INSTALLATION and MAINTENANCE INSTRUCTIONS
S-21 DIRECT DRIVE ELECTRIC CABLE REELS
MAINTENANCE
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.
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
“IN” with 2/3
Clock-type springs provide power for automatic cable take-up.
Spring must be pretensioned at time of installation to
insure that tension is applied to cable at all times. A tension
adjustment spanner wrench is provided with each reel.
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.
BROKEN SPRING
INDICATORS
cable off reel–
SPRING OK
WARNING
“OUT” with 2/3
cable off reel–
SPRING
Some reels with large or multiple springs are equipped with a
ratcheted adjustment wrench. Follow separate instructions
for its use. Failure to use ratcheted wrench, on reels so
equipped, could result in serious personal injury.
BROKEN
Figure 3
SPRING REPLACEMENT
WARNING
Do not attempt to relieve spring tension using spanner
wrench. Doing so may result in personal injury.
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.
INSTALLATION
1. Insure that machinery to be serviced by reel is at position
closest to 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 dis-
carded completely.
2. Securely mount reel in desired position using 3/8"(M10)
bolts. Be sure spool is aligned with cable run.
3. Position optional cable guide, if reel is so equipped.
See CABLE INSTALLATION DRAWING.
4. Unspool cable from reel, without allowing spool to rotate, so
that desired length of cable extends from reel. Do not pull
cable directly off reel as this will apply tension to the spring
and may cause overtensioning when the reel is put into
service. Connect free end of cable to junction box on
machine or adjust cable stop
1. Turn off all electric power.
2. Disconnect cable from machine junction box.
3. Wind all cable onto reel to relieve all spring tension.
4. Remove inspection cover from face of spring housing.
5. Rotate spool clockwise and observe inner 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 with a 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.
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.
5. Remove cover plate on spring housing to expose
shaft and spring hub. (See Figure 1).
6. Insert spanner wrench into holes in spring hub (Fig 2).
Rotate wrench counterclockwise (for standard rotation).
Number of 360O 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
clockwise. (See EXPLANATION on parts list page.)
COUNTER-
CLOCKWISE
FOR STANDARD
ROTATION
SPRING
HOUSING
COVER
PLATE
SPRING
PAWL
SPRING
HUB
HUB
SPOOL
SHAFT
SPANNER
WRENCH
(Spring not
shown)
Figure 2
Figure 1
SPRING
Install
against flat
CAUTION
SHAFT
GROOVE
Do not exceed number of turns indicated on serial plate.
Over-tensioning can cause a broken spring,
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 on machine or
adjust cord stop so that desired length of cord extends from reel.
11. Tension spring with spanner wrench. Refer to
INSTALLATION section.
NOTE: If reel is equipped with ratcheted adjustment
wrench, follow instructions on separate sheet.
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 collector cover and connect individual supply
conductors to collector terminals. See ELECTRICAL
CONNECTIONS diagram, on parts page.
12. Replace inspection cover.
CONTINUED ON BACK PAGE
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S-21 DIRECT DRIVE ELECTRIC CABLE REEL REPLACEMENT PARTS LIST
NOTE: Applicable mounting hardware included with each kit.
ITEM
KIT NO.
012393
DESCRIPTION
Frame Assembly
QTY.
ITEM
13
13
KIT NO.
017190
017191
DESCRIPTION
Spanner Wrench (35 – 80 Springs)
Spanner Wrench (100 Springs)
QTY.
1
1
1
2
3
1
1
1
012406
Discs (Set of two)
012397
Main Shaft Assembly
(Includes drive pin and retaining rings)
14
032805
Ratchet Wrench Kit (75, 80 Springs)
(Includes mounting bolts)
1
14
15
032804
017054
Ratchet Wrench KIt (100 Springs)
1
4
5
6
012402
012401
012456
Bearing Kit–2" Bore
(Includes housing and gasket)
1
1
1
Extension Bolts (35 – 80 Springs)
(4 bolts per kit–less hardware)
Extension Bolts (100 Springs)
ar
Bearing Kit–1.75" Bore
(Includes housing and gasket)
15
16
17
18
19
20
017055
016182
021291
100959
101211
P06-03
ar
ar
ar
ar
ar
ar
Carriage Bolt, .50–13 x 1.5
Lockwasher, .56 Med., Z.P.
Hex Nut, .50–13, Z.P.
Drive Stud Kit
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
012208
01220801
012209
01220901
012210
01221001
012211
01221101
012212
01221201
012213
01221301
012214
01221401
012371
Stub Shaft, Std. Rotation (351, 601)
Stub Shaft, Rev. Rotation (351, 601)
Stub Shaft, Std. Rot. (621, 751, 801)
Stub Shaft, Rev. Rot. (621, 751, 801)
Stub Shaft, Std. Rot. (622, 752, 802)
Stub Shaft, Rev. Rot. (622, 752, 802)
Stub Shaft, Std. Rot. (623, 753, 803)
Stub Shaft, Rev. Rot. (623, 753, 803)
Stub Shaft, Std. Rot. (624, 754, 804)
Stub Shaft, Rev. Rot. (624, 754, 804)
Stub Shaft, Std. Rotation (1001)
Stub Shaft, Rev. Rotation (1001)
Stub Shaft, Std. Rotation (1002)
Stub Shaft, Rev. Rotation (1002)
Stub Shaft, Std. Rotation (1003)
Stub Shaft, Rev. Rotation (1003)
Stub Shaft, Std. Rotation (1004)
Stub Shaft, Rev. Rotation (1004)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Flat Washer, .50
ESNA Lock Nut, .50–13, Z.P.
21
21
021762
021761
Hub Lock Pins (100 Springs)
Hub Lock Pins (All Other Springs)
ar
ar
22
012457
Button Plug
1
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
012285
012286
012287
012288
012289
012290
012291
012292
012293
012294
012295
012296
012297
012298
012299
012300
012376
012377
037194
037294
037295
012304
012381
012382
012383
012384
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, 20 Pole, 35 Amp
Collector Assembly, 24 Pole, 35 Amp
Collector Assembly, 30 Pole, 35 Amp
Collector Assembly, 36 Pole, 35 Amp
Collector Assembly, 2 Pole, 75 Amp
Collector Assembly, 3 Pole, 75 Amp
Collector Assembly, 4 Pole, 75 Amp
Collector Assembly, 6 Pole, 75 Amp
Collector Assembly, 8 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
Collector Assembly, 6 Pole, 200 Amp
Collector Assembly, 8 Pole, 200 Amp
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
01237101
014619
01461901
8
8
9
012416
012417
012444
Wrapper Kit–5" Wide, 8" to 14" Dia.
(Includes 4 wrapper sections)
1
1
1
Wrapper Kit–5" Wide, 15" to 20"Dia.
(Includes 8 wrapper sections)
Cable Clamp Kit .38–.74 Dia. Cable
(U-bolt with lockwashers and hex nuts)
Cable Clamp Kit .75–1.11 Dia. Cable
Cable Clamp Kit 1.12–1.50 Dia. Cable
9
9
012445
012446
1
1
10
10
10
10
10
10
10
10
10
012459
012460
012461
012462
012463
012464
012465
012466
012467
Cable Connector .38–.50 Cable Dia.
Cable Connector .50–.62 Cable Dia.
Cable Connector .62–.75 Cable Dia.
Cable Connector .75–.88 Cable Dia.
Cable Connector .88–1.00 Cable Dia.
Cable Connector 1.00–1.12 Cable Dia.
Cable Connector 1.12–1.25 Cable Dia.
Cable Connector 1.25–1.38 Cable Dia.
Cable Connector 1.38–1.50 Cable Dia.
1
1
1
1
1
1
1
1
1
24
012440
Brush Kit (35 Amp)
ar
(Each kit includes 4 brushes and 4 fingers)
Brush Kit (75 Amp)
11
017041
Spring Motor Kit, Std. Rot.–35
ar
24
24
012441
012443
ar
ar
(Includes pawl, pawl springs, cover, gaskets, and snap ring)
Brush Kit (125 Amp/200 Amp)
11
11
11
11
11
11
11
11
11
11
11
017042
017043
017044
017045
017046
017047
017048
017049
017050
017051
017052
Spring Motor Kit, Rev. Rot.–35
Spring Motor Kit, Std. Rot.–60
Spring Motor Kit, Rev. Rot.–60
Spring Motor Kit, Std. Rot.–62
Spring Motor Kit, Rev. Rot.–62
Spring Motor Kit, Std. Rot.–75
Spring Motor Kit, Rev. Rot.–75
Spring Motor Kit, Std. Rot.–80
Spring Motor Kit, Rev. Rot.–80
Spring Motor Kit, Std. Rot.–100
Spring Motor Kit, Rev. Rot.–100
ar
ar
ar
ar
ar
ar
ar
ar
ar
ar
ar
25
012409
Collector Cover Kit (8" long)
(Includes seal ring)
1
25
25
25
25
25
012410
012411
012412
012413
012414
Collector Cover Kit (10.5" long)
Collector Cover Kit (13" long)
Collector Cover Kit (15.5" long)
Collector Cover Kit (20.5" long)
Collector Cover Kit (28.5" long)
1
1
1
1
1
26
012458
Seal Ring (only)
1
NOTE:
Please consult factory for optional accessories: roller guides, ratchet lock, limit
switch, hoop guides, spool lock, and swivel base.
12
012425
Pawl Kit (35, 60 Springs)
(Includes 2 pawls and springs)
Pawl Kit (62, 75, 80 Springs)
Pawl Kit (100 Springs)
ar
12
12
012426
012427
ar
ar
MODEL NUMBER EXPLANATION
AMPACITY
SPRING
REEL
FRAME
SERIES
SPRING
SERIES
NO. OF
SPRINGS
NO. OF
POLES
CORE
DIAMETER
PRETENSION
TURNS
AMPACITY
CODE
AMPS
35
3
7
75
S 21 80 2 R - 12 3 10 - 1
12
20
125
200
INDICATES REVERSE ROTATION.
NO LETTER INDICATES STANDARD ROTATION.
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CABLE REMOVAL
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).
Use the following procedure to remove worn or damaged cable
from reel prior to installation of new cable.
NOTE: This may require that jacket of cable be stripped
to allow conductors to pass through shaft.
CAUTION
3. Connect individual conductors to appropriate rings on
collector using crimp fitting or similar connection method.
4. Tighten water-tight connector and U-bolt provided on
drum wrapper segments. 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 installation as
previously described.
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-tension at this point.
2. Turn off all electric power.
3. Lock spool to prevent turning using either a spool lock
mechanism or by tying off.
4. Disconnect cable from machine junction box.
5. Grip spool by hand and carefully release spool lock or
tie. Slowly unwind remaining tension.
6. Again lock or tie spool to prevent rotation.
7. Remove cable from spool. Loosen U-bolt and water-tight
connector and disconnect conductors from slip ring.
8. Install new cable following instruction at right.
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 studd 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 90O
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.
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.
7. Install new collector by reversing above steps.
NOTE: This step is not essential, but will aid in winding
operation of the reel and prolong cable life.
CABLE INSTALLATION REFERENCE DRAWING
SPOOL ROTATION DIRECTION
TO WIND CABLE WHEN
INSTALL CABLE
THIS DIRECTION
VIEWED FROM SPRING SIDE
(STANDARD ROTATION)
POSITION CABLE
GUIDE (OPTIONAL)
SO THAT ROLLER
TERMINATE THIS END TO
MACHINE JUNCTION BOX
CABLE
PAYOFF
DIRECTION–
OPTIONAL
GUIDE
PLATE FACES CABLE
PAYOFF DIRECTION.
BUTTON
PLUG
LINE
ATTACH INDIVIDUAL
CONDUCTORS TO
COLLECTOR LEADS
AT THIS END
U-BOLT
LOCATION
WATER- TIGHT
CONNECTOR
ENTRANCE
(NPT)
PRETENSION
HUB
COLLECTOR
COVER
PAYOFF
DIRECTION
REMOVE
SPRING
MOTOR
SPRING MOTOR
HOOP GUIDE
(OPTIONAL)
SLIP RING
ASSEMBLY
PAYOFF
DIRECTION–
OPTIONAL
GUIDE
SPOOL
MAIN SHAFT
LOCATION
GLEASON REEL CORP.
P.O. Box 26 • 600 South Clark St.
Mayville, WI 53050–0026
Phone 920–387–4120
®
®
HUBBELL A Hubbell Company
Fax 920–387–4189
Bulletin No. 040251.a
Printed in USA
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