For reels manufactured after April 16, 2001
INSTALLATION and MAINTENANCE INSTRUCTIONS
SM28 GEAR DRIVE ELECTRIC CABLE REELS
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.
MAINTENANCE
Periodically: A. Use compressed air to clean collector assembly
and inside of collector housing. Inspect collector assembly for
brush wear and pitted slip rings.
Clock-type springs provide power for automatic cable take-
up. Spring must be pretensioned at time of installation to
ensure that tension is applied to cable at all times. A tension
adjustment ratchet wrench is provided with each reel.
B. Inspect cable for wear and
check mounting bolts and other
hardware for tightness.
“IN” with 2/3
cable off reel–
SPRING OK
BROKEN SPRING
INDICATORS
C. Check for broken springs by
pulling about 2/3 cable off reel
and observing “Broken Spring
Indicators” on sides of spring
canisters. See Fig. 3.
“OUT” with 2/3
cable off reel–
SPRING
WARNING
!
Do not attempt to relieve spring tension using spanner
wrench. Doing so may result in personal injury.
BROKEN
NOTE: Bearings and springs
are prelubricated and require no
periodic maintenance.
Figure 3
INSTALLATION
1. Ensure that machinery to be serviced by reel is at position
closest to reel.
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.
2. Securely mount reel in desired position using 1/2"(M12)
bolts. Be sure spool is aligned with cable run.
3. Position optional cable guide, if reel is so equipped. See
CABLE INSTALLATION DRAWING
SPRING REPLACEMENT
4. Connect free end of cable to junction box on machine or
adjust cable stop so that desired length of cable extends
from 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 discarded
completely.
5. Remove ratchet wrench and cover plate on spring housing
to expose shaft and spring hub. (See Figure 1).
6. Reinstall ratchet wrench (Fig 2). Use long handled wrench
to rotate arbor driver clockwise (for standard rotation).
Number of 360° turns should match last digit in model
1. Turn off all electric power.
2. Disconnect cable from machine junction box.
3. Relieve all spring tension following steps under SPRING
DETENSIONING on last page.
4. Remove inspection cover from face of spring housing.
number on serial plate.
If model number includes an
"R", reel is reverse rotation and wrench must be rotated
counterclockwise. (See EXPLANATION on parts list page.)
5. Rotate spool clockwise and observe spring 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 several sharp
blows with a lead hammer or 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.
CAUTION
!
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.
Do not exceed number of turns indicated on
serial plate. Over-tensioning can cause a
broken spring, sheared shaft or other damage.
SPRING
PAWL
HUB
SPOOL
SHAFT
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.
(Spring not
shown)
SPRING
Install
against flat
SHAFT
GROOVE
7. Remove wrench and install on other spring stack. Add
pretension turns as in step 6, above. Springs on both sides
must be adjusted equally. Remove wrench, replace cover
plates and return wrench to stored position.
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 or adjust cord stop.
11. Retighten nut on spring detensioner. See SPRING
DETENSIONING, back page.
8. Remove collector cover and connect individual supply
conductors to collector terminals. See ELECTRICAL
CONNECTIONS diagram, on parts page.
12. Tension spring with spanner wrench. Refer to
INSTALLATION section
13. Replace inspection cover and top gear access cover.
CONTINUED ON BACK PAGE
SM-28 GEAR DRIVE ELECTRIC CABLE REEL REPLACEMENT PARTS LIST
For SM-28 Gear Drive Electric Cable Reels manufactured after April 16, 2001
NOTE: Applicable mounting hardware included with each kit.
ITEM
KIT NO.
DESCRIPTION
QTY.
ITEM
KIT NO.
DESCRIPTION
QTY.
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
012285
012286
012287
012288
012289
012290
012291
012292
012293
012298
012299
012300
037194
037294
037295
013756
016197
013757
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, 2 Pole, 75 Amp
Collector Assembly, 3 Pole, 75 Amp
Collector Assembly, 4 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
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
015901
015921
039358
012137
118322
Main Frame and Gear Case Assembly
Vertical Frame
1
1
1
1
2
Main Shaft
Drive Pin
Retaining Ring
Bearing Kit - 2"" Bore
(Includes mounting hardware)
6
7
8
016516
016517
016518
1
1
2
Bearing Kit - 1.75"" Bore
(Includes mounting hardware)
Bearing Kit - 1.25"" Bore
(Includes mounting hardware)
9
016519
015944
Drive Stud Bracket Kit
Stub Shaft, Drum Gear
1
1
10
Spool Assembly - 8"" Dia. Wrapper
(Includes two spool disks, wrapper segments & hardware)
11
04756201
1
11
11
11
11
11
11
11
11
11
12
12
12
12
12
12
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
04756202
04756203
04756204
04756205
04756206
04756207
04756208
04756209
04756210
04169201
04169202
04169203
04169204
04169205
04169206
04169207
04169208
04169209
04169210
04169211
04169212
04169213
04169214
012459
Spool Assembly - 9" Dia. Wrapper
Spool Assembly - 10" Dia. Wrapper
Spool Assembly - 11" Dia. Wrapper
Spool Assembly - 12" Dia. Wrapper
Spool Assembly - 13" Dia. Wrapper
Spool Assembly - 14" Dia. Wrapper
Spool Assembly - 15" Dia. Wrapper
Spool Assembly - 16" Dia. Wrapper
Spool Assembly - 17" Dia. Wrapper
Cable Clamp Kit, 0.68 Dia. Cable
Cable Clamp Kit, 0.75 Dia. Cable
Cable Clamp Kit, 0.81 Dia. Cable
Cable Clamp Kit, 0.87 Dia. Cable
Cable Clamp Kit, 0.94 Dia. Cable
Cable Clamp Kit, 1.00 Dia. Cable
Cable Clamp Kit, 1.06 Dia. Cable
Cable Clamp Kit, 1.12 Dia. Cable
Cable Clamp Kit, 1.18 Dia. Cable
Cable Clamp Kit, 1.25 Dia. Cable
Cable Clamp Kit, 1.31 Dia. Cable
Cable Clamp Kit, 1.38 Dia. Cable
Cable Clamp Kit, 1.43 Dia. Cable
Cable Clamp Kit, 1.50 Dia. Cable
Cable Connector, 0.38-0.50 Dia. Cable
Cable Connector, 0.50-0.62 Dia. Cable
Cable Connector, 0.62-0.75 Dia. Cable
Cable Connector, 0.75-0.88 Dia. Cable
Cable Connector, 0.88-1.00 Dia. Cable
Cable Connector, 1.00-1.12 Dia. Cable
Cable Connector, 1.12-1.25 Dia. Cable
Cable Connector, 1.25-1.38 Dia. Cable
Cable Connector, 1.38-1.50 Dia. Cable
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
1
1
1
1
1
1
Brush Kit (35 Amp)
(Each kit includes 4 brushes, and 4 fingers)
20
012440
AR
20
20
012441
012443
Brush Kit (75 Amp)
AR
AR
Brush Kit (125 Amp / 200 Amp)
Collector Cover Kit (9.75"" long)
(Includes seal ring)
21
03742101
1
21
21
21
22
23
24
03742102
03742103
03742104
016213
Collector Cover Kit (12.75" long)
Collector Cover Kit (14.75" long)
Collector Cover Kit (19.25" long)
Seal Ring (only)
1
1
1
1
1
1
015936
Gear Detensioner Cover
015937
Gear Detensioner Cover Gasket
Gear Detensioner Cover Kit
(Includes washers, pads and nut)
25
26
016525
016527
1
1
Gear Access Cover Kit
(Includes cover and gasket)
27
27
27
27
27
27
27
27
015945
01594501
015946
Spring Shaft, Gear, Std. Rot. (1001)
Spring Shaft, Gear, Rev. Rot. (1001)
Spring Shaft, Gear, Std. Rot. (1002)
Spring Shaft, Gear, Rev. Rot. (1002)
Spring Shaft, Gear, Std. Rot. (1003)
Spring Shaft, Gear, Rev. Rot. (1003)
Spring Shaft, Gear, Std. Rot. (1004)
Spring Shaft, Gear, Rev. Rot. (1004)
1
1
1
1
1
1
1
1
01594601
015947
012460
01594701
015948
012461
012462
01594801
012463
Collector Entrance Kit
(Includes wiring box, cover and gasket)
28
29
016529
016202
1
1
012464
012465
Gear Kit, Ratio 'M'
(Includes one drum gear, and two spring gears)
012466
29
29
29
29
29
29
29
29
29
30
31
32
33
34
35
36
37
38
016203
016204
016205
016206
016207
016208
016209
016210
016211
015958
015957
016234
015955
101377
047563
101030
015929
021762
Gear Kit, Ratio 'N'
1
1
1
1
1
1
1
1
1
1
1
1
5
3
1
1
2
1
012467
Gear Kit, Ratio 'P'
Spring Motor Kit, Standard Rotation-100
(Includes snap ring, two pawls, two springs, hub cover, and
gasket)
14
016520
AR
Gear Kit, Ratio 'Q'
Gear Kit, Ratio 'R'
14
15
016521
012427
Spring Motor Kit, Reverse Rotation-100
AR
1
Gear Kit, Ratio 'S'
Pawl Kit - 100 Spring
(Includes two pawls & two springs)
Gear Kit, Ratio 'T'
Gear Kit, Ratio 'V'
Spring Mounting Kit
(Includes four extension studs)
Gear Kit, Ratio 'W'
16
016522
1
Gear Kit, Ratio 'Y'
17
18
106873
032804
Collector Drive Access Plug
1
1
Lube Tube, 2" Bore Bearing
Lube Tube, Gearbox
Lube Tube, 1.25" Bore Bearing
Male Connector, 1/4" Tube x 1/8 NPT
Grease Fitting
Ratchet Spring Adjustment Wrench
NOTE: Please consult factory for optional accessories, roller guides,
ratchet lock and limit switch.
Hex Hd. Cap Screw, .75-10 x 4.00
Hex Nut, .75-10
Hoop Brace
Hub Lock Pin Kit (Includes 2 pins)
AMPACITY CODE
MAX
MODEL NUMBER EXPLANATION
SPRING FRAME
SPRING
NO. OF
NO. OF
POLES
CORE
GEAR
RATIO
PRETENSION
TURNS
CODE
AMPS
*
AMPACITY
REEL
SERIES
SERIES SPRINGS
DIAMETER
3
7
35
75
SM
28
100
4
R
- 2
20
10
- V -
1
12
20
125
200
* INDICATES REVERSE ROTATION
NO LETTER INDICATES STANDARD ROTATION
INSTALLATION
CABLE INSTALLATION
Use the following procedure to relieve spring tension prior to
cable or spring replacement.
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.
WARNING
!
DO NOT insert hands into gearbox until springs are fully
detensioned. Doing so could lead to serious injury.
NOTE: This step is not essential, but will aid in winding
operation of the reel and prolong cable life.
2. Feed one end of the cable through water-tight connector on
the main shaft inside the spool and into the slip ring side (See
drawing below).
1. Cycle reel thru normal operating cycle and stop when
maximum amount of cable is wound onto reel spool.
2. Set spool lock to prevent spool from turning.
3. Remove access cover from top of gearbox.
NOTE: This may require that jacket of cable be stripped to
allow conductors to pass through shaft.
4. Using open end wrench, loosen large hex nut slowly to allow
springs to unwind. Fully loosen nut further with wrench until
springs are completely unwound.
3. Connect individual conductors to appropriate rings on
collector using crimp fitting or similar connection method.
5. Repair reel or replace springs or cable as necessary.
4. Tighten water-tight connector and cable clamp in slot on spool
disk. Do not over-tighten.
6. Retighten nut until definite resistance is felt and spring
washers are full compressed (flat). Replace cover.
5. Wind the cable onto the reel spool by hand rotating spool in
direction it turns free of spring tension.
NOTE: If hex nut is not adequately tightened, spring unwinding
can occur during reel operation.
6. Connect free end of cable to machine junction box.
7. Pretension reel. See INSTALLATION section, front page.
7. Pretension reel and complete reel installation as previously
described.
CABLE REMOVAL
COLLECTOR REPLACEMENT
1. Turn off all power to reel.
Use the following procedure to remove worn or damaged cable
from reel prior to installation of new cable.
2. Remove collector cover and gasket.
!
CAUTION
3. Disconnect electric leads to and from collector.
4. Remove drive stud bolt from bearing housing.
Failure to relieve all spring tension prior to removing
cable could result in damage to equipment or
personal injury. Follow instructions carefully.
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 90° to one another.
1. Move machine serviced by reel to a position closest to reel.
Springs will still be under pre-tension at this point.
NOTE: Older reels may have lock screws which must be
removed to reach set screws holding collector to shaft.
2. Turn off all electric power.
6. Slide collector off shaft.
3. Using spool lock. lock spool to prevent turning.
4. Disconnect cable from machine junction box.
5. Detension springs as described above.
7. Install new collector by reversing
6. Remove cable from spool. Loosen cable clamp and water-tight
connector and disconnect conductors from slip ring.
GLEASON REEL CORP.
P.O. Box 26 • 600 South Clark St.
Mayville, WI 53050
Phone 920-387-4120 • Fax 920-387-4189
Printed in USA
Bulletin No. 049663.b
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