Removing the Cable Reel

Standard Operating Procedure

Removing the Cable Reel

Removing the Cable Reel

Prepare and Position the Machine

  1. 1.
    Park the machine on a dry and level surface.
  2. 2.
    Apply the parking brake.
  3. 3.
    Stop the machine.
  4. 4.
    Set the battery isolation switch to the OFF position.
  5. 5.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  6. 6.
    Block the wheels with wheel chocks in accordance with the site-specific procedures.

    NOTE

    Extra requirements can apply. Refer to local regulations.

  7. 7.
    Insert the articulation lock bar (Figure 1, item A) in position onto the pins of the machine frames.
    Figure 1

    A

    Articulation lock bar

    B

    Locking clip

  8. 8.
    Install the locking clips (item B) to attach the articulation lock bar (item A) to the pins.
  9. 9.

    WARNING

    Energized Machine

    Can cause serious injury.

    1. The machine must be fully energized and the engine must be switched on to complete this procedure.

    2. Be careful around moving parts and pinch points.

    Inform the supervisor, lead hand, and all other persons who are concerned of the intent to restart the machine.

    NOTE

    Make sure that all personnel and bystanders are clear of the machine before start-up.

  10. 10.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  11. 11.
    Set the battery isolation switch to the ON position.
  12. 12.
    Start the machine.
  13. 13.

    WARNING

    Accidental Movements

    Can cause serious injury or death.

    1. Make sure that no one is at danger or hazard zone before you start or operate the machine.

    Extend the front jack support legs fully from the jack beam (Figure 2).
    Figure 2
  14. 14.
    Lower the front and the rear support legs to lift the machine from the ground (Figures 3A and 3B).
    Figure 3A
    Figure 3B
  15. 15.
    Stop the machine.
  16. 16.
    Set the battery isolation switch to OFF position.
  17. 17.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  18. 18.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Put approved maintenance stands in the approved areas below the machine (Figure 4).
    Figure 4
  19. 19.

    WARNING

    Energized Machine

    Can cause serious injury.

    1. The machine must be fully energized and the engine must be switched on to complete this procedure.

    2. Be careful around moving parts and pinch points.

    Inform the supervisor, lead hand, and all other persons who are concerned of the intent to restart the machine.

    NOTE

    Make sure that all personnel and bystanders are clear of the machine before start-up.

  20. 20.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  21. 21.
    Set the battery isolation switch to the ON position.
  22. 22.
    Start the machine.
  23. 23.
    Lower the machine onto the maintenance stands and secure as per local requirements (Figure 4).
  24. 24.
    Put the boom and the Feed Assembly in center position and as low as possible (Figure 5).
    Figure 5
  25. 25.
    Operate the cable reel control (Figure 6, item A) to unwind the cable onto the pallet.

    NOTE

    Refer to Unwinding Main Power Cable from Reeling Unit in the Operation manual.

    Figure 6

    A

    Cable Reel Control

  26. 26.
    Stop the machine.
  27. 27.
    Set the battery isolation switch to the OFF position.
  28. 28.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  29. 29.
    Open the left side hatch or doors as follows:
    1. Alternative step
      For Boltec M, E, EC, Simba M6C, Boomer M1D, E2C, and Cabletec E Machine: Open the left side hatch (Figure 7A, item A) to get access to the directional valve lever.
      Figure 7A

      A

      Left side hatch

    2. Alternative step
      For Cabletec M, LC, and Simba E7C Machine: Open the left side door (Figures 7B, item A) and secure it with the lock pin in the open position.
      Figure 7B

      A

      Door

  30. 30.

    WARNING

    Energized Machine

    Can cause serious injury.

    1. The machine must be fully energized and the engine must be switched on to complete this procedure.

    2. Be careful around moving parts and pinch points.

    Inform the supervisor, lead hand, and all other persons concerned of the intent to restart the machine.

    NOTE

    Make sure that all personnel and bystanders are clear of the machine before start-up.

  31. 31.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  32. 32.
    Set the battery isolation switch to ON position.
  33. 33.
    Start the machine.
  34. 34.
    Swing out the hose reel from the machine as follows:
    1. Alternative step
      For Boltec M, E, EC, Simba M6C, Boomer M1D, E2C, and Cabletec E Machine: Operate the directional valve lever (Figure 8A, item A) and swing out the door with the Air Oil Cooler Assembly (item B) along with the hose reel.
      Figure 8A

      A

      Directional valve lever

      B

      Air Oil Cooler Assembly

    2. Alternative step
      For Cabletec M, LC, and Simba E7C Machine: Operate the controls to swing out the Hose Reel Assembly (Figure 8B).
      Figure 8B
  35. 35.
    Stop the machine.
  36. 36.
    Set the battery isolation switch to the OFF position.
  37. 37.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  38. 38.

    WARNING

    High-Pressure System

    Working with pressurized systems can cause personal injury.

    1. Do not do the maintenance work when you operate the machine.

    2. Make sure that the hydraulic, water, and air systems are depressurized before you start to work on these systems.

    3. Put on the applicable gloves.

    Release the stored energy from the hydraulic brake system.

    NOTE

    Make sure that there is no pressure in the system.

  39. 39.
    Release the stored energy from the hydraulic tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  40. 40.
    Release the stored energy from the air tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  41. 41.

    WARNING

    High-Pressure System

    Working with pressurized systems can cause personal injury.

    1. Do not do the maintenance work when you operate the machine.

    2. Make sure that the hydraulic, water, and air systems are depressurized before you start to work on these systems.

    3. Put on the applicable gloves.

    Remove the breather filter (Figures 9, item A) from the hydraulic oil tank.
    Figure 9

    A

    Breather filter

  42. 42.
    Connect a vacuum pump to the breather filter port to prevent the wastage of hydraulic oil while disconnecting the hydraulic hoses.
  43. 43.
    Open the right side door (Figure 10, item A) and secure it in the open position.
    Figure 10

    A

    Right side door

  44. 44.

    WARNING

    Crushing Hazard

    Can cause personal injury.

    1. Lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.

    2. Be careful when you lift heavy components.

    Attach an approved lifting device to the rear canopy and support it (Figures 11A and 11B).
    Figure 11A Boomer M1D, E2C, Boltec M, E, EC, Cabletec E, and Simba M6C
    Figure 11B Cabletec M, LC, and Simba E7C
  45. 45.
    Remove the screws (Figures 12A and 12B, item A) and the washers (item B) that attach the rear canopy to the machine frame. Discard the hardware.
    Figure 12A Boomer M1D, E2C, Boltec M, E, EC, Cabletec E, and Simba M6C
    Figure 12B Cabletec M, LC, and Simba E7C

    A

    Screw

    B

    Washer

  46. 46.
    Remove the screws (Figures 13A and 13B, item A), washers (item B), and lock nuts (item C) that attach the rear canopy to the machine frame. Discard the hardware.
    Figure 13A Boomer M1D, E2C, Boltec M, E, EC, Cabletec E, and Simba M6C
    Figure 13B Cabletec M, Cabletec LC and Simba E7C Machine

    A

    Screw

    B

    Washers

    C

    Lock nut

  47. 47.

    WARNING

    Crushing Hazard

    Unexpected movement of parts can cause personal injury or death.

    1. Do not put any part of your body on the object when lifting, moving, or lowering it.

    2. Do not go in, reside, or put body parts below unsecured, moveable, or lifted parts.

    3. Do not put hands and fingers in the pinch point areas when installing or tightening the parts.

    4. Stay away from moving parts.

    Slowly lift and remove the rear canopy from the machine with the attached lifting device. Put it in a safe location.
  48. 48.
    Remove the attached lifting device from the rear canopy.

Isolation of the Component

  1. 1.
    Remove the lock nuts (Figure 14, item A) and the washers (item B) that attach the cover (item C) to the cable reel drum. Discard the hardware.
    Figure 14

    A

    Lock nut

    B

    Washer

    C

    Cover

  2. 2.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    WARNING

    Electric Shock Hazard

    Failure to obey these instructions can cause serious personal injury.

    1. Only a skilled electrician or a specially-instructed personnel must work on the electrical system or on electrical equipment under the direct supervision and control of an electrician.

    2. All electricians must work in accordance with the applicable electrical engineering standards and guidelines.

    Remove the cover from the cable reel drum and disconnect the ground cable (Figure 15, item A). Cover the ends of the cable with an electrical tape.
    Figure 15

    A

    Ground cable

  3. 3.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Remove the slip ring cover (Figure 16, item A) from the cable reel drum and put it in a safe location.
    Figure 16

    A

    Slip ring cover

    B

    Brush holder

  4. 4.

    DANGER

    Electric Shock Hazard

    Electric shock while working with the electrical systems cause serious personal injury.

    1. Only authorized personnel can do the work involving cables, electrical cabinets, fuses, and connectors.

    2. Attach safety locks and tags to the electrical switches of the specific components before working.

    3. Do not use a high-pressure washer to clean the electrical components.

    Label and disconnect the cable from the brush holders (item B).

    NOTE

    Only certified electrical technician must work on the cable connections.

  5. 5.
    Label and disconnect the A10 panel cables (Figure 17, item A) from the slip rings. Cover the ends of the cable with an electrical tape.
    Figure 17

    A

    Cable

  6. 6.
    Remove the cables from the cable reel and put it in a safe location.
  7. 7.
    Remove the lock nuts (Figure 18, item A) and the washers (item B) that attach the wheel (item C) and the flange (item D) to the drum. Discard the hardware.
    Figure 18

    A

    Lock nut

    B

    Washer

    C

    Wheel

    D

    Flange

  8. 8.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    Remove the wheel (item C) and the flange (item D) from the machine and put them in a safe location.
  9. 9.

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    Remove the master link (Figure 19, item A) to disconnect the drive chain.
    Figure 19

    A

    Master link

  10. 10.
    Disconnect and remove the drive chain from the sprockets. Put it in a safe location.

Lifting and Removal

  1. 1.

    WARNING

    Crushing Hazard

    Can cause personal injury.

    1. Lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.

    2. Be careful when you lift heavy components.

    Attach an approved lifting device to the cable reel and support it (Figure 20, item A).
    Figure 20

    A

    Cable reel

  2. 2.
    Remove the two rear rubber damper screws (Figure 21, item A) and the washers (item B) from the bottom of the A10 panel (item C). Discard the hardware.
    Figure 21

    A

    Screw

    B

    Plain washer

    C

    A10 panel

  3. 3.

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    Push the A10 panel (Figure 22, item A) forward slightly and put an approved wooden block (item B) between the A10 panel and the frame.
    Figure 22

    A

    A10 panel

    B

    Wooden block

  4. 4.
    Remove the six screws (Figure 23, item A) and the washers (item B) that attach the cable reel to the rear frame. Discard the hardware.
    Figure 23

    A

    Screw

    B

    Washer

  5. 5.
    Pull the A10 panel cable from the cable reel flange hole and secure it aside.
  6. 6.

    WARNING

    Crushing Hazard

    Unexpected movement of parts can cause personal injury or death.

    1. Do not put any part of your body on the object when lifting, moving, or lowering it.

    2. Do not go in, reside, or put body parts below unsecured, moveable, or lifted parts.

    3. Do not put hands and fingers in the pinch point areas when installing or tightening the parts.

    4. Stay away from moving parts.

    Slowly lift and remove the cable reel with the attached lifting device. Put it in a safe location.
  7. 7.
    Remove the attached lifting device from the cable reel.
  8. 8.
    Put a tag onto the battery isolation switch stating that the cable reel is removed from the machine.