Installing the Cable Reel

Standard Operating Procedure

Installing the Cable Reel

Installing the Cable Reel

Prepare and Position the Machine

  1. 1.
    Make sure that the machine is isolated and, if necessary, isolate the machine with the battery isolation switch.

Lifting and Installation

  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.
  2. 2.

    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.

    Lift and put the cable reel in position onto the rear frame with the attached lifting device (Figure 24).
    Figure 24
  3. 3.
    Route the A10 panel cables through the cable reel flange hole.
  4. 4.
    Install the washers (Figure 25, item B) and insert the screws (item A) to attach the cable reel to the rear frame.
    Figure 25

    A

    Screw

    B

    Washer

  5. 5.
    Torque the screws to 171 Newton meters (126 foot-pounds) dry.
  6. 6.
    Remove the attached lifting device from the cable reel.
  7. 7.

    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 26, item A) forward slightly and remove the wooden block (item B) between the panel and the frame.
    Figure 26

    A

    A10 panel

    B

    Wooden block

  8. 8.
    Align and position the A10 panel to the machine frame.
  9. 9.
    Insert the screws (Figure 27, item A) and the washers (items B) to attach the A10 panel (item C) to the machine at the bottom.
    Figure 27

    A

    Screw

    B

    Plain washer

    C

    A10 panel

  10. 10.
    Torque the screws to 40 Newton meters (30 foot-pounds) dry.
  11. 11.

    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).

    Align the sprockets to the correct position.
  12. 12.
    Install the drive chain in position onto the sprockets and connect it with the master link (Figure 28, item A).
    Figure 28

    A

    Master link

  13. 13.
    Adjust the tension of the drive chain in accordance with the procedure.

    NOTE

    Refer to Adjusting Reeling Unit Drive Chain in the maintenance manual.

  14. 14.

    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).

    Put the flange (Figure 29, item D) and the wheel (item C) in position onto the cable reel drum.
    Figure 29

    A

    Lock nut

    B

    Washer

    C

    Wheel

    D

    Flange

  15. 15.
    Insert the washers (item B) and the lock nuts (item A) to attach the wheel (item C) and the flange (item D) to the cable reel drum.
  16. 16.
    Torque the lock nuts to 40 Newton meters (30 foot-pounds) dry.
  17. 17.

    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 30, item A) to access the slip rings (item B).
    Figure 30

    A

    Slip ring cover

    B

    Slip ring

Preparation of the Component

  1. 1.
    Put the pallet with the main power cable near to the rear of the machine.

    NOTE

    A qualified technician must install the cable.

  2. 2.
    Install the end of the cable through the wire mesh hose (Figure 31, item A), cable gland (item B), flange (item C), and reel housing (item D).

    NOTE

    Make sure to leave enough free cable to reach the slip rings.

    Figure 31

    A

    Wire mesh hose

    B

    Cable gland

    C

    Flange

    D

    Reel housing

  3. 3.
    Secure the wire mesh hose (item A) to the cable reel with the clevis.
  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.

    Connect the main power cable to the brush holders (Figure 32, item A) on the slip rings.
    Figure 32

    A

    Brush holder

  5. 5.
    Connect the A10 panel cables (Figure 33, item A) to the slip rings as per the labels.
    Figure 33

    A

    Cable

  6. 6.

    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.

    Install the slip ring cover (Figure 34, item A) in position into the cable reel drum.
    Figure 34

    A

    Slip ring cover

  7. 7.

    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.

    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 the cover in position and install the ground cable (Figure 35, item A) onto the cover.
    Figure 35

    A

    Ground cable

  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).

    Install the cover (Figure 36, item C) onto the cable reel drum and attach it with the washers (item B) and the lock nuts (item A).
    Figure 36

    A

    Lock nut

    B

    Washer

    C

    Cover

  9. 9.
    Torque the lock nuts to 20 Newton meters (15 foot-pounds) dry.
  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.

    WARNING

    Energized Machine

    Can cause personal injury to the surrounding people.

    1. Warn the surrounding people that the machine is about to be started and operated.

    Start the machine.
  13. 13.
    Wind the cable onto the cable reel with the cable reel control (Figure 37, item A).

    NOTE

    Refer to Winding Main Power Cable onto Reeling Unit in the operation manual.

    Figure 37

    A

    Cable Reel Control

  14. 14.
    Stop the machine.
  15. 15.
    Set the battery isolation switch to the OFF position.
  16. 16.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  17. 17.

    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.

  18. 18.
    Release the stored energy from the hydraulic oil tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  19. 19.
    Release the stored energy from the air tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  20. 20.

    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.
  21. 21.

    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.

    Put the rear canopy in position onto the machine and align it in position.
  22. 22.
    Install the washers (Figures 37A and 37B, item B), lock nuts (item C), and insert the screws (item A) to attach the rear canopy to the machine frame.

    NOTE

    Do not tighten the screws at this stage.

    Figure 37A Boomer M1D, E2C, Boltec M, E, EC, Cabletec E, and Simba M6C
    Figure 37B Cabletec M, Cabletec LC, and Simba E7C Machine

    A

    Screw

    B

    Washers

    C

    Lock nut

  23. 23.
    Install the washers (Figure 38A and 38B, item B) and insert the screws (item A) to attach the rear canopy to the machine frame.
    Figure 38A Boomer M1D, E2C, Boltec M, E, EC, Cabletec E, and Simba M6C
    Figure 38B Cabletec M, LC, and Simba E7C

    A

    Screw

    B

    Washer

  24. 24.
    Torque all the screws to 69 Newton meters (51 foot-pounds) dry.
  25. 25.
    Remove the attached lifting device from the rear canopy.
  26. 26.

    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.

  27. 27.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  28. 28.
    Set the battery isolation switch to ON position.
  29. 29.
    Start the machine.
  30. 30.
    Swing in the hose reel in position into 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 39A, item A) and swing in the Air Oil Cooler Assembly (item B) along with the hose reel to its position.
      Figure 39A

      A

      Directional valve lever

      B

      Air Oil Cooler Assembly

    2. Alternative step
      For Cabletec M, LC, and Simba E7C Machine: Operate the controls and swing in the Hose Reel Assembly to its position (Figure 39B).
      Figure 39B
  31. 31.
    Stop the machine.
  32. 32.
    Set the battery isolation switch to the OFF position.
  33. 33.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  34. 34.

    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.

  35. 35.
    Release the stored energy from the hydraulic oil tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  36. 36.
    Release the stored energy from the air tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  37. 37.
    Close the left side hatch and door as follows:
    1. Alternative step

      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.

      For Boltec M, E, EC, Simba M6C, Boomer M1D, E2C and Cabletec E Machine: Close the left side hatch (Figure 40A, item A) and lock it in position.
      Figure 40A

      A

      Left side hatch

    2. Alternative step
      For Cabletec M, LC and Simba E7C Machine: Close the left side door (Figure 40B, tem A) at the rear side of the machine.
      Figure 40B

      A

      Door

  38. 38.
    Close the right side door (Figure 41, item A).
    Figure 41

    A

    Right side door

  39. 39.

    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.

    Disconnect the vacuum pump from the hydraulic oil tank and install the breather filter (Figure 42, item A).
    Figure 42

    A

    Breather filter

  40. 40.

    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.

  41. 41.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  42. 42.
    Set the battery isolation switch to the ON position.
  43. 43.

    WARNING

    Energized Machine

    Can cause personal injury to the surrounding people.

    1. Warn the surrounding people that the machine is about to be started and operated.

    Start the machine.
  44. 44.
    Lower the front and the rear support legs onto the ground to lift the machine from the maintenance stands.
  45. 45.
    Stop the machine.
  46. 46.
    Set the battery isolation switch to the OFF position.
  47. 47.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  48. 48.
    Remove the maintenance stands that are placed below the machine.
  49. 49.

    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.

  50. 50.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  51. 51.
    Set the battery isolation switch to the ON position.
  52. 52.

    WARNING

    Energized Machine

    Can cause personal injury to the surrounding people.

    1. Warn the surrounding people that the machine is about to be started and operated.

    Start the machine.
  53. 53.
    Retract the front and the rear support legs to lower the machine onto the ground (Figures 43A and 43B).
    Figure 43A
    Figure 43B
  54. 54.
    Retract the front jack support legs fully into the jack beam (Figure 44).
    Figure 44
  55. 55.
    Stop the machine.
  56. 56.
    Set the battery isolation switch to the OFF position.
  57. 57.

    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.

  58. 58.
    Release the stored energy from the hydraulic oil tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  59. 59.
    Release the stored energy from the air tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  60. 60.
    Adjust the limit switch if the cable or cable reel is replaced.

    NOTE

    Refer to Adjust Limit Switch in the maintenance manual.

  61. 61.
    Put a tag onto the battery isolation switch stating that the cable reel is replaced.