end of cable to junction box or adjust cord stop.

11.Retighten nut on spring detensioner. See SPRING DETENSIONING, back page.

12.Tension spring with spanner wrench. Refer to

INSTALLATION section

13. Replace inspection cover and top gear access cover.

CONTINUED ON BACK PAGE

ILLUSTRATED PARTS LIST

SM-21GEAR DRIVE ELECTRIC CABLE REELS manufactured after April 16, 2001

38

14

14

18

23

8 35 36 24

26

25

25

10

33

1

29

Always specify SERIAL NUMBER & MODEL NUMBER when ordering parts.

27

 

 

 

 

34

 

 

 

 

 

 

 

15

 

 

 

17

33

 

 

 

 

 

 

 

 

 

 

37

 

30

6

16

 

 

11

 

 

 

16

 

11

 

5

 

 

 

 

 

 

 

11

12

4

13

 

 

28

 

 

 

 

 

 

5

 

 

2

 

7

 

 

3

 

 

 

 

 

11

 

 

21

 

 

 

 

 

 

 

 

 

 

 

8

 

 

 

22

 

 

19

31

33

32 34

20

TO DETERMINE ROTATION OF REEL

9

STANDARD REVERSE

ROTATION ROTATION

Cable is payed out and retracted as shown when viewing reel from spring motor side.

ELECTRICAL CONNECTIONS

SM-21GEAR DRIVE ELECTRIC CABLE REEL REPLACEMENT PARTS LIST

For SM-21Gear Drive Electric Cable Reels manufactured after April 16, 2001

NOTE: Applicable mounting hardware included with each kit.

ITEM

KIT NO.

DESCRIPTION

QTY.

 

 

 

 

1

015899

Main Frame and Gear Case Assembly

1

2

015920

Vertical Frame

1

3

047565

Main Shaft

1

4

012137

Drive Pin

1

5

118322

Retaining Ring

2

6

016516

Bearing Kit - 2"" Bore

1

(Includes mounting hardware)

 

 

 

7

016517

Bearing Kit - 1.75"" Bore

1

(Includes mounting hardware)

 

 

 

8

016518

Bearing Kit - 1.25"" Bore

2

(Includes mounting hardware)

 

 

 

9

016519

Drive Stud Bracket Kit

1

10

015944

Stub Shaft, Drum Gear

1

11

04756601

Spool Assembly - 8"" Dia. Wrapper

1

(Includes two spool disks, wrapper segments & hardware)

 

 

 

11

04756602

Spool Assembly - 9" Dia. Wrapper

1

11

04756603

Spool Assembly - 10" Dia. Wrapper

1

11

04756604

Spool Assembly - 11" Dia. Wrapper

1

11

04756605

Spool Assembly - 12" Dia. Wrapper

1

11

04756606

Spool Assembly - 13" Dia. Wrapper

1

11

04756607

Spool Assembly - 14" Dia. Wrapper

1

11

04756608

Spool Assembly - 15" Dia. Wrapper

1

11

04756609

Spool Assembly - 16" Dia. Wrapper

1

11

04756610

Spool Assembly - 17" Dia. Wrapper

1

12

04169201

Cable Clamp Kit, 0.68 Dia. Cable

1

12

04169202

Cable Clamp Kit, 0.75 Dia. Cable

1

12

04169203

Cable Clamp Kit, 0.81 Dia. Cable

1

12

04169204

Cable Clamp Kit, 0.87 Dia. Cable

1

12

04169205

Cable Clamp Kit, 0.94 Dia. Cable

1

12

04169206

Cable Clamp Kit, 1.00 Dia. Cable

1

12

04169207

Cable Clamp Kit, 1.06 Dia. Cable

1

12

04169208

Cable Clamp Kit, 1.12 Dia. Cable

1

12

04169209

Cable Clamp Kit, 1.18 Dia. Cable

1

12

04169210

Cable Clamp Kit, 1.25 Dia. Cable

1

12

04169211

Cable Clamp Kit, 1.31 Dia. Cable

1

12

04169212

Cable Clamp Kit, 1.38 Dia. Cable

1

12

04169213

Cable Clamp Kit, 1.43 Dia. Cable

1

12

04169214

Cable Clamp Kit, 1.50 Dia. Cable

1

13

012459

Cable Connector, 0.38-0.50Dia. Cable

1

13

012460

Cable Connector, 0.50-0.62Dia. Cable

1

13

012461

Cable Connector, 0.62-0.75Dia. Cable

1

13

012462

Cable Connector, 0.75-0.88Dia. Cable

1

13

012463

Cable Connector, 0.88-1.00Dia. Cable

1

13

012464

Cable Connector, 1.00-1.12Dia. Cable

1

13

012465

Cable Connector, 1.12-1.25Dia. Cable

1

13

012466

Cable Connector, 1.25-1.38Dia. Cable

1

13

012467

Cable Connector, 1.38-1.50Dia. Cable

1

14

016520

Spring Motor Kit, Standard Rotation-100

AR

(Includes snap ring, two pawls, two springs, hub cover, and

 

 

gasket)

 

14

016521

Spring Motor Kit, Reverse Rotation-100

AR

15

012427

Pawl Kit - 100 Spring

1

(Includes two pawls & two springs)

 

 

 

16

016522

Spring Mounting Kit

1

(Includes four extension studs)

 

 

 

17

106873

Collector Drive Access Plug

1

18

032804

Ratchet Spring Adjustment Wrench

1

NOTE: Please consult factory for optional accessories, roller guides, ratchet lock and limit switch.

ITEM

KIT NO.

DESCRIPTION

QTY.

 

 

 

 

19

012285

Collector Assembly, 2 Pole, 35 Amp

1

19

012286

Collector Assembly, 3 Pole, 35 Amp

1

19

012287

Collector Assembly, 4 Pole, 35 Amp

1

19

012288

Collector Assembly, 6 Pole, 35 Amp

1

19

012289

Collector Assembly, 8 Pole, 35 Amp

1

19

012290

Collector Assembly, 10 Pole, 35 Amp

1

19

012291

Collector Assembly, 12 Pole, 35 Amp

1

19

012292

Collector Assembly, 14 Pole, 35 Amp

1

19

012293

Collector Assembly, 16 Pole, 35 Amp

1

19

012298

Collector Assembly, 2 Pole, 75 Amp

1

19

012299

Collector Assembly, 3 Pole, 75 Amp

1

19

012300

Collector Assembly, 4 Pole, 75 Amp

1

19

037194

Collector Assembly, 2 Pole, 125 Amp

1

19

037294

Collector Assembly, 3 Pole, 125 Amp

1

19

037295

Collector Assembly, 4 Pole, 125 Amp

1

19

013756

Collector Assembly, 2 Pole, 200 Amp

1

19

016197

Collector Assembly, 3 Pole, 200 Amp

1

19

013757

Collector Assembly, 4 Pole, 200 Amp

1

20

012440

Brush Kit (35 Amp)

AR

(Each kit includes 4 brushes, and 4 fingers)

 

 

 

20

012441

Brush Kit (75 Amp)

AR

20

012443

Brush Kit (125 Amp / 200 Amp)

AR

21

03742101

Collector Cover Kit (9.75"" long)

1

(Includes seal ring)

 

 

 

21

03742102

Collector Cover Kit (12.75" long)

1

21

03742103

Collector Cover Kit (14.75" long)

1

21

03742104

Collector Cover Kit (19.25" long)

1

22

016213

Seal Ring (only)

1

23

015936

Gear Detensioner Cover

1

24

015937

Gear Detensioner Cover Gasket

1

25

016525

Gear Detensioner Cover Kit

1

(Includes washers, pads and nut)

 

 

 

26

016527

Gear Access Cover Kit

1

(Includes cover and gasket)

 

 

 

27

015945

Spring Shaft, Gear, Std. Rot. (1001)

1

27

01594501

Spring Shaft, Gear, Rev. Rot. (1001)

1

27

015946

Spring Shaft, Gear, Std. Rot. (1002)

1

27

01594601

Spring Shaft, Gear, Rev. Rot. (1002)

1

27

015947

Spring Shaft, Gear, Std. Rot. (1003)

1

27

01594701

Spring Shaft, Gear, Rev. Rot. (1003)

1

27

015948

Spring Shaft, Gear, Std. Rot. (1004)

1

27

01594801

Spring Shaft, Gear, Rev. Rot. (1004)

1

28

016529

Collector Entrance Kit

1

(Includes wiring box, cover and gasket)

 

 

 

29

016202

Gear Kit, Ratio 'M'

1

(Includes one drum gear, and two spring gears)

 

 

 

29

016203

Gear Kit, Ratio 'N'

1

29

016204

Gear Kit, Ratio 'P'

1

29

016205

Gear Kit, Ratio 'Q'

1

29

016206

Gear Kit, Ratio 'R'

1

29

016207

Gear Kit, Ratio 'S'

1

29

016208

Gear Kit, Ratio 'T'

1

29

016209

Gear Kit, Ratio 'V'

1

29

016210

Gear Kit, Ratio 'W'

1

29

016211

Gear Kit, Ratio 'Y'

1

30

015958

Lube Tube, 2" Bore Bearing

1

31

015957

Lube Tube, Gearbox

1

32

016234

Lube Tube, 1.25" Bore Bearing

1

33

015955

Male Connector, 1/4" Tube x 1/8 NPT

5

34

101377

Grease Fitting

3

35

047563

Hex Hd. Cap Screw, .75-10x 4.00

1

36

101030

Hex Nut, .75-10

1

37

015925

Hoop Brace

2

38

021762

Hub Lock Pin Kit (Includes 2 pins)

1

MODEL NUMBER EXPLANATION

SPRING

FRAME

SPRING

NO. OF

*

NO. OF

AMPACITY

CORE

GEAR

PRETENSION

REEL

SERIES

SERIES

SPRINGS

POLES

DIAMETER

RATIO

TURNS

 

 

 

 

 

 

 

 

 

 

 

 

SM

21

100

4

R

- 2

20

10

- V -

1

* INDICATES REVERSE ROTATION

NO LETTER INDICATES STANDARD ROTATION

AMPACITY CODE

 

MAX

CODE

AMPS

3

35

7

75

12

125

20

200

INSTALLATION

Use the following procedure to relieve spring tension prior to cable or spring replacement.

! WARNING

DO NOT insert hands into gearbox until springs are fully detensioned. Doing so could lead to serious injury.

1.Cycle reel thru normal operating cycle and stop when maximum amount of cable is wound onto reel spool.

2.Set spool lock to prevent spool from turning.

3.Remove access cover from top of gearbox.

4.Using open end wrench, loosen large hex nut slowly to allow springs to unwind. Fully loosen nut further with wrench until springs are completely unwound.

5.Repair reel or replace springs or cable as necessary.

6.Retighten nut until definite resistance is felt and spring washers are full compressed (flat). Replace cover.

NOTE: If hex nut is not adequately tightened, spring unwinding can occur during reel operation.

7. Pretension reel. See INSTALLATION section, front page.

CABLE REMOVAL

Use the following procedure to remove worn or damaged cable from reel prior to installation of new cable.

!CAUTION

Failure to relieve all spring tension prior to removing cable could result in damage to equipment or personal injury. Follow instructions carefully.

1.Move machine serviced by reel to a position closest to reel. Springs will still be under pre-tensionat this point.

2.Turn off all electric power.

3.Using spool lock. lock spool to prevent turning.

4.Disconnect cable from machine junction box.

5.Detension springs as described above.

6.Remove cable from spool. Loosen cable clamp and water-tightconnector and disconnect conductors from slip ring.

CABLE INSTALLATION

Use the following procedure to replace cable or if reel was ordered without cable. Refer to CABLE INSTALLATION REFERENCE DRAWING, below.

1.Unspool new cable from shipping spool and lay out to eliminate twist.

NOTE: This step is not essential, but will aid in winding operation of the reel and prolong cable life.

2.Feed one end of the cable through water-tightconnector on the main shaft inside the spool and into the slip ring side (See drawing below).

NOTE: This may require that jacket of cable be stripped to allow conductors to pass through shaft.

3.Connect individual conductors to appropriate rings on collector using crimp fitting or similar connection method.

4.Tighten water-tightconnector and cable clamp in slot on spool disk.Do not over-tighten.

5.Wind the cable onto the reel spool by hand rotating spool in direction it turns free of spring tension.

6.Connect free end of cable to machine junction box.

7.Pretension reel and complete reel installation as previously described.

COLLECTOR REPLACEMENT

1.Turn off all power to reel.

2.Remove collector cover and gasket.

3.Disconnect electric leads to and from collector.

4.Remove drive stud bolt from bearing housing.

5.Remove button plug from hole in side of housing. Insert long 1/8" Allen wrench through hole and loosen two set screws in collector locking collar. Set screws are at 90° to one another.

NOTE: Older reels may have lock screws which must be removed to reach set screws holding collector to shaft.

6.Slide collector off shaft.

7.Install new collector by reversing

Printed in USA

GLEASON REEL CORP.

P.O. Box 26 • 600 South Clark St.

Mayville, WI 53050

Phone 920-387-4120• Fax920-387-4189

Bulletin No. 049661.b