Hubbell Stereo System SM21 User Manual

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.  
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.  
Clock-type springs provide power for automatic cable take-  
up. 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.  
B. Inspect cable for wear and  
check mounting bolts and other  
hardware for tightness.  
“IN” with 2/3  
cable off reel–  
SPRING OK  
BROKEN SPRING  
INDICATORS  
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.  
“OUT” with 2/3  
cable off reel–  
SPRING  
WARNING  
!
Do not attempt to relieve spring tension using spanner  
wrench. Doing so may result in personal injury.  
BROKEN  
NOTE: Bearings and springs  
are prelubricated and require no  
periodic maintenance.  
Figure 3  
INSTALLATION  
1. Ensure that machinery to be serviced by reel is at position  
closest to reel.  
WARNING  
!
Do not attempt to remove spring from its housing. Clock-  
type springs can be dangerous to handle. Removal of  
spring from housing could result in personal injury.  
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  
SPRING REPLACEMENT  
4. Connect free end of cable to junction box on machine or  
adjust cable stop so that desired length of cable extends  
from reel.  
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.  
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  
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.  
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.)  
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: On multi-spring reels, be sure to remove and save  
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.  
CAUTION  
!
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.  
Do not exceed number of turns indicated on  
serial plate. Over-tensioning can cause a  
broken spring, sheared shaft or other damage.  
SPRING  
PAWL  
HUB  
SPOOL  
SHAFT  
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.  
(Spring not  
shown)  
SPRING  
Install  
against flat  
SHAFT  
GROOVE  
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.  
END VIEW  
SIDE VIEW  
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.  
8. Remove collector cover and connect individual supply  
conductors to collector terminals. See ELECTRICAL  
CONNECTIONS diagram, on parts page.  
12. Tension spring with spanner wrench. Refer to  
INSTALLATION section  
13. Replace inspection cover and top gear access cover.  
CONTINUED ON BACK PAGE  
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SM-21 GEAR DRIVE ELECTRIC CABLE REEL REPLACEMENT PARTS LIST  
For SM-21 Gear Drive Electric Cable Reels manufactured after April 16, 2001  
NOTE: Applicable mounting hardware included with each kit.  
ITEM  
KIT NO.  
DESCRIPTION  
QTY.  
ITEM  
KIT NO.  
DESCRIPTION  
QTY.  
19  
19  
19  
19  
19  
19  
19  
19  
19  
19  
19  
19  
19  
19  
19  
19  
19  
19  
012285  
012286  
012287  
012288  
012289  
012290  
012291  
012292  
012293  
012298  
012299  
012300  
037194  
037294  
037295  
013756  
016197  
013757  
Collector Assembly, 2 Pole, 35 Amp  
Collector Assembly, 3 Pole, 35 Amp  
Collector Assembly, 4 Pole, 35 Amp  
Collector Assembly, 6 Pole, 35 Amp  
Collector Assembly, 8 Pole, 35 Amp  
Collector Assembly, 10 Pole, 35 Amp  
Collector Assembly, 12 Pole, 35 Amp  
Collector Assembly, 14 Pole, 35 Amp  
Collector Assembly, 16 Pole, 35 Amp  
Collector Assembly, 2 Pole, 75 Amp  
Collector Assembly, 3 Pole, 75 Amp  
Collector Assembly, 4 Pole, 75 Amp  
Collector Assembly, 2 Pole, 125 Amp  
Collector Assembly, 3 Pole, 125 Amp  
Collector Assembly, 4 Pole, 125 Amp  
Collector Assembly, 2 Pole, 200 Amp  
Collector Assembly, 3 Pole, 200 Amp  
Collector Assembly, 4 Pole, 200 Amp  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
015899  
015920  
047565  
012137  
118322  
Main Frame and Gear Case Assembly  
Vertical Frame  
1
1
1
1
2
Main Shaft  
Drive Pin  
Retaining Ring  
Bearing Kit - 2"" Bore  
(Includes mounting hardware)  
6
7
8
016516  
016517  
016518  
1
1
2
Bearing Kit - 1.75"" Bore  
(Includes mounting hardware)  
Bearing Kit - 1.25"" Bore  
(Includes mounting hardware)  
9
016519  
015944  
Drive Stud Bracket Kit  
Stub Shaft, Drum Gear  
1
1
10  
Spool Assembly - 8"" Dia. Wrapper  
(Includes two spool disks, wrapper segments & hardware)  
11  
04756601  
1
11  
11  
11  
11  
11  
11  
11  
11  
11  
12  
12  
12  
12  
12  
12  
12  
12  
12  
12  
12  
12  
12  
12  
13  
13  
13  
13  
13  
13  
13  
13  
13  
04756602  
04756603  
04756604  
04756605  
04756606  
04756607  
04756608  
04756609  
04756610  
04169201  
04169202  
04169203  
04169204  
04169205  
04169206  
04169207  
04169208  
04169209  
04169210  
04169211  
04169212  
04169213  
04169214  
012459  
Spool Assembly - 9" Dia. Wrapper  
Spool Assembly - 10" Dia. Wrapper  
Spool Assembly - 11" Dia. Wrapper  
Spool Assembly - 12" Dia. Wrapper  
Spool Assembly - 13" Dia. Wrapper  
Spool Assembly - 14" Dia. Wrapper  
Spool Assembly - 15" Dia. Wrapper  
Spool Assembly - 16" Dia. Wrapper  
Spool Assembly - 17" Dia. Wrapper  
Cable Clamp Kit, 0.68 Dia. Cable  
Cable Clamp Kit, 0.75 Dia. Cable  
Cable Clamp Kit, 0.81 Dia. Cable  
Cable Clamp Kit, 0.87 Dia. Cable  
Cable Clamp Kit, 0.94 Dia. Cable  
Cable Clamp Kit, 1.00 Dia. Cable  
Cable Clamp Kit, 1.06 Dia. Cable  
Cable Clamp Kit, 1.12 Dia. Cable  
Cable Clamp Kit, 1.18 Dia. Cable  
Cable Clamp Kit, 1.25 Dia. Cable  
Cable Clamp Kit, 1.31 Dia. Cable  
Cable Clamp Kit, 1.38 Dia. Cable  
Cable Clamp Kit, 1.43 Dia. Cable  
Cable Clamp Kit, 1.50 Dia. Cable  
Cable Connector, 0.38-0.50 Dia. Cable  
Cable Connector, 0.50-0.62 Dia. Cable  
Cable Connector, 0.62-0.75 Dia. Cable  
Cable Connector, 0.75-0.88 Dia. Cable  
Cable Connector, 0.88-1.00 Dia. Cable  
Cable Connector, 1.00-1.12 Dia. Cable  
Cable Connector, 1.12-1.25 Dia. Cable  
Cable Connector, 1.25-1.38 Dia. Cable  
Cable Connector, 1.38-1.50 Dia. Cable  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Brush Kit (35 Amp)  
(Each kit includes 4 brushes, and 4 fingers)  
20  
012440  
AR  
20  
20  
012441  
012443  
Brush Kit (75 Amp)  
AR  
AR  
Brush Kit (125 Amp / 200 Amp)  
Collector Cover Kit (9.75"" long)  
(Includes seal ring)  
21  
03742101  
1
21  
21  
21  
22  
23  
24  
03742102  
03742103  
03742104  
016213  
Collector Cover Kit (12.75" long)  
Collector Cover Kit (14.75" long)  
Collector Cover Kit (19.25" long)  
Seal Ring (only)  
1
1
1
1
1
1
015936  
Gear Detensioner Cover  
015937  
Gear Detensioner Cover Gasket  
Gear Detensioner Cover Kit  
(Includes washers, pads and nut)  
25  
26  
016525  
016527  
1
1
Gear Access Cover Kit  
(Includes cover and gasket)  
27  
27  
27  
27  
27  
27  
27  
27  
015945  
01594501  
015946  
Spring Shaft, Gear, Std. Rot. (1001)  
Spring Shaft, Gear, Rev. Rot. (1001)  
Spring Shaft, Gear, Std. Rot. (1002)  
Spring Shaft, Gear, Rev. Rot. (1002)  
Spring Shaft, Gear, Std. Rot. (1003)  
Spring Shaft, Gear, Rev. Rot. (1003)  
Spring Shaft, Gear, Std. Rot. (1004)  
Spring Shaft, Gear, Rev. Rot. (1004)  
1
1
1
1
1
1
1
1
01594601  
015947  
012460  
01594701  
015948  
012461  
012462  
01594801  
012463  
Collector Entrance Kit  
(Includes wiring box, cover and gasket)  
28  
29  
016529  
016202  
1
1
012464  
012465  
Gear Kit, Ratio 'M'  
(Includes one drum gear, and two spring gears)  
012466  
29  
29  
29  
29  
29  
29  
29  
29  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
016203  
016204  
016205  
016206  
016207  
016208  
016209  
016210  
016211  
015958  
015957  
016234  
015955  
101377  
047563  
101030  
015925  
021762  
Gear Kit, Ratio 'N'  
1
1
1
1
1
1
1
1
1
1
1
1
5
3
1
1
2
1
012467  
Gear Kit, Ratio 'P'  
Spring Motor Kit, Standard Rotation-100  
(Includes snap ring, two pawls, two springs, hub cover, and  
gasket)  
14  
016520  
AR  
Gear Kit, Ratio 'Q'  
Gear Kit, Ratio 'R'  
14  
15  
016521  
012427  
Spring Motor Kit, Reverse Rotation-100  
AR  
1
Gear Kit, Ratio 'S'  
Pawl Kit - 100 Spring  
(Includes two pawls & two springs)  
Gear Kit, Ratio 'T'  
Gear Kit, Ratio 'V'  
Spring Mounting Kit  
(Includes four extension studs)  
Gear Kit, Ratio 'W'  
16  
016522  
1
Gear Kit, Ratio 'Y'  
17  
18  
106873  
032804  
Collector Drive Access Plug  
1
1
Lube Tube, 2" Bore Bearing  
Lube Tube, Gearbox  
Lube Tube, 1.25" Bore Bearing  
Male Connector, 1/4" Tube x 1/8 NPT  
Grease Fitting  
Ratchet Spring Adjustment Wrench  
NOTE: Please consult factory for optional accessories, roller guides,  
ratchet lock and limit switch.  
Hex Hd. Cap Screw, .75-10 x 4.00  
Hex Nut, .75-10  
Hoop Brace  
Hub Lock Pin Kit (Includes 2 pins)  
AMPACITY CODE  
MAX  
MODEL NUMBER EXPLANATION  
SPRING FRAME  
SPRING  
NO. OF  
NO. OF  
POLES  
CORE  
GEAR  
RATIO  
PRETENSION  
TURNS  
CODE  
AMPS  
*
AMPACITY  
REEL  
SERIES  
SERIES SPRINGS  
DIAMETER  
3
7
35  
75  
SM  
21  
100  
4
R
- 2  
20  
10  
- V -  
1
12  
20  
125  
200  
* INDICATES REVERSE ROTATION  
NO LETTER INDICATES STANDARD ROTATION  
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INSTALLATION  
CABLE INSTALLATION  
Use the following procedure to relieve spring tension prior to  
cable or spring replacement.  
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.  
WARNING  
!
DO NOT insert hands into gearbox until springs are fully  
detensioned. Doing so could lead to serious injury.  
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-tight connector on  
the main shaft inside the spool and into the slip ring side (See  
drawing below).  
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.  
NOTE: This may require that jacket of cable be stripped to  
allow conductors to pass through shaft.  
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.  
3. Connect individual conductors to appropriate rings on  
collector using crimp fitting or similar connection method.  
5. Repair reel or replace springs or cable as necessary.  
4. Tighten water-tight connector and cable clamp in slot on spool  
disk. Do not over-tighten.  
6. Retighten nut until definite resistance is felt and spring  
washers are full compressed (flat). Replace cover.  
5. Wind the cable onto the reel spool by hand rotating spool in  
direction it turns free of spring tension.  
NOTE: If hex nut is not adequately tightened, spring unwinding  
can occur during reel operation.  
6. Connect free end of cable to machine junction box.  
7. Pretension reel. See INSTALLATION section, front page.  
7. Pretension reel and complete reel installation as previously  
described.  
CABLE REMOVAL  
COLLECTOR REPLACEMENT  
1. Turn off all power to reel.  
Use the following procedure to remove worn or damaged cable  
from reel prior to installation of new cable.  
2. Remove collector cover and gasket.  
!
CAUTION  
3. Disconnect electric leads to and from collector.  
4. Remove drive stud bolt from bearing housing.  
Failure to relieve all spring tension prior to removing  
cable could result in damage to equipment or  
personal injury. Follow instructions carefully.  
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.  
1. Move machine serviced by reel to a position closest to reel.  
Springs will still be under pre-tension at this point.  
NOTE: Older reels may have lock screws which must be  
removed to reach set screws holding collector to shaft.  
2. Turn off all electric power.  
6. Slide collector off shaft.  
3. Using spool lock. lock spool to prevent turning.  
4. Disconnect cable from machine junction box.  
5. Detension springs as described above.  
7. Install new collector by reversing  
6. Remove cable from spool. Loosen cable clamp and water-tight  
connector and disconnect conductors from slip ring.  
GLEASON REEL CORP.  
P.O. Box 26 • 600 South Clark St.  
Mayville, WI 53050  
Phone 920-387-4120 • Fax 920-387-4189  
Printed in USA  
Bulletin No. 049661.b  
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