Hubbell Work Light S 21 User Manual

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  
INwith 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 Indicatorson 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  
OUTwith 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 530500026  
Phone 9203874120  
®
®
HUBBELL A Hubbell Company  
Fax 9203874189  
Bulletin No. 040251.a  
Printed in USA  
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