INSTALLATION and MAINTENANCE INSTRUCTIONS
TMR SERIES ELECTRIC CABLE REELS
OPERATION
DESCRIPTION
The reel is activated when power is supplied to the torque
motor through the main starting control of the equipment.
Care should be taken to see that all electrical connections are
made before power is turned on to the collector ring and
torque motor. All nuts and bolts should be checked to see that
they are tight. Check to make sure collector ring brushes are
aligned on rings.
The TMR series reel is designed to automatically lift and
retrieve electric cable. The reel incorporates a rotating hollow
shaft with spool mounted outboard on one end and collector
assembly on the opposite end. The main shaft, rotating on
two flange block bearings, is driven by an electric torque motor
through a chain drive. The torque motor has an electronically
released break holding the spool stationary when the reel is
not in use.
MAINTENANCE
INSTALLATION
GENERAL LUBRICATION: All bearings provided with grease
fittings are lubricated at the factory before shipment. They
should be regreased periodically depending on the running
time of the reel, more often if used in dusty conditions. Parts
with bearing assemblies not provided with grease fittings are
equipped with sealed bearings and do not require lubrication.
1. Thoroughly inspect reel upon receipt for damage that may
have been caused in shipping.
2. Mount reel with the main shaft horizontal and level and
with the spool centerline in line with the cable tray. Mount
at recommended height so that proper distance from the
center of the spool to the cable tray is maintained.
CHAIN CASE: Every three months, remove cover from chain
case, check chain tension, and lubricate chain using a lithium
based heavy duty chain lubricant.
CAUTION
Exceeding designed lift distance may lead
to poor cable spooling and
erratic operation because the electric motor
will have insufficient torque.
TORQUE MOTOR GEAR REDUCER: See section 5.2.2 of
the enclosed brake motor operation instructions for grease
lubrication. This gear reducer is filled with grease when used
with 600 RPM torque motor.
3. Remove collector cover. Connect conduit to line entrance
of collector housing and connect wires to brushes of
collector assembly. Brush terminals are number coded.
Be careful that incoming wires do not put strain on brush
terminals and cause brush misalignment. Replace
collector cover.
4. Connect motor to electric line of proper specification as
stamped on motor nameplate. Refer to wiring diagram
(below, in terminal box or on name plates. 3-lead
polyphase and 2-lead single phase do not require
diagram). Provide suitable overload protection based on
full load ampere rating shown on nameplate as
recommended by control manufacturer. Protect wiring circuit
with proper fuses selected according to local codes.
TORQUE MOTOR: Reel is equipped with a Demag torque
motor. See enclosed brake motor operation instructions.
INSPECTION: Every six months inspect entire reel to see that
all nuts, bolt, screws, and set screws are in place and tight and
that no parts show undue wear. Yearly (more often depending
on duty cycle), check brushes on collector rings. Replace
brushes when worn to the shunt
TORQUE MOTOR
3/60Hz/230V
TORQUE MOTOR
3/60Hz/460V
WIRING DIAGRAM
4
5
6
4
7
1
5
8
2
6
9
3
REEL MOTOR
CONTROL PANEL
(Supplied by customer
7
1
8
2
9
3
L3
L2
L1
T3
T2
T1
T3
SUPPLY VOLTAGE
230V or 460V
T2
3 PHASE 60Hz
T1
NOTE: Reel start/stop circuit should be wired into main machine
power master switch (not to machine travel drive motors). Frequent
starting and stopping of torque motor is not recommended.
Torque motor should be wired to wind cable only. Torque motor
compensates for direction change when cable is unwound.
1
7
4
2
8
5
3
9
6
1
7
2
8
3
9
4
5
6
BLOWER
3/60Hz/460V
BLOWER
3/60Hz/230V
NOTE: Be sure blower motor is also wired up with motor.
CONTINUED ON BACK PAGE
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TMR SERIES ELECTRIC CABLE REEL REPLACEMENT PARTS LIST
NOTE: Applicable mounting hardware included with each kit.
ITEM KIT NO.
DESCRIPTION
Frame Assembly-TMR
Collector Shaft
QTY.
ITEM KIT NO.
DESCRIPTION
Pipe Plug
QTY.
1
1
2
3
021372
020784
021752
1
1
1
14
101652
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
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
Bearing Kit–2" bore
(Includes housing and gasket)
4
5
012402
105060
Bearing Kit–2" Bore
(Includes housing and gasket)
1
1
Retaining Ring
6
6
6
6
6
6
021407
021408
021409
021410
021411
021412
Torque Motor-2
Torque Motor-3
Torque Motor-5
Torque Motor-7
Torque Motor-10
Torque Motor-14
1
1
1
1
1
1
7
021771
Sprocket Kit, Ratio AA
(Includes two sprockets and keys)
Sprocket Kit, Ratio AB
1
7
7
7
7
021772
021773
021774
021775
1
1
1
1
Sprocket Kit, Ratio AC
Sprocket Kit, Ratio AD
Sprocket Kit, Ratio AE
8
021759
Idler Kit
1
(Includes sprocket, shaft, tensioner bar,
locking collar and mounting hardware)
9
021760
Roller Chain Kit
(Includes connecting link)
1
1
10
021006
Reinforcing Plate
16
012440
Brush Kit (35 Amp)
(Each kit includes 4 brushes and 4 fingers)
Brush Kit (75 Amp)
ar
11
11
11
11
11
11
11
11
11
11
11
012459
012460
012461
012462
012463
012464
012465
012466
012467
021764
021765
Cable Connector–.38 to .50 Dia. Cable
Cable Connector–.50 to .62 Dia. Cable
Cable Connector–.62 to .75 Dia. Cable
Cable Connector–.75 to .88 Dia. Cable
Cable Connector–.88 to 1.00 Dia. Cable
Cable Connector–1.00 to 1.12 Dia. Cable
Cable Connector–1.12 to 1.25 Dia. Cable
Cable Connector–1.25 to 1.38 Dia. Cable
Cable Connector–1.38 to 1.50 Dia. Cable
Cable Connector–1.50 to 1.62 Dia. Cable
Cable Connector–1.62 to 1.75 Dia. Cable
1
1
1
1
1
1
1
1
1
1
1
16
16
012441
012443
ar
ar
Brush Kit (125 Amp/200 Amp)
17
012409
Collector Cover Kit (8" long)
(Includes seal ring)
1
17
17
17
17
17
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
18
19
012458
Seal Ring (only)
Spool Assembly
1
1
*
12
021763
Chain Cover Kit
1
(Includes cover, gasket and hardware)
* Consult factory for part number of Spool Assembly and related hardware.
Please give model number and serial number to obtain correct Spool Assembly.
13
016337
Collector Entrance Assembly
1
*SLIP RING
AMPACITY CODE
MAX
**CHAIN RATIO
CODE
MODEL NUMBER EXPLANATION
(Typical model number)
CHAIN
TMR -
4
12
-
XX XX XX
-
AE
-
3
CODE
AMPS
CODE
RATIO
REEL
TYPE
NUMBER
POLES
AMPACITY
CODE*
SPOOL
DIMENSIONS
and TYPE
CHAIN
RATIO
CODE**
MOTOR
SIZE
3
7
12
20
35
75
125
200
AE
AD
AC
AB
AA
1.0:1
1.5:1
2.0:1
2.5:1
3.0:1
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CABLE REMOVAL
3. Connect individual conductors to appropriate rings on
collector using crimp fitting or similar connection method.
4. Tighten cable 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.
Use the following procedure to remove worn or damaged cable
from reel prior to installation of new cable.
1. Move machine serviced by reel to a position closest to
reel.
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. Remove cable from spool. Loosen cable connector (Item 11
on parts list) and disconnect conductors from slip ring.
6. Install new cable following instruction below.
6. Connect free end of cable to machine junction box.
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 plug 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..
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: Older reels may have lock screws which must be
removed to reach set screws holding collector to shaft.
6. Slide collector off shaft.
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 cable connector on
the main shaft inside the spool and into the slip ring side.
(See drawing below).
7. Install new collector by reversing above steps.
NOTE: This may require that jacket of cable be stripped
to allow conductors to pass through shaft.
CABLE INSTALLATION REFERENCE DRAWING
Cable
(Input)
Cable
(Output)
Collector
Reel
Shaft
Cable Gland
Thread gland into
shaft. Thread cable
thru gland and shaft.
Tighten gland cover
to secure cable.
Connect leads
to collector
NOTE:
Strip cable to inside
of gland. Wrap
leads with electrical
tape thru shaft.
Frame/Gear Case
Spool
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. 053151.a
Printed in USA
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