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Hubbell Gear Drive Electric Cable Reels S-28 User Manual

Installation and maintenance instructions, S-28 gear drive electric cable reels, Warning

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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-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.

INSTALLATION

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

closest to reel.

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

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 clockwise (for standard rotation).
Number of 360

O

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.)

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.

CONTINUED ON BACK PAGE

INSTALLATION and MAINTENANCE INSTRUCTIONS

S-28 GEAR DRIVE ELECTRIC CABLE REELS

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.

D. Apply grease to gears

through grease fitting on side
of gear housing.

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

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 dis-
carded completely.
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 spring shaft. Shaft

should rotate counterclockwise 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 reel 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.

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.

12. Replace inspection cover.

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.

WARNING

BROKEN SPRING

INDICATORS

“IN” with 2/3

cable off reel–

SPRING OK

“OUT” with 2/3

cable off reel–

SPRING

BROKEN

Figure 3

COVER

PLATE

SPRING

HUB

SPRING

HOUSING

CLOCKWISE

FOR STANDARD

ROTATION

SPANNER

WRENCH

Figure 1

Figure 2

PAWL

SIDE VIEW

END VIEW

SPRING

Install

against flat

SPRING

HUB

(Spring not

shown)

SHAFT

GROOVE

SPRING

SHAFT

Printed in USA

Bulletin No. 040254.c

®

HUBBELL

®

A Hubbell Company

GLEASON REEL CORP.

P.O. Box 26 • 600 South Clark St.

Mayville, WI 53050–0026

Phone 920–387–4120

Fax 920–387–4189

INSTALL CABLE
THIS DIRECTION

SLIP RING

ASSEMBLY

CABLE

SPOOL

HOOP GUIDE

(OPTIONAL)

PAYOFF

DIRECTION

PRETENSION

HUB

PAYOFF

DIRECTION–

OPTIONAL

GUIDE

LOCATION

POSITION CABLE

GUIDE (OPTIONAL)

SO THAT ROLLER

PLATE FACES CABLE

PAYOFF DIRECTION.

U-BOLT

WATER- TIGHT
CONNECTOR

SPRING MOTOR

SPRING
MOTOR

MAIN SHAFT

TERMINATE THIS END TO
MACHINE JUNCTION BOX

ATTACH INDIVIDUAL

CONDUCTORS TO

COLLECTOR LEADS

AT THIS END

COLLECTOR

COVER

REMOVE

LINE

ENTRANCE

(NPT)

PAYOFF

DIRECTION–

OPTIONAL

GUIDE

LOCATION

CABLE INSTALLATION REFERENCE DRAWING

SPOOL ROTATION DIRECTION

TO WIND CABLE WHEN

VIEWED FROM SPRING SIDE

(STANDARD ROTATION)

PIPE

PLUG

SPRING DETENSIONING

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

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.
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 spool lock.
4. Disconnect cable from machine junction box.
5. Detension springs as described above.
6. Remove cable from spool. Loosen U-bolt and water-tight

connector 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-tight connector 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-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.

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 pipe 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

O

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 above steps.

DO NOT insert hands into gearbox until springs are fully

detensioned. Doing so could lead to serious injury.

WARNING

Failure to relieve all spring tension prior to removing cable

could result in damage to equipment or personal injury.

Follow instructions carefully.

CAUTION

Do not attempt to relieve spring tension using spanner

wrench. Doing so may result in personal injury.

WARNING

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.

WARNING

Do not exceed number of turns indicated on serial plate.

Over-tensioning can cause a broken spring,

sheared shaft or other damage.

CAUTION

For reels manufactured after July 1, 1999