Cable Reel Manual PDF

INSTRUCTION MANUAL
FOR
CABLE REEL TYPE:
700.6 TM1126-71G
K4360/FC/R
TM9P
WORKS ORDER N. 100994

ORDER N. 34933-1 dated 18.05.10
CAVOTEC SVERIGE AB / MAC-GREGOR
CAVOTEC SPECIMAS HYDRODYNAMIC SYSTEM
INDEX
TECHNICAL DESCRIPTION:
- Cable reel code key

- Installation drawing and reel calculation
- Technical specification
- General information
General warnings and safety precautions ................................................. chp 0 -rev.1
Introduction to the system ......................................................................... chp 1 -rev.1
How the torque unit works ......................................................................... chp 2 -rev.1
Cable reel assembly instructions .....................................................chp 3.1 -C.100994
Drum assembly instructions .............................................................chp 4.8 -C.100994
Electric diagram ........................................................................................chp 5 -Rev.0

Functional descriptions
Torque output regulation, measuring and testing instructions ................ chp 6.3 -rev.3
Maintenance instructions ........................................................................... chp 7 -rev.9
Trouble shooting the hydrodynamic drive................................................... chp 8 -rev.2
Limit switch STROMAG........................................................................... chp 9.1 -rev.0
Parts lists............................................................................................................ chp 10
CAVOTEC SPECIMAS
Works order nr. Date Edited By
100994 28.07.10 E. ROSSETTO
Approved By
ING. ROSENWALD
WARRANTY FORM
Order N° :
Delivery date :
Warranty Expire date :
1.- All Cavotec Specimas products are warranted against material defects and faulty workmanship for a
period of 12 months from start-up or 18 months from date of delivery ex-works Italy (unless other
wise agreed).
Special Warranty period agreed: ………………………………………………………………...
2.- During the warranty period, Cavotec Specimas SpA will repair or substitute free of charge any parts
that are shown to be defective as a result of material defects or faulty workmanship.
3.- All repairs or substitutions will be carried out by Cavotec Specimas SpA at Via Galvani 1, I-20054,
Nova Milanese - MI, Italy (our factory), or by an authorised representative. Transportation costs are
excluded from the warranty.
4.- This warranty does not cover:
- Defects resulting from inappropriate transport, storage, or usage.
- Defects resulting from incorrect mounting or modifications made by the customer.
- Defects resulting from the use of non-genuine spare parts.
- Parts that have failed as a result of normal wear and tear (Eg. brushes, oil, wearing strips, etc)
- Consequential damages resulting from incorrect mounting, start-up, bad storage, bad
maintenance or abuse of the equipment.
5.- Cavotec Specimas SpA will not be held liable for:
- Costs associated with dismounting, mounting and adjustments.
- Direct or indirect damages.
6.- In order to assist our customers, Cavotec Specimas SpA agree, in certain breakdown situations, to
send emergency replacement warranty parts without necessarily first confirming the validity of any
associated claim. However, the customer must immediately send the damaged part/s to our factory
for analysis. If we don’t receive the damaged part/s within 1 (one) month, or if we determine that
the claim is invalid upon inspecting the damaged part/s, Cavotec Specimas SpA will invoice the
customer the total amount of the part/s sent for replacement.
Claims:
- The Company will not consider claims for short supply of equipment unless made within fifteen
days of receipt by the Buyer.
- The Company will not assume any expenses, liability or responsibility for repairs made outside
its plant without its written authority.
- The Company’s liability in all cases is strictly limited to the cost of replacement or of the repair
to the actual goods sold, and does not extend, in any circumstances including the negligence of
the Company or those for whom the Company is responsible, to any other claims, amounts or
damages of any nature whatsoever.
- The Company is not in any circumstances, including the negligence of the Company or those
for whom the Company is including negligence, responsible for consequential damages or
secondary charges.
Jurisdiction:
In case of disputes in connection with these terms, the Law Court of the place of registration of the
Company – Monza (MI) Italy, will settle them according to the law of Italy.
Cavotec Specimas SpA Via Galvani, 1, 20054 Nova Milanese (MI) Italy Tel.+39 0362 451 111 Fax +39 0362 41 233
11/07/97 Rev.1 TB185 page1
Customer: MacGregor Date: 20/07/2010
Your Project: MacGregor Our re SF
Cable reel calculation. Quotation N. V100174
Input data: Cable type: 3x240+3x50
Installation type: Horizontal
Drum type: Triple monospiral Reel
Working voltage: 690 Volts
Reeling cable capacity: 432 Amp at 100% ED:
Reeling cable length: 40 meters
Max cable reeling tension: 1110 daN
Cable weight / diameter: 10,20 kg/m / 67 mm
Crane speed: 15 m/min
Acceleration time: 2,0 sec 0,13 m/sec2
Installation height: 7,0 m
Mechanical duty cycle: 40 %ED
Height between cable guide 500,0 mm
Max / Min ambient temp.: 45 \ -10 °C
Results: Drive type: Hydrodynamic

Drum ID: 1100 mm
Drun OD: 2600 mm Torque regulation: Constant
Drum nominal width: 71 mm Torque levels:
Outer layer on drum: 2306 mm TL1 = 393 daNm
Drum weight: 320 kg
Torque: Acceleration torque: 16 daNm
Lifting torque: 278 daNm
Total toque: 300 daNm
Max. Setting Torque: 393 daNm
Gearbox: Gearbox type: 700
Prereducer type: not needed
Gearbox reduction: 256,0
Motor Nr 1 data: 5,5 kW
Motor Nr 2 data: 5,5 kW no brake used
Motor data: 440 Volt/Hz 60

Motor temp.sensor Clixon
Motor heater 220V 25W
Recovery speed: 20 m/min Max.drum rot.speed 3,3 rpm
Nr of drum turns: 7 revs Max.reel motor spe 1110 rpm
Appr.weight: Cable reel with cable 3069 kg
Cable reel without cable: 1608 kg
Reel type: 700.6 TM1126-71G K4360/FC/R - TM9P
Collector: Heater: 220/240V 50W self reg Cable guide: TM9P

Collector end limit switchFce/1:29/4 Stromag Limit switches:
5th ring no centre point direction: yes
Pilot ring number no slack cable: yes
Hinged door no over tension: no
Klockner for door no Wired switches no
Lexan Windows no P-belt lifter: no
Security lock no
Surge arrestors no
Fibre Optic FO - Nr fibres no
Fibre type no
Revolution number: no
Connectors type: no
Lexan Windows no Hydrodynamic Motor control:
FO box heater: no Hydrodynamic motor contrno
Accessories: Hydrodynamic Motor Numb no
Accessories: Hydro Panel :
Turnover anchor: no
Cable grip type: no
Other: motor special voltage

Other: drum front box
Other: special TM9P
Other: cast iron motor
Other: Copper bar + basement
Notes:
TECHNICAL SPECIFICATION
CAVOTEC SPECIMAS CABLE REEL
Customer: CAVOTEC SVERIGE AB / MAC-GREGOR
Customer P.O.: 34933-1 dated 18.05.10
Internal works: 100994
POWER CABLE REEL TYPE
700.6 TM1126-71G K4360/FC/R TM9P
COMPOSED OF:
1) Torque unit: Manufacturer: CAVOTEC SPECIMAS S.p.A.

Type: 700.0
Reduction: 1:256
Maximum Torque: 570 daNm
Oil type: SHALL SPIRAX ASX 75W 90
Torque setting: 393 Kgm
2) Motor: Manufacturer: CAVOTEC SPECIMAS S.p.A.

Number of motors: 2 CAST IRON
Size: 6 poles
Voltage/cycle: 690V – 60Hz
Power: 5.5 kW
Speed: 920 Rpm
Insulation Class: CLASS F
Protection class: IP55
Space heater: 220V - 25W
3) Drum: Manufacturer: CAVOTEC SPECIMAS S.p.A.

Type: TM1126-71G Triple monospiral
Outside diameter: 2600 mm
Internal diameter: 1100 mm
Width: 71 mm
Accessory: Front box on flange
Surface treatment: Hot dip galvanized
4) Slipring: Manufacturer: CAVOTEC SPECIMAS S.p.A.

Type: K4360/FC/R
Nominal operating voltage: 1000V
Nr of rings: power: 12
control: //
Rating(60% Duty Cycle): 600 Amp
Rating(100% “ ): 300 Amp
Space heater type: self-regulating
Space heater Watlow: 220/240V - 50W
Housing: stainless steel AISI 304
27.07.10 Rev.0 c. 100994 page 1/2
5) Rotary Limit
Switch: Manufacturer: STROMAG
Number of contacts: 4
Contacts type: Changeover
Reduction ratio: 1:25
Max operating voltage: 250V/6A
6) Cable guide: Manufacturer: CAVOTEC SPECIMAS S.p.A.

Type: TM9P
Microswitches type / number: Telemecanique / 4
Max operating voltage: 500V
Pendulum: YES
TECHNICAL DATA:
The reel has been engineered and manufactured according to the technical data given by
the customer.
Recovery type: Horizontal

Cable type: 3x240+3x50
Cable diameter and weight per meter: 67 mm and 10.20 Kg/m
Reeling length: 40 m
Installation height: 7.0 m
Crane speed: 15.0 m/min
Acceleration time: 2.0 sec.
Ambient Temperature: - 10 degree C / 45 degree C
Mechanical Duty Cycle: 40%ED
Feed point: central
27.07.10 Rev.0 c. 100994 page 2/2

GENERAL INFORMATION
This “operations manual” is intended as a guide to the mounting, use and maintenance of
Specimas “cable reel “ Specimas S.p.A. or its affiliated Companies accept no liability for
loss or damage suffered as a result of the use of this manual.
If in doubt, always refer to the original equipment manufacturer.
Refer at all time to the “General Warnings” chp. 0H.
Warranty is not valid in any way if the cable reel has been used in the wrong way or the
technical specifications for use and installation of the cable reel has not been followed.
Only instructed maintenance people are allowed to be near the cable reel during
supervised maintenance.
GENERAL WARNINGS AND SAFETY PRECAUTIONS
The cable reel movement is remotely controlled by the crane or the machine on which it is
installed. Thus if the machine starts moving the cable reel will start rotating.
People should not stay in the proximity of the cable reel during normal operation.
Maintenance people should be informed and understand the risks before working on the
cable reel.
The area around the cable reel should be closed for any other people.
All persons working with the cable reel must be informed where the nearest emergency
stop button is located.
Before removing the cover of the collector be sure the power (medium or low voltage) has
been shut off.
For this reason check again with your specialised personnel that there is no power on line
and there is no possibility to switch on the power while you have access to the power rings
of the collector.
Check always before touching the collector’s ring, with an appropriate tool, that there is
no power on.
The warning panels (on the medium voltage collectors) are placed in view to warn you
about the danger: “HIGH VOLTAGE”.
Inside the medium voltage collector, once you remove the cover, there is another
protection in order to do not touch the rings: a metallic net with the warning “HIGH
VOLTAGE”
The padlock keys supplied for the interlock of the protection net inside the medium voltage
collector has to be welded or fixed to the central main circuit breaker’s key, in a manner
that is not possible to have access to the collector’s power rings if the power is on.
Whenever must be open a medium voltage collector, after switching off the power,
connect each phase ring to the ground with an earthling cable.
If heaters or travel limit switches are delivered in the collector enclosure these can still
have tension on the terminals even if the main power is switched off.
Stay away from all moving parts, such as drums, motors, cable guides, cables.
Specimas will not be held responsible for the lack or misuse of above systems
ENGINEERING WARNING FOR THE CABLE REEL INSTALLATION!
Walkways suggested at least along one drum side in order to allow an easy access
to the cable reel for the maintenance and torque set-up operations.
30/07/1997 REV 1 Chp0H page 1

INTRODUCTION TO THE SYSTEM
Specimas cable reeling system is composed of module groups, each one performs a
specific function; the drawing shown below allows an easy identification of each
component, which is individually described in the following page.
1. MOTOR electric, hydraulic, pneumatic

2. TORQUE UNIT worm reduction gear
automatic braking,
adjustable torque hydrodynamic coupling
Comprising irreversible worm reduction and built in
automatic brake.
Torque output adjustable through the hydrodynamic
clutch.
3. DRUM monospiral, threespiral, wide.
4. COLLECTOR or hydraulic swivel on hose reels
5. FIBER OPTIC ACCUMULATOR optional.
6. CABLE GUIDE optional switches for: slack cable, cable direction,
and cable overtension. With optional Panzerbelt 
lifting device
7. CABLE normally not Specimas supply.
30/07/1997 REV.1 Chp 1H page 1/4

8. TURNOVER ANCHOR optional (central feeding point made by others)
9. CABLE TRENCH not delivered by Specimas
Trench profiles delivered in conjunction with the
Panzerbelt  System.

10. CABLE PROTECTION SYSTEM Panzerbelt system delivered by Specimas on
request.
11. JUNCTION BOX optional (or fixed junction)
12. CABLE GRIP optional for fixing cable on drum and in center
feeding point.
13. CABLE TERMINATION KITS optional
THE BASIC FEATURES OF THE SYSTEM

- Maximum compactness of torque unit, motor and collector when assembled together.
- Possibility to adjust the output torque according to the work or load requirement.
- Automatic braking which allows the cable to be unreeled in case of power failure.
- Few components, easily interchangeable.
- Can be powered by conventional squirrel cage, flange mounted motors.
1. MOTOR
Any type of motor is suitable, providing it can be fed by the power available on the machine
on which the cable reel is fitted.
The most widely used are squirrel cage electric motors, but hydraulic and pneumatic
motors are also frequently used, for instance, in most mining applications.
Optional motor heater or motor heat sensors can be installed (clixon, PTC, PT100).
2. TORQUE UNIT
This is the basic component of the Specimas system. It incorporates an irreversible worm
reduction which is automatically braking and totally immersed in oil. The irreversible worm
reduction gives these three functions in one compact unit:
− reduction of motor speed to needed drum speed
− self braking (always with constant torque)
− adjustable torque output clutch.
The output torque can be easily adjusted according to the requirement of the application.
This operation is carried out during the initial setting up of the cable reel, and few further
adjustments are generally required.
The torque unit is explained in detail in chapter 2.
Optional low and high temperature sensors can be mounted.
3. DRUM
Specimas drums are module designed, using standard stock components, offering a wide
range of selections.
Drums are manufactured from steel tubing and surface treated to withstand tropical and
marine corrosive conditions (hot dip galvanized).
30/07/1997 REV.1 Chp 1H page 2/4

Screws and bolts for drum assembly and adjustment are of stainless material (tie rods of
stainless steel, nuts of stainless steel or zinc plated brass).
Screws and bolts fixing the drum to the gearbox flange are of galvanized tensile steel.
When required for highly corrosive areas the drums can be completely manufactured from
stainless steel.
Special drums for vertical cable retrieve and extreme cable lengths are also manufactured.
4. COLLECTOR
The purpose of the collector is to allow the reeling of the cable onto the drum without
twisting the cable.
Specimas collectors are self-contained units and are fitted onto the torque unit by a dog-
hub connection and 4 supporting bolts.
The ring assembly utilizes air insulation between rings to eliminate risk of short circuit due
to contaminated insulation surfaces.
In an emergency situation, the collector can quickly be replaced.
All components of the collectors are designed and manufactured by Specimas.
Collector can be equipped with the following optional equipment:
− Resistance heaters (standard in High Voltage units)
− Rotary travel limit switch ( with 4 cams as standard)
Switch 1: used to detect center feeding point and by-pass any slack-cable signal
used. (drum full)
Switch 2: used to detect drum empty
Switch 3 and 4: used by client if needed.
Can be used to slow down crane speed over center feed point or to
slow
down crane speed before drum empty signal.
− Pilot ring
If a pilot core for earth sensing is incorporated in the reeling cable a pilot ring will be
inserted in the collector.
5. FIBER OPTIC ACCUMULATOR

If fiber optics are incorporated in the reeling cable a F.O. joint is attached on the rear of the
collector. Standard units are for 6 fibers and 40 drum revolutions with 62.5/125 um
multimode fiber.
Connectors type ST or FC are most commonly required.
6. CABLE GUIDE
This device is used both in horizontal and vertical applications.
In horizontal application it is essential in both modes of operation, i.e. reeling and
unreeling to ensure that regular laying of the cable is achieved.
Normally all cable reels are fitted with a cable guide.
The cable guide is normally fitted with devices to sense crane location in respect to center
feed point (left/right), slack cable and optionally overtension.
In vertical applications it normally depends on mounting type and drum type if a guide is
used or not. If the drum is not of a monospiral type (that is semi wide or wide), it is
recommended to use a guide below the drum to guide the cable centrally onto the drum
and absorb shock and sway from the cable.
30/07/1997 REV.1 Chp 1H page 3/4

7. CABLE
It is highly recommended to use a good cable designed for reeling applications.
The cable is normally not delivered by Specimas and in any case it is delivered separately
and mounted on the drum when the drum is erected on site.
8. TURN OVER ANCHOR

Optionally delivered by Specimas on request.
Specimas normally delivers turnover anchors in stainless steel as these are mounted in the
central feeding point with very harsh environment.
The center feeding point is designed by others taking in account the application limits and
environment and the channel or cable support used.
If the Panzerbelt  system is used Specimas can supply different suggestions to center
feed point layout.
9. CABLE TRENCH
Not in Specimas scope of supply.
Trench, cable support or directly on the ground depending on application. It is though
important that the surface where the cable is laid is horizontal and free from parts which
can damage the cable.
10. PANZERBELT  CABLE PROTECTION

As an optional Specimas can supply a steelcord reinforced rubber covering system to
protect the cable when the cable is laying in the cable trench. In this case a special channel
supplied by Specimas is made where the cable is laid and the Panzerbelt  system is fixed.
11. JUNCTION BOX

Specimas standard junction boxes are manufactured in stainless steel.
As an alternative a fixed junction can be used at this point to connect the reeling cable to
the fixed power supply cable.
12. CABLE GRIP

It is highly recommended to use a good cable tension relief system, both on the drum and
in the center feeding point. This is specially valid for vertical retrieve reels and high speed
horizontal retrieve reels.
13. CABLE TERMINATION KITS

Specially for medium voltage cables it is important to terminate the cables with appropriate
termination kits.
Kits will be needed for:
− Collector, ring side (special kit available)
− Collector, brush side
− Center feeding point, if junction box is used.
30/07/1997 REV.1 Chp 1H page 4/4

HOW THE TORQUE UNIT WORKS
Figure 1
SPECIMAS reels are driven by torque units which work on a patented self braking
hydrodynamic clutch system.
The functions of the torque unit are:

− To provide a constant torque on the drum shaft.
− To gear the drum rotating speed to the reeling diameter of the cable.
− To brake the drum when stationary.

− To allow a controlled unreeling of the cable.
− To regulate the torque output accordingly to the requirements of each application.
The torque unit is powered by a motor rotating at constant speed. Normally a conventional
electric squirrel cage motor is used but also an air or hydraulic motor can be used.
The torque of the driving motor is transmitted to the drum shaft through a hydrodynamic
clutch which is combined with a worm gear reduction.
The output torque is only minimally affected by the rotating speed of the input and output
shaft. The output torque can be set from zero to maximum torque through a spring
arrangement of the clutch.
30/07/1997 REV.1 Chp2H page 1/2

The following is a brief description of the torque unit components:
The bronze crown gear (pos. 3) which is freely mounted on the drum shaft (pos. 1) has
specially machined surfaces on either side.
The two friction plates (pos. 4, 5) are mounted on both sides of the crown gear. These are
made of steel and are fixed to the drum shaft through a key.
The friction plates are also specially machined so that an oil film is created whilst turning,
thus transmitting the torque between the crown gear and the friction plates.
Due to the special machining of the clutch surfaces, they remain lubricated even when the
clutch is not moving; thus eliminating normally occurring stick-slip effect. The variation
between the dynamic and the static friction remains within 3-10% depending on the size of
the torque unit.
Since the worm gear is irreversible the clutch also functions as a brake when the motor is
off. This gives two major advantages:
The electro-magnetic brake, which is required in conventional cable reels has been
eliminated in the SPECIMAS torque unit.
a) The torque of the brake is the same as the reeling torque which thereby avoids an
uneven pull on the cable when the motor is switched on and off.
b) In order to vary the pressure on the clutch to obtain the required output, the torque unit
has an adjustable spring assembly.
The spring assembly consists of the rear friction plate (pos. 5), compression springs (pos.
6), the spring holder plate (pos. 7) and the torque regulating nut (pos. 8).
The springs are placed between the rear friction plate and the spring holder which is in turn
fixed onto the drum shaft through a key but can slide along the shaft axis.
The torque regulating nut is screwed onto the drum shaft and pushes against the spring
holder plate through a series of steel ball bearings.
The torque can be regulated by using the torque regulating key (pos. 10) by placing it
upside-down into the torque unit. With the torque regulating nut held in position the drum
can be turned manually or by help of the cable reel motor thus increasing the pressure on
the spring assembly and thereby increasing the torque output of the clutch.
Torque unit Reduction Weight Fixing Bolts Max. torque

type ratio (kg) (Nr. x Size) (daNm)
10.0 1:42 35 4 x M10 8

20.0 1:60 55 4 x M16 16
40.0 1.63 125 4 x M16 32
120.0 1:90 320 4 x M20 100
200.0 1:186 610 4 x M24 200
300.0 1:237 610 4 x M24 270
550.0 1:202 1005 8 x M24 450
700.0 1:256 1020 8 x M24 570
30/07/1997 REV.1 Chp2H page 2/2

CABLE REEL ASSEMBLY INSTRUCTIONS
The following points are only a general guide to the correct installation of the Cavotec Specimas
cable reels. In fact, further on in the manual, you will find the specific instructions to the operations
only briefly described hereafter.
A. Fix the torque unit on the mounting base through the holes on the feet (see table in chp. 2). Use
high tensile steel bolts (10.9).
Remove the tape applied on the oil breather hole on the torque regulating key.
Fixing bolts for cable reel basement to crane mounting base (see installation drawing).
The mounting base must be flat.
B. Fit the motor and collector to the torque unit.(normally the collector and the motor are fitted
before delivery. Sometimes the motor is not assembled due to delivery space).
C. Assemble the drum according to the separate instructions. (see chp.4)

When lifting the assembled drum from the ground to be fixed on the torque unit it is not allowed
to lift in the outer rim. The drum must be lifted with lifting straps around the tie-rods on the inner
ring of the drum.
When the drum is to be fixed to the torque unit’s flange the fixing bolts on the tie-rods must be
aligned with holes in the torque unit’s flange. To align the fixing flange with the drum bolts the
torque unit motor can be rotated by hand (turn the motor fan by hand).
D. Cable
Cable preparation
Check that the cable diameter and weight are as originally specified (see Cable in Technical data
sheet) and ensure that the cable length does not exceed that for which the reel was designed.
Generally, reputable manufactures will supply their cables free of induced twist on storage
drums. If, however, the cable on the storage drum is second hand, or the supplier cannot
guarantee the cable to be free of induced twist, the cable should be prepared in accordance with
the following.
The transport drum should be supported on stands or rollers to allow free rotation. The cable
must always be pulled from the top of the drum. Refer to Figure 1.
CABLE
TRANSPORT
DRUM
DRUM JACKS
Figure 1 – Cable Transport Drum
06.08.10 REV.1 Chp31H / C.100994 page 1/6

Lay out the full length of the cable as it is pulled off the drum, either by manhandling with one
person every 5m approximately or by pulling over cable rollers. On no account should the full
length of the cable be dragged over the ground, nor should a dozer, tractor or any other
powered machine be used to pull or drag the cable.
There may be some twist evident in the cable, which is due to the manufacturing process, and this
should now be removed. Leave one end of the cable fixed (eg. still attached to the transport drum)
and working from this end, run the twist out of the cable by either (a) placing a suitable bar under
the cable and walking towards the free end while gently moving the bar up and down (Figure 2), or
(b) forming a coil of cable as near as possible to the fixed end and rolling it along to the free end
(Figure 3). If there is a lot of twist in the cable, the process described above may need to be
repeated several times.
CABLE
TRANSPORT
DRU M
CABLE
ROUN D BAR
DRU M JAC KS
Figure 2 – Removal of Cable Twist Using Round Bar

CABLE
TRANSPORT
DRUM
DRUM JACKS
CABLE LOOP CABLE
Figure 3 – Removal of Cable Twist Using Cable Coil Method
Cable installation
In order to ensure satisfactory performance of a reeling cable, the following installation procedure
should be adopted. If the cable has been layed out according to the instructions “Cable
preparation”, then it should be rewound onto the storage drum before being transferred to the
reeler using the method described below.
Manually rotate the reeler drum so that the opening in the inner ring is pointing vertically upwards.
With the machine located as close to the feed point as possible, feed the cable from the top of the
cable transport drums directly onto the top of the reeler drum (refer to Figure 5).
Continue feeding it through the opening of the inner ring of the drum, out through the space
between the spokes and then through the cable gland as shown in Figure 4.
06.08.10 REV.1 Chp31H / C.100994 page 2/6

OPENING
INNER RING
CABLE
FRONT BOX
Figure 4 – Cable entry
Once the cable has been terminated to the sliprings in the collector, tighten the cable gland to
exclude moisture and dirt.
Secure the cable onto the drum inner band with a number of heavy duty cable ties.
CABLE REELER
CABLE
CABLE TRANSPORT DRUM
CABLE GUIDE
DRUM JACKS
Figure 5 – Correct Method of Cable Installation

The drive unit needs to be energised to rotate the reel for cable fitting.
Ensure that an operator is available to immediately switch off the motor in the
event of a problem.
The cable can now be wound onto the reel, and it is essential that this be done with the
cable under some tension to ensure uniform tight layering on the reel. It is most important that the
cable be wound onto the reel drum without any induced twist. Figure 5 shows the correct method
of cable transfer from the storage drum. The use of any other method will induce twist in the cable.
06.08.10 REV.1 Chp31H / C.100994 page 3/6

The ends of the cable can now be passed down through the cable guide (if fitted) and manually
pulled along the ground or cable tray to the nearby feedpoint.
Lay out the cable as it is pulled off the reel, either by manhandling with one person approximately
every 5 m or by pulling over cable rollers. On no account should the cable be dragged over the
ground, nor should a dozer, tractor or any other powered machine be used to pull or drag
the cable.
Periodic maintenance
The cables should be inspected after a short time in operation. Twisting may occur as the cable
runs in due to the lay of the cable relaxing slightly under operation. This twisting will tend to move
towards the feed point over time, and can eventually cause damage to the cable. If twisting is
apparent at any time, the cable should be freed at the feed point with the reel at the furthest point
of travel (ie. with all the cable paid out), and the twist should be removed by following the
instructions “Cable preparation”. Due to variations in operating conditions, it is impossible to
state an exact number of cycles which need to be carried out, or period of time after which twisting
will cease, and in some cases it may be several weeks. Periodic inspections are advisable after
the machine has begun operation.
E. Collector connection
Ensure that all circuits are isolated by an authorised person prior to removing the
cover of the collector housing. Electrical connections should only be carried out by
qualified persons.
Reeling cable connection (Rings side)

Pass cables in the cable glands on front box.
Strip the outer sheath in order to expose sufficient core length to neatly arrive at the rings
connection points, and shorten individual cores as necessary.
Put on every phase core the cable terminal A48 M12 and on every earth core the cable terminal
A10 M12.
Connect every phase V (V1, V2, V3) on shoe bar A. (see Figure 6)
Connect every phase W (W1, W2, W3) on shoe bar B. (see Figure 6)
Connect every phase U (U1, U2, U3) on shoe bar C. (see Figure 6)
Connect every earth PE on shoe bars D and E. (see Figure 6)
Figure 6 – Reeling cable connection in front box

06.08.10 REV.1 Chp31H / C.100994 page 4/6
Fixed cable connection (Brusghgear side)
Feed the fixed cable through the glands mounted below of the collector housing, ensuring that it is
well supported so as not to put any bending force on the gland.
Strip the outer sheath in order to expose sufficient core length to neatly arrive at the brushgear
connection points, and shorten individual cores as necessary.
Terminate each core with an appropriately sized ring terminal to suit the brush.
Ensure that the cores are neatly arranged and properly supported inside the collector housing, and
ensure that the cores are not in contact with live metal parts.
Tighten the cable gland.
Anti-condensation heater
Fit a suitably sized cable gland to the removable blanking plate located on the side of the collector
housing for the heater cable.
Pass the heater connection cable through this gland up to the heater terminal block. Fix the cable
well along the path selected, and ensure that it does not come any closer than 50mm to live metal
parts.
Strip the cable cores to the correct length, and terminate using appropriately sized blade terminals.
Connect the cable cores to the appropriate terminals as indicated by the schematic See Chapter 5.
Tighten the screws to 0.8Nm.
NOTE: Limit switch is installed Outside the collector box on the rear wall. When closing the collector
box be sure that the limit switch shaft is driven from the foreseen device. See chapter 9.
F. Test run crane and check reel function in all working modes.
Horizontal retrieval:
The most difficult working mode is reeling in and accelerating with drum nearly full.
In this working mode check that the cable leaves the cable guide with a slight slack; the cable
should hardly touch the last roller in the cable guide.
In this way the torque is correct and the reel is not pulling too hard on the cable.
G. After a few weeks to a month of operation it is normal that the torque must be re-adjusted.
This as the initial wear in of the clutch plates has occurred. After this re-adjustment might be
needed every 12 months depending on working load and intensity.
At the same time check screws, bolts, and electric connection.
06.08.10 REV.1 Chp31H / C.100994 page 5/6

TIGHTENING TORQUE FOR NUTS
Rs = yield stress - Rm = breaking stress
8.8 Rs= 640 MPa Rm=800 MPa
Standard Screw Material: 10.9 Rs= 900 MPa Rm=1000 MPa
Aisi 304 Rs= 240 MPa Rm=600 MPa
6 S with 8.8 Checking Min.hard.

800 MPa
screw stress = HV=190
Standard Nut Material:
8 G with Checking Min. hard.

1000 MPa
10.9 screw stress = HV=255
Kp bronze Min.hard.
Rs= 200 MPa Rm=400 MPa
head HV=80
Special Nut Material:
Brass zinc Min.hard.

Rs=225 MPa Rm=450 MPa
plated HV=90
Recommended tightening torque for cast resin HV insulators.
SIZE TORQUE
M 12 30 – 35 Nm
M 16 80 – 90 Nm
Tightening torque - Nm Tightening torque - Nm

Standard screw with standard nut Standard screw with brass-nickel plated nut
8.8 10.9 Aisi 304
M6 9 12 4 M6 6
M8 22 30 8 M8 12
M10 44 60 16 M10 24
M12 77 110 27 M12 42
M16 190 260 70 M16 100
M20 372 520 140 M20 210
M24 640 890 245 M24 344
M30 1314 1830 500 M30 720
M36 2297 3210 920 M36 1200
06.08.10 REV.1 Chp31H / C.100994 page 6/6

DRUM ASSEMBLY INSTRUCTIONS
Drum Torque unit

TM1126-71G 700
The reference numbers of each single component shown in the figures appearing in these
instructions correspond to the ones mentioned in the parts list.
It is advisable to carry out the assembly of the drum on the ground.
1. Lay the four pre-assembled drum halves on a pair of supports with the small internal diameter
side facing upwards as shown in Figure 1.
2. Loosely join the four halves together using the supplied M12 fasteners (items 13, 14 & 15).
3. Ensure that the inner faces of the mating halves are flush, and then tighten the M12 fasteners
to 30Nm.
Supports
13 14 15
Figure 1 – Half wheels assembly
DRUM INSTALLATION
4. Prepare the 12 M20 tie rods (30) with the nuts (27+28) and washers (26); insert them in the
holes of diameter Ø 740 mm and screw on the third nut and washer (see fig. 2)
5. Insert the 12 M20 tie rods (31) + (26+27+28) on diameter Ø 1100 mm, for the supporting of the
inner ring (9) (see fig.2).
6. Fit the inner ring (9) onto the M20 tie rods (30+31), using, if necessary, some washers (26) to
reach the required spacing between the two wheels (cable ext. diameter +10%).
7. Fit the other four half wheels central (2) onto the M20 tie rods (30+31) as in point 2. See figure 1.
8. Mount the first wheel central + the inner ring (9) and second wheel central + inner ring (9) on
M20 tie rods (30+31).
9. Fit the final half wheels (8) onto the M20 tie rods (30+31) as in point 2. See figure 1.
06.08.10 REV.1 Chp 48DMH / c.100994 page 1/3

10. Fix the drum to the torque unit with bolts M20 (25+26+27+28+29) on Ø440 mm; tighten all bolts
and nuts. (see fig. 2)
Ø740
Ø1100
Figure 2 – Drum installation
11. Fit the Pal nuts 28, placing the flat side against the full-nut as shown in Figure 3.
Figure 3 – Pal nut installation
12. For front box connection see chapter 3.

13. Proceed to the adjustment of spacing as explained in the next page.
06.08.10 REV.1 Chp 48DMH / c.100994 page 2/3

S2
S1
D c
a b
Figure 4 – Spacing adjustment
SPACING ADJUSTMENT (Fig. 4)
In order to ensure reliable performance of the reel, it is very important that the spacing between the
spokes is accurately set.
Measure the exact diameter of the cable at a minimum of 3 points along its length and calculate the
average value D.
Referring to Figure 4, remove all Pal nuts from (b) then loosen all nuts (a) and (b) on the external
main spokes.
If the drum width S1 is greater than D+ 4mm, or less than D+ 1mm, partially remove each tie-rod (c)
one at a time, and remove or insert washers (w) to bring the width to within the correct range.
Re-insert each tie-rod, refit each washer and loosely refit each full-nut.
Once the adjustment has been completed, tighten all the full-nuts to 210Nm. Refit the Pal nuts,
placing the flat side against the full-nut as shown in Figure 3.
Adjust the parallelism of every main spoke pair (internal and external) so that S2 is between
D+2mm and D+3 mm.
To increase S2, loosen nut (a) and tighten nut (b). To decrease S2, loosen nut (b) and tighten nut
(a).
Tighten all the full-nuts to 210Nm, and check the spacing again. If no changes need to be made,
refit the Pal nuts, placing the flat side against the full-nut as shown in Figure 3.
06.08.10 REV.1 Chp 48DMH / c.100994 page 3/3

Functional Description for Hydrodynamic
Centre-Feed Reeling System
Document No: SC-100994-FD1 Revision: A Date: 27 July 2010
REVISION STATUS
A Issued for information ER 27/7/10

Rev Description By Date
GEARED ROTARY LIMIT SWITCH (OPTIONAL)
The geared rotary limit switch is used for reel full-reel empty detection.
During commissioning, the reel full switch is set to trip approximately 1~2 metres before the feedpoint,
and reset a similar distance beyond this feed point. The resultant closed contact is utilised to bypass
the under tension detection circuit, thus allowing the cable to pass through the vertical position as the
machine travels over the turn over point.
The reel empty switch is set to trip when the last turn of cable is reached on the reeler drum. It should
only trip if (a) the machine limits fail or (b) the cable is snagged at some point resulting in it being
pulled from the reeler instead of recovering. The switch would then stop the machine before all the
cable is pulled from the reel.
MOTOR OPERATION
The direction switches, together with the travel direction signal from the machine, determines how the
reeler drive motor/s will operate.
When the machine is travelling towards the feed point, the reel needs to recover cable.
Therefore, the motor/s must be energised in the reeling in direction. In this case, the direction
switch output and travel direction will be equivalent.
When the machine is travelling away from the feed point, the cable will be pulled off the reel.
Therefore, the motor/s must be de-energised. In this case, the direction switch output and
travel direction will be opposing.
At the end of any recovery cycle, the reeler motor/s should remain energised for a few
seconds. This is typically achieved with a ‘Coasting’ timer. This allows the reeler to continue
recovering the cable as the machine coasts to a complete stop. The duration of the coasting
timer is typically between 3-5 seconds.
HEATERS
Anti-condensation heaters mounted in the collector housing/s need to be energised at all times to
prevent the build-up of moisture. Motor and brake heaters need to be energised whenever they are
not running.
Cavotec Specimas SpA Page 1 of 1

Via Galvani, 1
I-20054 Nova Milanese (MI), Italy
A MANUFACTURING COMPANY OF THE CAVOTEC GROUP
Triple Roller Guide Functional Description

Document No: SC-100994-FD1 Revision: A Date: 09 July 2010
Figure 1 – Triple Roller guide switches
GENERAL NOTE
When you reel two or more cable/hole, the tension is distributed differently between them. This will
have diffent tensions, resulting in different cable lengths.This behaviour requires us to control only
the position of the single cable. In our case we choose to control only the first cable.

Via Galvani, 1
SLACK CABLE SWITCH
The normally closed undertension switch BG4 is centrally located in the lower part of the roller guide
(refer to Figure 1), and is actuated when the cable is in the vertical position. This switch is used to
indicate a failure by the reeler to properly recover the cable/hose. Except in the case when the
machine is travelling over the feedpoint, tripping of this switch should emergency stop machine travel
to prevent damage to the cable/hose. Note that the undertension switch signal needs to be latched
because the actual switch may only be activated briefly.
DIRECTION SWITCHES
One cable direction switch BG1 with change over contacts is located inside a common housing as
shown in Figure 1. This is actuated by the first cable/hose and contacts are used to indicate from
which side the cable/hose is exiting the guide. This information can then used to determine how the
reeler should operate. For example, if the cable/hose is exiting on the left and the machine is
travelling left, then the reeler must recover cable. On the other hand, if the cable is exiting on the left
and the machine is travelling right, then the reeler must payout cable/hose.
PRE SLACK SWITCHES
During the normal using of the machine, it’s possible that it is firm for more time. In this case, when
we are in present of hight vibration it’s possible that the hydrodynamic reducer (normally irreversible)
can be reversible. For this reason, the cable can lose its tension and is thus highlighted from two
normally open pre slack cable switches BG2 and BG3 as shown in Figure 1.
The pre slack cable signal can be used in two possible ways:
1. as alarm signal
2. as start signal for reeling cable for short time (maximum 1 or 2 second).

Via Galvani, 1
TYPICAL SCHEMATIC

Via Galvani, 1
TORQUE OUTPUT REGULATION
1. Unscrew both torque regulating keys (see diagram).

2. Turn keys upside down and replace them into torque unit.
3. Turn drum slowly until both keys enter completely in the holes into locked position.
4. Switching on the electric motors or pulling the drum turn drum clockwise to decrease
torque; turn drum counter-clockwise to increase torque.(cable reel seen from the drum side).
5. Adjust torque by turning the drum 15° - 30° of a turn at a time direction. The torque must
be sufficient to recover the cable at full drum but should not exert too much pull on the
cable when drum is empty.
6. On completion remove regulating keys and replace them the correct way round.
WARNING!
The regulation has no safety limitation. Over torque settings may damage the worm screw
and crown gear and cause internal dangerous vibrations.
Driving a crane with torque setting keys locked will damage the gearbox.
If torque regulation is not done simultaneously with both keys locked unbalanced setting
will result. Check may be done by inverting one motor and checking the output torque to be
zero when both motors are running.
NOTE! At delivery the torque output is pre-set at about the theoretical torque value of the
unit. It might therefore be necessary to adjust the output on site at start-up accordingly to
the specific torque requirement of each application.
Torque unit 550.0 700.0

Drums turns from min to max torque settings 1,5 1,1
21/10/1998 REV.3 Chp 63H page 1/1

DETERMINING THE DIRECTION OF ROTATION OF THE DRUM
DETERMINARE IL SENSO DI ROTAZIONE DEL TAMBURO
(for torque unit 550.0-700.0 / per unità di comando 550.0-700.0)
Cable reel seen from the drum side Avvolgicavo visto dalla parte del tamburo
CASE 1 CASO 1
Drum rotating clockwise Tamburo ruota in senso orario
Motor A must rotate anticlockwise Motore A deve girare in senso antiorario

Motor B must rotate clockwise Motore B deve girare in senso orario
CASE 2 CASO 2
Drum rotating anticlockwise Tamburo ruota in senso antiorario
Motor A must rotate clockwise Motore A deve girare in senso orario

Motor B must rotate anticlockwise Motore B deve girare in senso antiorario
NOTE/NOTA
Direction of rotation of motors is determined by looking at motor from fan side.
Il senso di rotazione del motore é determinato guardando il motore dalla parte della flangia
del ventilatore.
21/07/1997 Rev.1 Chp 631H page 1/1

MAINTENANCE INSTRUCTIONS
Cavotec Specimas cable and hose reels are designed so that maintenance is reduced to a
minimum. However, in order to guarantee a correct and continuous function of the reel, it is
necessary to follow a few simple rules, hereafter described.
ATTENTION: Clean carefully, with ONLY a dry rag (no water or solvents), collector
insulators and brushgear before initial cable reel start.
AFTER FIRST OPERATING WEEK:
Drum
Verify the tightening of all bolts and nuts including the ones fixing the torque unit onto its
support, the collector, the drum and the motor to the torque unit.
In case that the drum is of a monospiral type check that the spacing between the wheels
at the inner ring is cable diameter + 10% (max. 4mm) and at the outer diameter
corresponds to cable diameter + 2-3 mm.
Collector (if any)

Verify tightening of all electrical connections and check ring - brush alignment. All carbon
brushes must be in the grooves of the rings.
Note! Always switch current off before removing collector cover.
AT REGULAR INTERVALS (TWO MONTHS):
The frequency of these regular checks will also depend on the severity of the environment
in which the reel is working and on the duty cycle intensity.
Collector (if any)

Verify tightening of all electrical connections and check ring - brush alignment. All carbon
brushes must be in the grooves of the rings.
Note! Always switch current off before removing collector cover.
If necessary clean collector inside noting the following:

a) Never use water when cleaning. Use vacuum cleaner, brush or lint-free cloth.
b) Sliprings must be dry, clean and free from oil or other covering stains.
c) If any part is found to be damaged it must be replaced as soon as possible with a new
original spare part.
d) After cleaning the rings remount the collector housing ensuring that the drainage holes
are downwards. Also make sure the rubber gasket is in place with its joint downwards as
well. This will ensure a good sealing.
Rotary joint (if any)

Change the gasket only if there are some dribbles. The ball bearings do not need any
maintenance, since they normally are life-lubricated; on the contrary there will be special
instructions about the lubrication.
26.02.09 REV.9 Chp 7H page 1/3

Torque unit
Check oil level through the level gauge, and, if necessary, top it up with the oil type
specified further on.
With the aid of a dynamometer check that the output torque has not changed since start-
up due to the setting of mechanical components during run-in. The torque should be set
so that the cable is pulled up evenly, without slackening or excessive tension.
Electric motor (if any)

Keep the motor surface clean, in order to ensure a proper cooling. The ball bearings do
not need any maintenance, since they are of the sealed type, life-lubricated.
Hydraulic motor (if any)

Check fittings.
Drum
Check regularly the gap between spokes: at the inner ring is cable diameter + 10% (max.
4mm) and at the outer diameter corresponds to cable diameter + 2-3 mm.
EVERY TWELVE MONTHS:
General
Carry out all the operations described in the previous points.
Torque unit
Change oil in the torque unit. The oil to be used is specified in the specification sheet at
the front of this manual. The minimum ambient temperature for each oil type is listed
below:
Oil type Minimum ambient

MOBILUBE HD 85W-140 -15 oC
MOBILUBE HD 80W-90 -25oC
SHELL SPIRAX ASX 75W-90 -42oC
For lower temperatures please contact the manufacturer or one of its representatives.
The maximum ambient temperature for each oil is dependent on the drive torque setting
and duty cycle. The drive selection has been made taking these factors into
consideration.
Note! When the reel is used for severe applications (i.e. vertical recovery or continuos
operation) the oil should be changed about every 500 hours of work.
Recheck the torque. If torque adjustment is needed decrease or increase the torque
setting for a lower or higher torque requested by the single application.
26.02.09 REV.9 Chp 7H page 2/3

Drum
Verify the tightening of all bolts and nuts including the ones fixing the torque unit onto its
support, the collector, the drum and the motor to the torque unit.
In case that the drum is of a monospiral type check that the spacing between the wheels
at the inner ring is cable diameter + 10% (max. 4mm) and at the outer diameter
corresponds to cable diameter + 2-3 mm.
Limit switch (if any) : check cam positions and that switches are operating.
Heaters (if any) : check that they are operating.
Read carefully the chapter 0-General warnings and safety precautions.
Torque Oil capacity
unit (Kg)
10.0 1,7
20.0 2,2
40.0 16,0
120.0 27,0
200.0 67,0
300.0 67,0
550.0 98,0
700.0 98,0
26.02.09 REV.9 Chp 7H page 3/3

TROUBLE SHOOTING THE HYDRODYNAMIC DRIVE
Below is a trouble shooting scheme for the hydrodynamic drive unit.
The main reason for failure of this unit is heat, heat is created because of:
A. Unit working too long time - over the ED% capacity (depends on torque output).
B. Motor running too long time or not shut off at all.
C. Unit working over its torque capacity at the used ED%.
FAILURE CAUSE ACTION

Motor not running Fuses lines etc Change if necessary.
Motor starter in crane If burnt change
command
Timer relay in crane If burnt change
command (used to switch off
the cable reel motor with
slight delay
Signal to cable reel motor Cable reel motor should be on only
starter from crane control when cable reel is to reel in cable
Cable reel motor should be off
when cable reel is to reel out cable
Timer relay used to delay stop of
cable reel motor when crane is
stopped.
Signal from cable guide Only for centre feed applications,
pendulum - microswitch to check signal and logic’s to motor
sense left/right side of centre starter
point of track
Crane command logic Only for centre feed
sensing microswitch on cable applications,check that logic is
guide (see above) and crane correct and motor starter
travel direction works when it should
Motor burnt Change motor
Motor running No Torque not set in torque unit Set torque see torque setting
torque instructions
When setting torque only turn drum
1/4 of a turn at a time and check
result. Then, readjust if necessary.
Maximum torque is needed when
drum is nearly full (horizontal travel
application) Check functions in this
area.
Do not set torque higher than
necessary.
02.03.09 REV.2 Chp. 8H 1/4

FAILURE CAUSE SOLUTION
Motor running No Too much torque will only result in:
torque higher stress on cable than
necessary
more heat in gearbox than
necessary
you paying for energy lost in
heat
Check that motor key is in Mount motor with key in shaft
place on the motor shaft
Check that the key does not slide
up when motor is put in place
Motor running too Torque not set Set torque
little torque
Oil damaged Change oil
When oil gets burnt or damaged
the result can be a loss in output
torque. Change only to specified oil
type
Torque unit Disassemble and check friction
plates.
Excessive cable length and/or Check design data
weight
Torque unit friction plates Replace worm out parts.
worm out
Reel working Check oil Change oil
vibrations or If oil is not correct type or there is
sounds when water in the oil vibrations can
reeling out easily happen.
Type should be MOBILUBE HD
85W140 or MOBILUBE HD 80W90
for low ambient temperature
applications SHELL SPIRAX ASX
75W-90
No similar oils from other
manufacturers are recommended.
If unit is set to a very high torque
this phenomena can occur during
running in when the crane is
moving slowly (reel rotating slowly)
in reeling out mode.
Consult with Specimas for a
possible solution.
Check torque unit This will normally happen if unit
has been overheated and the oil
has been burnt.
Teeth on crown gear not existing
anymore.
02.03.09 REV.2 Chp. 8H 2/4

Cable drops when Check torque unit Two alternatives are:
standing No braking 1. Unit is heavily overloaded or
effect motor has run 100%. This problem
will appear within short time days to
week.
2. Unit is slightly overloaded or unit
is working very intensively and oil
has not been changed at regular
intervals. Oil will degenerate a little
by little until the total volume of oil is
destroyed. The crown gear will
wear out. Units with very high
working intensity should have the
oil changed every 3 months.
Check motor If motor is not running when cable
reel is to reel in crane will trip.
Check signal from crane to motor
starter.
Check logic so motor is running
when crane moves to center point
(against cable)
Check that motor starts again after
inverting direction without stopping.
(Joy-Stick full speed left to full
speed right)
Check that motor starts again after
inverting direction with a stop in-
between (brakes applied)
Check motor Check that motor is not always on.
Motor should be on only when
reeling in. Check motor delay off
timer. If delay is too long or timer is
not working gearbox will overheat.
Correct timer setting is approx. 5
sec.
Reel pulling too hard Too high torque Set lower torque level.
Crane trippes when Slack cable switch in cable Check that signal is correct and that
reeling in guide signal is not too early. A movement
of the pendulum must be accepted,
signal should come slightly before
pendulum reaches its vertical
position.
02.03.09 REV.2 Chp. 8H 3/4

Crane trippes when Slack cable switch in cable NOTE: The signal should break the
reeling in guide crane emergency in a definitive way.
Resetting must
be done manually after that the
reason for the slack cable has been
determined and the cable stretched
manually so that the pendulum is
reset to its normal working position.
Resetting may not be done by the
driver from the driver cabin.
Torque set too low Set torque
See torque setting instructions (see
notes under motor running no
torque)
Crane trippes when Motor should not run If motor is running backwards stop
reeling out or cable motor. Motor should always run only
drops when reeling in one direction
out -the reeling in direction
When reeling out or standing still
motor should stopped.
Cable drops slowly Torque unit reversible due Mount brake motor or
when standing still - to crane vibrations Mount anti return unit on motor fan.
Motor not on
Cable reel trippes Overtension switch Set switch to less sensitive position
when reeling out - or
overtension Set torque lower
Collector : defective Incorrect wiring cable Rewiring
or discontinuous
conduction
Collector: short overvoltage Replace collector
circuit humidity
defective cable
contact between more
cables
Incorrect cable Cable guide roller blocked Replace roller
position
Misalignment of the cable Correct the alignment of cable guide
guide with the cable
Sheathing cable Heavy machine cut it Repair cable or replace
damaged
Other causes Control all cable guide rollers and
replace if necessary
Check pull force and regulate it
Check the feed pit
02.03.09 REV.2 Chp. 8H 4/4

STROMAG ROTARY LIMIT SWITCH
The limit switch is located inside the collector enclosure. Ensure that all circuits
are isolated by an authorised person prior to removing any covers. Electrical
connections should only be carried out by qualified persons.
General
Stromag rotary limit switch

The geared rotary limit switch (GRLS) consists of a number of cam activated switches used for drum
full/drum empty detection. These cams rotate via a gear reduction connected to the input shaft, with
one turn of the input shaft resulting in a partial rotation of the cams that is proportional to this gear
reduction.
Additional cam operated switches are available for other functions if required.
Electrical connection
Remove the cover of the collector, ensuring beforehand that all live electrical circuits have
been isolated.
Pass the limit switch connection cable through the appropriate gland on the side of the collector
housing and up to the limit switch. Fix the cable well along the path selected, and ensure that it does
not come any closer than 50 mm to live metal or moving parts.
Strip the cable cores to the correct length, and terminate using appropriately sized forked lugs.
Connect the cable cores to the appropriate terminals as indicated by the schematic. Tighten the
screws to 0.8Nm. Tighten the cable gland.
20.07.10 REV.0 Chp 91H page 1/2

Setting
2 4 2 4 2 4 2 4 2 4
(15°) (15°) (optional°) (optional°)

DRIVEN END
BF0 BF1 BF2 BF3 BF4

Not used Reel Reel Spare Spare
full empty
1 1 1 1 1
Rotary limit switch contacts

Travel the machine upwards and note the rotation direction of the limit switch shaft when viewed
from the rear.
Position the machine at its upper limit, and set the drum full BF1 switches as follows:
If the GRLS shaft was turning clockwise during recovery, turn the first white adjustment
screw (BF1) in the clockwise direction until the second cam just activates the switch (there
will be an audible click).
If the GRLS shaft was turning anti-clockwise during recovery, turn the first white adjustment
screw (BF1) in the anti-clockwise direction until the second cam just activates the switch
(there will be an audible click).
Ensure that the incoming wires on switch BF1 are connected to the normally closed
terminals marked 1 and 2.
Travel the machine downwards and then back upwards. Ensure that the drum full switch does not
trip within the normal travel limits.
Position the machine at its lower limit, and set the drum empty switch BF2 as follows:
If the GRLS shaft was turning clockwise during recovery, turn the second white adjustment
screw (BF2) in the anti-clockwise direction until the third cam just activates the switch (there
will be an audible click).
If the GRLS shaft was turning anti-clockwise during recovery, turn the second white
adjustment screw (BF2) in the clockwise direction until the third cam just activates the
switch (there will be an audible click).
Ensure that the incoming wires on switch BF2 are connected to the normally closed
terminals marked 1 and 2.
Travel the machine upwards and then back downwards. Ensure that the drum empty switch does
not trip within the normal travel limits.
Note that if the anti-hysteresis adjustment screw (black) is turned after the switches have been set, it
will be necessary to re-set the switches.
The spare switches BF3 and BF4, if used, should be set using the procedures described above.
Periodic maintenance
Ensure that all live electrical circuits have been isolated before performing
any maintenance inside the collector housing.
Check that the wires are properly connected to the terminals, and that the terminal screws
are correctly tightened.
20.07.10 REV.0 Chp 91H page 2/2

Lista Pezzi/Parts List
Codice/Part No: SC-100994-CR1
Lista/List Rev: 15
Data/Date: 14/07/2010
Descrizione: Avv.cavo 700.6 K4360/FC/R
Description: Reel 700.6 K4360/FC/R
Disegno/Drawing No:
Disegno/Drawing Rev: 0
Peso/Weight (kg): 0,0 kg
Peso
Pos. Codice/Part No. Descrizione Description Qty Disegno/Dwg No. Rev
(kg)
5 S01-H7000-000 Riduttore 700.0 Gearbox 700.0 1 1020,1 AR-029/1 1
10 SK1-00075-700 Kit olio sintetico 75W-90 per 700.0 Kit oil synthetic 75W-90 for 700.0 1 98,0
15 SK1-00110-000 Kit trascinatore 110 per 120/200/300/550/700/T8 110 doghub kit suits 120/200/300/550/700/T8 1 10,0
20 SC-100994-MC1 Mot.Cav. ghisa 132D 6poli 5,5 kW - 690 V 60Hz -IP55 Cav.cast iron mot.132D 6p 5,5 kW 690 V 60 Hz IP55 2 55,5
25 S17-0000R-009 Scaldiglia per motori Cavotec Anticondensation heater suits Cavotec motor 2 0,1
30 S17-0000C-009 Clixon per motori Cavotec Clixon to suit Cavotec motor 2 0,1
40 SK2-00700-006 Kit basamento per 700.0 + collettore 6 kV Kit basement for 700.0 + 6kV collector 1 163,0
45 SC-100994-AC1 Collettore K4360 Collector K4360 1 110,0
46 S95-PM050-P15 Pressacavo M50x1,5 completo di ghiera Cable gland M50x1,5 8 0,0
50 S02-6SG02-400 FCe Stromag BT 1:25/4 FCe Stromag LV 1:25/4 1 0,0 AS-385 Z
55 S02-70050-220 Kit Resistenza Watlow 50W - 220-240V Watlow Heater kit 50W - 220-240V 1 0,1 AS-638 B
MPC BOM.xls Page 1 of 1 Printed 20/07/2010

Codice/Part No: S01-H7000-000
Lista/List Rev: 1
Data/Date: 23-set-05
Descrizione: Riduttore 700.0
Description: Torque unit 700.0
Disegno/Drawing No: AR-029/1
Disegno/Drawing Rev: F
Peso
(kg)
1 SR1-04046-001 Carter 500/700 Carter 500/700 1 0,0 PS-4046/1
2 S79-41050-000 Anello OR 41050 O-ring 41050 1 0,0
3 SR1-00224-001 Vite senza fine 200/300/ 550/700 Worm screw 200.0/300.0/ 550.0/700.0 2 6,5 PS-224/1 D
4 S88-06206-000 Cuscinetto 6206 SKF Bearing 6206 SKF 2 0,0 SKF
5 S53-E0030-000 Anello seeger E 30 Circlip E 30 2 0,0 UNI 7435
6 S88-03213-000 Cuscinetto 3213 SKF Bearing 3213 2 0,0 SKF
8 SR1-00225-000 Anello spallamento v.s.f Spacer ring 2 0,1 PS-225 0
9 S78-06512-101 Anello AS 6510012 viton Oil seal AS 6510012Viton 2 0,0
10 S79-04512-000 Anello OR 4512 O-ring 4512 2 0,0
11 SR1-03622-000 Flangia motore 200/300/ 550/700 Motor flange 200/300/550/700 2 10,0 PS-3622 0
12 S40-73912-025 Vite TE M 12x25 Hexag.screw M 12x25 8 0,0
13 SR1-00307-000 Albero primario 200/300/ 550/700 Driving shaft 200/300/550/700 2 25,0 PS-307 B
14 S88-06024-000 Cuscinetto 6024 naz Bearing 6024 national 2 2,0
15 SR1-00229-000 Anello spallamento albero prim. Spacer ring of primary shaft 2 0,3 PS-229 0
16 SR1-00569-001 Linguetta pignone albero primario Key 2 0,3 PS-569/1 0
17 SR1-00344-000 Pignone 300.0 Pinion 300.0 2 7,5 PS-344 0
18 SR1-00567-000 Frizione conica 200/300 Conical clutch plate 200/300 2 10,6 PS-567 0
20 SR1-00558-000 Corona dentata 120/200/ 300 Crown gear 120/200/300 2 17,0 PS-558 0
21 SR1-00569-002 Linguetta frizione albero primario Key 2 0,4 PS-569/2 0
22 SR1-00568-000 Frizione portamolle 200/3 200/300 REV.C Spring holder clutch 200/300 2 10,8 PS-568 B
24 SR1-00108-000 Molla 40.0/120.0/300.0 Spring 32 0,0 PS-108
25 SR1-00305-000 Contr.p.molle 200/300 Spring holder clutch 200/300 2 8,0 PS-305 0
26 S60-30012-000 Sfera 1/2" Steel ball 1/2" 116 0,0
27 SR1-00304-000 Ghiera regolazione 200/300/550/700 Adjusting ring nut 200/300/550/700 2 15,0 PS-304 0
S01-H7000-000 - Riduttore 700.0.xls Page 1 of 3

Lista/List Rev: 1
Peso
(kg)
30 SR1-04050-001 Albero flangiato 550/700 Main shaft 550/700 1 0,0 PS-4050/1 B
31 S77-00180-000 V-Ring VS-180 V-RingVS-180 1 0,0
32 S78-18015-210 Anello AS 18021015 Oil seal AS 18021015 1 0,0
33 SR1-04056-000 Coperchio ant.alb.fla.700 Flan. shaft front cap 550/700 1 4,0 PS-4056 A
34 S89-01034-0NU Cuscinetto NU 1034 SKF Roller bear. NU 1034 1 0,0
35 SR1-04059-000 Anello spallamento albero flang. 550/700 Spacer ring of drive shaft 550/700 1 0,0 PS-4059
36 SR1-04052-000 Linguet. albero flang. 550/700 Key 500/700 1 0,0 PS-4052
37 SR1-04054-000 Ruota dentata 700.0 Driven gear wheel 700.0 1 0,0 PS-4054
39 S88-06032-000 Cuscinetto 6032 naz. Bearing 6032 national 1 5,9
41 S54-C0016-035 Spina cilind. 16x35 rettifica/temperata Cylindrical pin 16x35 4 0,0
45 S78-16015-190 Anello AS 16019015 Oil seal AS 16019015 1 0,0
46 SR1-04057-000 Coperchio pos.albero flan 500/700 Flang. shaft rear cap 550/700 1 13,0 PS-4057 B
47 S40-93112-035 Vite TCEI M 12x35 Screw M 12x35 8 0,0
48 SR1-00310-000 Cop.post.albero primario 200/300/550/700 Driv.shaft rear cover 200/300/550/700 2 4,0 PS-310 2
50 SR1-00308-000 Coperc.ant.albero.primari 200/300/550/700 Driv.shaft front cover 200/300/550/700 2 4,0 PS-308 2
52 S60-10000-004 Tappo scarico TM 3/4 Plug TM 3/4 2 0,0 TM 3/4"
53 S60-10000-002 Tappo livel. LMA 3/4 Plug LMA 3/4 1 0,0 LMA 3/4"

Lista/List Rev: 1
Peso
(kg)
54 SR1-04049-001 Coperchio superiore 550.0 - 700.0 Top cover 1 12,7 PS-4049/1C
55 SR1-04088-000 Targhetta alluminio Aluminium label 2 0,0 PS-4088 0
56 S79-04093-000 Anello OR 4093 O-ring 4093 2 0,0
57 SR1-04047-000 Bussola perno reg. 700.0 Bushing for adj. pin 2 0,0 PS-4047
58 SR1-04048-000 Perno regolazione 700.0 Adjusting pin 2 0,0 PS-4048
59 SR2-01392-001 Targhetta numero codice e serie marcat. CE Code label with CE mark 1 0,0 PS-1392/1 A
60 S55-0025X-005 Rivetto autof. 2,5x5 Hammer rivets 2,5x5 12 0,0
62 S47-6592R-008 Rosetta piana M 8 rame Plain washer M 8, copper 12 0,0
64 S60-10000-000 Tappo sfiato 3/4" Elesa Filler breather plug 3/4" Elesa 1 0,0 SFN.40-3/4
66 S42-33604-045 Copiglia 4x45 Gudgeon 4x45 2 0,0
67 S48-8842X-008 Rosetta dent. M 8 Lock washer M 8 s.s. 12 0,0

1
Codice/Part No: SC-100994-AT1 Rev Data Nome Descrizione
Lista/List Rev: 2 0 28-mag-10 AR Pubblicato per produzione
Data/Date: 05-ago-10 1 22-giu-10 AR Aggiunta sp. 35
Descrizione: Tamburo TM1126-71G 2 05-ago-10 SP Aggiornato
Description: Drum TM1126-71G 3
Disegno/Drawing No: SC-100994-AT1 4
Disegno/Drawing Rev: C 5
Peso/Weight (kg): 380,0 kg 6
Peso
Pos. Codice/Part No. Descrizione Description Qty Disegno/Dwg No. Rev Comment
(kg)
1 SC-100994-001 Semiruota interna 1126G, 12 razze 60x40x2 Half wheel internal 1126G, 12 spokes 60x40x2 1 28,8 SC-100994-001 A
2 SC-100994-002 Semiruota centrale 1126G, 12 razze 40x40x2 Half wheel central 1126G, 12 spokes 40x40x2 4 23,1 SC-100994-002 A
3 SC-100994-003 Cassetta anteriore Front box 1 22,4 SC-100994-003 B
Semiruota interna 1126G, 12 razze 60x40x2 per Half wheel internal 1126G, 12 spokes 60x40x2 for
4 SC-100994-004 1 29,3 SC-100994-004 A
ingresso cavo cable entry
5 SC-100994-037 Barra di rame per e PE Copper bar for PE 1 0,9 SC-100994-037 B
6 SC-100994-036 Ba a di ame pe V1 U1 W1 Coppe ba fo V1 U1 W1 1 1,0 SC-100994-036 B
7 SC-100994-008 Barra di rame per supporto capicorda di Terra PE Earth cable shoe bar 1 1,2 SC-100994-008 B
8 SR4-41126-GH0H Semiruota esterna 1126G, 12 razze 60x40x2 Half wheel external 1126G, 12 spokes 60x40x2 2 28,5 PS-971 D
9 SR4-05836-X11 Bandella in due metà Ø1100, 12xM20, AISI 304 Inner ring in two halves Ø1100, 12xM20, AISI 304 3 7,8 PS-5836 C A=59 mm
10 SR4-05642-000 Flangia intermedia tipo G dia. 790, sp. 15 Flange intermediate type G dia. 790, 15t 1 55,0 PS-5642 0
11 S91-10028-000 Isolatore Schiavi AC028 H=36 Insulator Schiavi AC028- H=36 9 0,1 AC028
12 SC-100994-048 Coperchio cassetta anteriore Top plate 1 6,0 SC-100994-048 A RICAVATO DA PS-4328
13 S42-73912-090 Vite TE M12x90 filetto completo, AISI 304 Hexag. screw M12x90 full thread, AISI 304 24 0,1 UNI 5739
14 S47-6593X-012 Rosetta piana extra larga M12xØ36, AISI 304 Washer plain extra large M12xØ36, AISI 304 48 0,0 UNI 6593
15 S49-7473X-012 Dado autobloccante M12, AISI 304 Lock nut M12, AISI 304 24 0,0 UNI 7473
16 SR4-05790-000 Guarnizione accoppiamento riduttore 1 0,0 PS-5790 A
17 SR2-00200-000 Guarnizione neoprene Neopren gasket 1,86 0,2 PS-200
18 S45-0800G-055 Tirante M8x55 Galvanizzato Tie rod M8x55 Galvanised 6 0,0 DIN 976
UNI 6592/DIN
19 S47-6592X-008 Rosetta piana M8 AISI 304 Plain washer M8 AISI 304 6 0,0
125A
20 S49-5588G-008 Dado esagonale medio M8 galvanizzato Nut M8 6 0,0 UNI 5588/DIN 934
21 S49-5721G-008 Dado cieco M8 Galvanizzato Domed nut M8 6 0,0 UNI 5721 / DIN 1587
22 S40-73910-020 Vite TE M10x20 filetto completo zincata Hexagon screw M10x20 full thread zinc plated 9 0,0 UNI 5739/DIN 933
23 S47-6592G-010 Rosetta piana M10 galvanizzato Plain washer M10 zinc pla ted 33 0,0 UNI 6592/DIN 125A
24 S95-PM080-000 Pressacavo CCGM80 +NUT+OR Cable gland M80 complete of ring nut 3 1,0
25 S42-73920-070 Vite TE M20x70 AISI 304 Hexagon setscrew M20x70 AISI 304 2 0,2 UNI 5739 / DIN 933
UNI 6592/DIN
125A
27 S49-5588B-020 Dado esagonale medio M20 ottone Hexagonal full-nut M20, zinc-plated brass 122 0,1 UNI 5588/DIN 934
Controdado di sicurezza M20 AISI 316
28 S44-8835X-020 Safety lock nut M20 AISI 316 56 0,0 DIN 7967
(Palmutter)
100994-LP.xls Page 1 of 2 Printed 06/08/2010
1
Codice/Part No: SC-100994-AT1 Rev Data Nome Descrizione
Lista/List Rev: 2 0 28-mag-10 AR Pubblicato per produzione
Data/Date: 05-ago-10 1 22-giu-10 AR Aggiunta sp. 35
Descrizione: Tamburo TM1126-71G 2 05-ago-10 SP Aggiornato
Description: Drum TM1126-71G 3
Disegno/Drawing No: SC-100994-AT1 4
Disegno/Drawing Rev: C 5
Peso
(kg)
30 S45-2000X-500 Tirante M20x500 AISI 304 Tie rod M20x500 AISI 304 11 1,2 DIN 976
UNI 6592/DIN
125A
34 S98-A4800-M12 Capocorda A48 M12 Cable terminal A48 M12 9 0,0 CEA49-M12 Da fornire sciolti
35 S98-A1000-M12 Capocorda A10 M12 Cable terminal A10 M12 9 0,0 CEA10-M12 Da fornire sciolti
36 SC-100994-047 Supporto per barra di connessione Connection bar support 1 0,6 SC-100994-047 A
37 SC-100994-045 Flangia per cassetta anteriore Flange 1 0,8 SC-100994-045 A
38 S91-51000-033 Termorestringente AMP BPTM-50/20-A/U Shrinkable tube Raytech BPTM-50/20-A/U 0,08 0,0 BPTM-50/20-A/U L = 80 mm.
40 S49-5588G-010 Dado esagonale medio M10 Galvanizzato Nut M10 12 0,0 UNI 5588/DIN 934
4
Codice/Part No: SC-100994-AC1 Rev Data Nome Descrizione
Lista/List Rev: 1 0 26-lug-10 SP Pubblicato per produzione
Data/Date: 26-lug-10 1 06-ago-10 SP Aggiornato
Descrizione: Assieme collettore K 4360/FC/R 2
Description: Collector assembly K 4360/FC/R 3
Disegno/Drawing No: SC-100994-AC1 4
Disegno/Drawing Rev: B 5
Peso
(kg)
1 SR2-00962-001 Basetta anel.110 Al. Slipring support 110 All. 1 13,0 PS-962/1 A
2 SR2-00772-002 Triangolo base anelli Base triangle 1 1 PS-772/2/A B
4 S47-6592G-010 Rosetta piana M10 zincata Plain washer M10 zinc plated 5 0,0 UNI 6592/DIN 125A
5 S48-00137-010 Rosetta elastica ondulata M10 DIN 137 B Elastic washer M10 3 0,0 DIN 137 B
6 SC-100994-031 Tirante filettato estremita M14 alta resistenza Tie rod M14 3 0,6 SC-100994-031 A Acc. NiCrMo bonificato
7 S92-1520W-714 Tubo WT 15.5x20 L=714 WT 15,5x20 fibre glass t L= 714 mm 3 0,1
8 SR2-01267-000 Anello dia270 Slipring dia. 270 12 1 PS-1267 D
9 SR2-01031-002 Distanziale ottone 21x30 x30 Brass spacer 21x30x30 15 0,05 PS-1031/2 A
10 SR2-01073-000 Rondella dist. 35x5 Spacer ring 35x5 9 0,026 PS-1073 0
12 S47-6592G-012 Rosetta piana M12 zincata Plain washer M12 zinc plated 20 0,0 UNI 6592/DIN 125A
14 S92-2131W-090 Tubo WT 21x31 L=90 WT 21x31fibre glass tube L= 90 mm 3 0,07
17 SC-100994-021 Barra di connessione Connection bar 1 12,0 SC-100994-021 B
18 SC-100994-039 Squadretta per ultimo anello di terra Support earth 1 0,3 SC-100994-039 A
19 SC-100994-040 Squadretta per penultimo anello di terra Support earth 1 0,3 SC-100994-040 A
20 SC-100994-041 Squadretta per terzultimo anello di terra Support earth 1 0,2 SC-100994-041 A
21 SC-100994-022 Barra di collegamento serie "V..." Connection bar 1 4,6 SC-100994-022 A
22 SC-100994-023 Barra di collegamento serie "U..." Connection bar 1 4,1 SC-100994-023 A
23 SC-100994-024 Barra di collegamento serie "W..." Connection bar 1 3,6 SC-100994-024 A
24 SC-100994-034 Squadretta di collegamento Support connection 3 0,1 SC-100994-034 A
25 SC-100994-035 Squadretta di collegamento Support connection 6 0,1 SC-100994-035 A
26 SC-100994-025 Isolatore distanziale filettato Insulator 10 0,0 SC-100994-025 A
28 S47-6592G-005 Rosetta piana M5 galvanizzato Plain washer M5 Galvanised 10 0,0 UNI 6592/DIN 125A
29 S48-1751G-005 Rosetta elastica grover M5 Spring washer M5 10 0,0 UNI 1751 / DIN127 B
30 S40-93106-030 Vite TCEI M6x30 zincata Socket head cap screw M6x30 zinc plated 27 0,0 UNI 5931 / DIN 912
31 S47-6592G-006 Rosetta piana M6 galvanizzato Plain washer M6 Galvanise d 47 0,0 UNI 6592/DIN 125A
33 S40-73912-035 Vite TE M12x35 filetto completo zincata Hexagon screw M12x35 fu ll thread zinc plated 3 0,0 UNI 5739/DIN 933
4
Peso
(kg)
36 SR2-00756-008 Crociera K460/4121 foro D=20,2 mm Crosspiece K460/4121 1 0,7 PS-756 D
37 SR2-01143-000 Supporto di base Base plate 1 3,5 PS-1143 C
38 S45-1000G-824 Tirante M10x824 Galvanizzato Tie rod M10x824 Galvanised 6 0,5 DIN 976
39 S92-1016P-787 Tubo PVC 10.5x16 L=787 PVC 10,5x16 insulating tu L= 787 mm 4 0,1
40 S92-1522W-384 Tubo WT 15.5x22 L=384 WT 15,2x22 fibre glass tu L = 384 mm 2 0,1
41 S92-1522W-397 Tubo WT 15.5x22 L=397 WT 15,2x22 fibre glass tu L = 397 mm 2 0,1
42 SR2-00755-001 Flangia superiore cuscinetto Upper bearing flange 1 1,5 PS-755/1 D
43 S87-10201-000 Supporto SBPF 201 Support SBPF 201 1 0,3
44 S40-73906-016 Vite TE M6x16 filetto completo zincata Hexagon screw M6x16 fu ll thread zinc plated 3 0,0 UNI 5739/DIN 933
47 SR2-S0163-000 Portaspazzole KP20/270 (600A) Brushgear KP20/270 (600A) 24 0,7 AS-163 B
48 SC-100994-028 Sbarra connessione Connection bar 4 2,8 SC-100994-028 A
51 S47-6592G-012 Rosetta piana M12 galvanizzato Plain washer M12 Galvanis ed 49 0,0 UNI 6592/DIN 125A
52 S49-5588X-012 Dado esagonale medio M12 AISI 304 Hexagonal full-nut M12, AISI 304 24 0,0 UNI 5588/DIN 934
56 SR2-03744-000 Anello distanziatore 6 KV (bachelite) Spacer ring 1 0,4 PS-3744 B
57 SC-100994-026 Piastrina di collegamento fasi Connection bar 2 0,4 SC-100994-026 B
59 S49-7473G-010 Dado autobloccante M10 Galvanizzato Self-locking nut M10 8 0,0 UNI 7473/DIN 982
60 S49-5589G-020 Dado basso M20 Half nut M20 1 0,0 UNI 5589/DIN 936
66 S49-7473G-010 Dado autobloccante M10 Galvanizzato Self-locking nut M10 12 0,0 UNI 7473/DIN 982
67 S98-A0700-M06 Capocorda A7 M6 Cable terminal A7 M6 2 0,0 CEA7-M6
68 S96-N0035-GV0 Cavo 1x35 mmq GIALLO VERDE Wiring cable 1x35 Yellow/ Green 1 0,0
69 S91-50398-048 Termorestringente diam.19 l=1200 G/V Heat shrink tube Atum 12/4 1 0,0
S ad e a di c lllegame fa i V1 - U1
71 SC-100994-033 Support connection 3 0,7 SC-100994-033 B
W1
4
Peso
(kg)
72 SC-100994-042 Piatto distanziale terra Earth spacer 1 0,2 SC-100994-042 A
73 SC-100994-046 Piastrina di spessoramento fasi Thickness bar 2 0,2 SC-100994-046 A
74 SC-100994-044 Flangia supporto barre support bar 2 0,06 SC-100994-044 B
76 S47-6592X-008 Rosetta piana M8 AISI 304 Plain washer M8 AISI 304 8 0,0 UNI 6592/DIN 125A
78 S49-7473X-008 Dado autobloccante M8 AISI 304 Self-locking nut M8 2 0,0 UNI 7473/DIN 982
80 S91-51000-039 Termorestringente Raychem WCSM-130/36 Shrinkable tube Raychem WCSM-130/36 0,6 0,0 L = 630
81 SC-100994-SP2
Contenitore completo K460/2710/1/FC/R AISI 304 Complete housing K460/2710/1/FC/R 304 s.s. 1 39 SC-100994-SP2 A
82 SR2-S0175-000 Kit piastrina di chiusura per K450/K460 Blind flange kit 3 0,5 AS-175 0
5
Codice/Part No: SC-100994-SP2 Rev Data Nome Descrizione
Lista/List Rev: 0 0 Pubblicato per produzione
Data/Date: 05-lug-10 1
Descrizione: Contenitore completo K460/2710/1/FC/R AISI 304 2
Description: Complete housing K460/2710/1/FC/R 304 s.s. 3
Disegno/Drawing No: SC-100994-SP2 4
Disegno/Drawing Rev: A 5
Peso
(kg)
1 SR2-04303-000 Targhetta Cavotec 250x120 PVC Cavotec label mm 250x120 1 0,0 PS-4303 C
2 S98-A0700-M10 Capocorda A7 M10 Cable terminal A7 M10 4 0,0 CEA7-M10
3 S96-N0035-GV0 Cavo 1x35 mmq GIALLO VERDE Wiring cable 1x35 Yellow/ Green 1 0,0
4 S91-50398-048 Termorestringente diam.19 l=1200 G/V Heat shrink tube Atum 12/4 1 0,0
Contenitore (modifiche su contenitore gia'
5 SC-100994-030 Modified housing 1 29,0 SC-100994-030 A
esistente)
Pressacavo Lapp SKINDICHT SVRE-M dia. 7-16,
6 S95-PM020-150 Gland Lapp SKINDICHT SVRE-M dia. 7-16, M20 1 0,1 5210 5000
M20
Tappo Lapp Skindicht BL-M M20x1,5, ottone, O-
7 S95-TM20B-000 Plug Lapp Skindicht BL-M M20x1.5, brass, O-ring 2 0,0 5210 3125
ring
8 S95-DM200-020 Dado Lapp SKINDICHT SM-M M20x1,5 ottone Lock nut Lapp SKINDICHT SM-M M20x1.5 brass 3 0,0 5210 3020
9 SR2-01081-000 Targhetta contenitore collettore - alluminio Collector housing name pl ate - aluminium 1 0,0 PS-1081 E
10 S55-0032X-S08 Rivetto a tenuta stagna 3,2x8 inox Sealed blind rivet 3,2x8 s.s. 28 0,0
11 S42-73908-010 Vite TE M8x10 AISI 304 Hexagon setscrew M8x10 AI SI 304 1 0,0 UNI 5739 / DIN 933
12 S42-73906-016 Vite TE M6x16 AISI 304 Hexagon setscrew M6x16 AI SI 304 4 0,0 UNI 5739 / DIN 933
16 S42-93106-016 Vite TCEI M6x16 AISI 304 Socket head cap screw M6x16 AISI 304 9 0,0 UNI 5931/DIN 912
17 SR2-01861-001 Coperchio 6 KV AISI 304 Cover 6KV 1 8,5 PS-1861/1 B Gia' esistente
18 SR2-03897-000 Etichetta manutenzione collettore 130x130 argent Maintenance instructions collector 130x130 silver 1 0,0 PS-3897 A
19 SR2-03898-000 Etichetta manutenzione gruppi 130x180 argento Maintenance instructions gearbox 130x180 silver 1 0,0 PS-3898 A
20 SR2-00203-160 Guarnizione L=3160 Gasket L= 3160 1 0,0 PS-200/3160 0
22 S49-5588X-010 Dado esagonale medio M10 AISI 304 Hexagonal full-nut M10, A ISI 304 2 0,0 UNI 5588/DIN 934
23 SR2-01439-001 Angolare di supporto pacco anelli per coll. K Connecting bushing 1 0,8 PS-1439/1 B
3
Codice/Part No: SC-100994-AD1 Rev Data Nome Descrizione
Lista/List Rev: 0 0 14-giu-10 AR Pubblicato per produzione
Data/Date: 14-giu-10 1
Descrizione: Dispositivo guidacavo TM9 2
Description: Cable guide TM9 3
Disegno/Drawing No: SC-100994-AD1 4
Peso
(kg)
1 SC-100994-SP1 Assieme rullo piatto D=54mm Assembly roller D=54mm 54 0,7 SC-100994-SP1 A anticipato
2 SC-100994-011 Fiancata esterna TM9 External side TM9 1 50,0 SC-100994-011 A
3 SC-100994-012 Fiancata posteriore TM9 Internal side TM9 1 50,0 SC-100994-012 A
Tubo contenimento cavo inferiore per fiancate
4 SC-100994-014 Lower tube for external side panel 2 2,5 SC-100994-014 A
esterne
Tubo contenimento cavo superiore per fiancate
5 SC-100994-015 Upper tube for external side panel 2 1,7 SC-100994-015 A
esterne
6 SC-100994-017 Assieme fiancata centrale TM9 Assembly central side TM9 2 51,2 SC-100994-017 A
7 SC-100994-018 Carter di protezione Protection cover 1 4,7 SC-100994-018 A
8 SC-100994-019 Supporto per FC di direzione Support for limit switsch 1 0,4 SC-100994-019 A
UNI 6592/DIN
125A
13 S49-5588B-020 Dado esagonale medio M20 ottone Hexagonal full-nut M20, zinc-plated brass 28 0,1 UNI 5588/DIN 934
UNI 6592/DIN
125A
15 S92-2125X-108 Tubo inox 25x21 sp. 2 L=108 S.s. tube L=108 24 0,1
UNI 6592/DIN
125A
UNI 6592/DIN
20 S47-6592X-006 Rosetta piana M6 AISI 304 Plain washer M6 304 s.s. 8 0,0
125A
22 S42-93105-016 Vite TCEI M5x16 AISI 304 Socket head cap screw M5x16 AISI 304 2 0,0 UNI 5931 / DIN 912
UNI 6592/DIN
125A
Micro Telem. ZCKJ1H29 corpo 1NA+1NC, IP66, Limit switch body 1NO+1NC IP66, M20,
25 S99-TQ000-037 3 0,0 ZCK J1H29
M20 Telemecan. XCK
26 S99-TQ000-044 Micro ZCK E056 testa Micro ZCK E056 head 3 0,0
3
Codice/Part No: SC-100994-AD1 Rev Data Nome Descrizione
Lista/List Rev: 0 0 14-giu-10 AR Pubblicato per produzione
Data/Date: 14-giu-10 1
Descrizione: Dispositivo guidacavo TM9 2
Description: Cable guide TM9 3
Disegno/Drawing No: SC-100994-AD1 4
Peso
(kg)
27 S99-TQ000-028 Micro ZCK Y59 leva Micro ZCK Y59 lever 3 0,0 ZCK Y59
28 S99-TQ000-051 Micro XCK MR54D1H29 Switch XCK MR54D1H29 1 0,0 XCK MR54D1H29
29 SR2-01392-X00 Targhetta numero codice e serie AISI 304 Label caode 1 0,0 PS-1392
30 S55-0025X-005 Rivetto autof. 2,5x5 Hammer rivet 2,5x5 2 0,0
31 S42-93105-020 Vite TCEI M5x20 AISI 304 Socket head cap screw M5x20 AISI 304 6 0,0 UNI 5931 / DIN 912

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INSTRUCTION MANUAL

WORKS ORDER N. 100994

- Cable reel code key

General warnings and safety precautions ................................................. chp 0 -rev.1

Introduction to the system ......................................................................... chp 1 -rev.1

How the torque unit works ......................................................................... chp 2 -rev.1

Cable reel assembly instructions .....................................................chp 3.1 -C.100994

Drum assembly instructions .............................................................chp 4.8 -C.100994

Electric diagram ........................................................................................chp 5 -Rev.0

Maintenance instructions ........................................................................... chp 7 -rev.9

Trouble shooting the hydrodynamic drive................................................... chp 8 -rev.2

Limit switch STROMAG........................................................................... chp 9.1 -rev.0

Parts lists............................................................................................................ chp 10

Results: Drive type: Hydrodynamic

Motor data: 440 Volt/Hz 60

Reel type: 700.6 TM1126-71G K4360/FC/R - TM9P

Collector: Heater: 220/240V 50W self reg Cable guide: TM9P

Other: motor special voltage

1) Torque unit: Manufacturer: CAVOTEC SPECIMAS S.p.A.

2) Motor: Manufacturer: CAVOTEC SPECIMAS S.p.A.

3) Drum: Manufacturer: CAVOTEC SPECIMAS S.p.A.

4) Slipring: Manufacturer: CAVOTEC SPECIMAS S.p.A.

6) Cable guide: Manufacturer: CAVOTEC SPECIMAS S.p.A.

Recovery type: Horizontal

27.07.10 Rev.0 c. 100994 page 2/2

If in doubt, always refer to the original equipment manufacturer.

Refer at all time to the “General Warnings” chp. 0H.

ENGINEERING WARNING FOR THE CABLE REEL INSTALLATION!

30/07/1997 REV 1 Chp0H page 1

1. MOTOR electric, hydraulic, pneumatic

30/07/1997 REV.1 Chp 1H page 1/4

THE BASIC FEATURES OF THE SYSTEM

30/07/1997 REV.1 Chp 1H page 2/4

5. FIBER OPTIC ACCUMULATOR

30/07/1997 REV.1 Chp 1H page 3/4

8. TURN OVER ANCHOR

10. PANZERBELT  CABLE PROTECTION

11. JUNCTION BOX

12. CABLE GRIP

13. CABLE TERMINATION KITS

30/07/1997 REV.1 Chp 1H page 4/4

The functions of the torque unit are:

− To brake the drum when stationary.

30/07/1997 REV.1 Chp2H page 1/2

Torque unit Reduction Weight Fixing Bolts Max. torque

10.0 1:42 35 4 x M10 8

30/07/1997 REV.1 Chp2H page 2/2

C. Assemble the drum according to the separate instructions. (see chp.4)

Figure 1 – Cable Transport Drum

06.08.10 REV.1 Chp31H / C.100994 page 1/6

Figure 2 – Removal of Cable Twist Using Round Bar

CABLE LOOP CABLE

Figure 3 – Removal of Cable Twist Using Cable Coil Method

06.08.10 REV.1 Chp31H / C.100994 page 2/6

Figure 4 – Cable entry

CABLE TRANSPORT DRUM

Figure 5 – Correct Method of Cable Installation