Instruções de Manutenção de Reels
Instruções de Manutenção de Reels
Maintenance and
Mounting Instructions
for
Cable and hose reels
People are not to be in the working area of the cable/hose reel during normal use.
Maintenance people are to be informed and understand the risks involved with working
with a cable reel.
The area around the cable/hose reel is to be off limits for people not working on the
machine during normal use.
Emergency Stop push button must always be accessible near the cable reel and the personnel
must be informed of it's location.
Cable/hose -reels which are delivered with chain drives for the drive of the reel or for
indexing of a spooling device must be mounted with protective covers around the chain,
chain wheels and sprockets. If these protections are not in the supply of the reel they
must be incorporated in the machine on which the reel is mounted.
Do not stand close to moving parts as the reel, chain-drives, cable-guides or the cable.
Electric Hazards:
Before the lid of the collector (slipring) is opened be sure the power is switched off and
the main cable is removed from the wall-socket.
Note: The tension in the collector arrives from the main cable on the drum and must be
switched off at the main switchboard.
It must be possible to lock the main switch in the off position during maintenance so
nobody else can apply tension during the work.
There must be a responsible person who supervises that the tension is removed before
maintenance in the collector and that it is not possible to apply the tension during the
work.
Always check with an instrument that all phases are without tension before starting to
work in the collector. During the work it is recommended to short circuit all phases to
earth with earthing cables ( e.g. start cables )
If anti-condense heaters , end-limit switches or lid-opening switches are mounted in the
collector these could be under tension even if the main power is switched off. These
could be supplied via another source. Always check with an instrument before work is
started.
Components:
A. Lift the pre-mounted reel on place. Do not lift in the drum outer rim but lift in the
torque unit and around the drum inner ring or around the cable on the drum.
If delivery is with gearbox and drum separate, mount torque unit first.
Fix the torque unit to the base with high tensile screws (min. class 10.9)
Base must be level and horizontal
B. Mount motor (adapter flange and hydraulic motor) and collector on the gearbox.
(These are normally factory mounted but could be delivered separately due to
transport reasons)
C. If drum and gearbox are delivered as separate parts. Lift drum in place and fix it to the
gearbox flange. If holes do not match then it is possible to turn the gearbox
shaft with a bar until holes match up.
CABLE REELS:
D. Note: All electric installation work must be done by qualified fitters and comply with
general electric installation rules and also comply to any local installation rules.
Pre-wire cable from the collector rings to the terminal box on the drum.
Put cable relief sock on cable and pull cable through entry on drum inner diameter.
Pass cable through cable gland into terminal box (cut conical cable gland to fit cable
diameter). Split cable, prepare ends with cable lugs and fix to terminals.
Seal cable gland well with two tie-raps, and fluid gasket material if needed.
( Silicon is not recommended, use other type of fluid gasket if possible )
When fixing the cables to the terminals and in collector note the following:
- cable shoes and terminal surface must be clean
- tighten screws with nuts as recommended by cable shoe manufacturer
Cables fixed to the rings, earth brushes or cables fixed to the phase brushes
in the K460/-- collector should be tightened to 18 Nm
(Note: These are the screws which have threading in the bronze)
Other cable fixings – with screw and nut – should be tightened to the torque
recommended by the cable shoe manufacturer.
- check and respect insulation distances
- any extra length of cable should be well fixed with tie-raps so it can not interfere
with the function of the collector
- check that all brush carbons are located in the grooves of the rings when finished
- Wind up the cable on the drum with the help of the motor.
If torque is low increase it slightly at a time , torque setting is done by the
hydraulic pressure in the system.(see instructions from machine supplier)
Setting torque too high could damage the cable.
- Follow cable manufacturers instructions on how to reel on the cable the first time.
-cable should be reeled on the same way as it is delivered on the delivery
drum
- do not twist cable when it is reeled onto the drum
- It is important to do this well the first time as the cable life time depends on it.
E. The fixed cable coming from the machine is to be fixed to the brush holders.
See above regarding the fixing of cables to the terminals and the cabling.
When all is ready check extra carefully that all the carbons are lying on the rings
in the correct grooves and that no carbon is outside the rings.
Do this check by feeling with the hand all around the rings.
Also check that the brushes are parallel to the rings and that they are mounted
straight above the ring. (It is possible that they move due to the forces applied when
the screws to the cable shoe fixing is applied - when tightening the screws for the
cable fixing the brush holder should always be held firm)
Collector
− 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.
Collector
− 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.
Gearbox
- Check oil level through the level gauge, and, if necessary, top it up with the oil type
specified further on.
- Pre-reducer is grease filled
General
− Carry out all the operations described in the previous points.
Gearbox
− Change oil in the torque unit. The oil to be used for ambient temperatures between:
-10oC and +40oC is Esso GX 80W-90
For higher or lower temperatures please contact the manufacturer or one of his
representatives.
− Recheck the torque. If torque adjustment is needed decrease or increase the torque setting
for a lower or higher torque requested by the application.
− Limit switch (if any): check cam positions and that switches are operating.
− Lid opening switches (if any): check function. Check that the main power supply is
cut off when switch is activated.
(kg)
T4. 3
TORQUE SETTING
Note that the reels are not intended to work as winches and drag the cable/hose over the
ground. The torque is to be set so the reels lift and recover the cable/hose and keep them
tensioned when the machine is moving in the direction of the cable/hose. When the
machine is moving away from the cable/hose the cable/hose is pulled off the drum against
the set torque.
A too high torque setting could damage the cable or the reels.
5. DIAGNOSTICS ............................................................................................................................... 17
5.1. Troubleshooting table ..................................................................................................................................... 17
Main components
15
13
13
9 11
3.1 4 5
12
1
2 10
3.2 6
7
14
ID: 14060
12 Heater cell (water heating) There is engine coolant circulating in the cell, which gives
(optional) warmth to the air blown through the cell to the cabin.
Located in the air conditioner housing.
The cabin temperature is changed with a control located
in the heater housing or on the adjustment panel.
13 Fresh (atmospheric) air filter Removes the dust from the incoming air.
Located on the outer wall of the cabin.
The air filter must be cleaned with compressed air (the
coarse filter may also be washed in soap solution) and
replaced regularly. The maintenance interval depends on
the quality of the external air.
14 Air filter for internal air circulation Removes impurities from the air circulating in the cabin.
(metal) Located in front of the air conditioner air intake, inside the
cabin.
The filter must be cleaned regularly by washing or by
blowing with compressed air.
15 Cabin bleed valve
16 Electric resistor control box Contains the control contactor and fuels.
Function
The gas pressurised by the compressor is guided through the condenser (3.1). Because the gas
temperature is higher than the external air temperature, the gas gives warmth to the ambient air. This
causes the gas to condense. The condenser fans (3.2) create the necessary condensing capacity.
The liquid refrigerant flows through the dryer (4). Humidity is the biggest threat to the air conditioning
unit, so it must be removed as carefully as possible. A damp system will freeze!
The liquid refrigerant flows on through the expansion valve (7) to the vaporiser (6). The expansion
valve controls the amount of refrigerant that flows through the vaporiser by restricting flow to the cell.
The refrigerant reaching the vaporiser absorbs ambient heat. The air in the cabin is absorbed through
the vaporiser (fan 8), and the warmth and moisture from the air transfers to the cold vaporiser surface.
In the vaporiser, the low boiling point liquid refrigerant reverts to a gas state.
The gaseous refrigerant returns to the suction side of the compressor, and circulation continues in
the same manner.
1. Keep the condenser clean. Remove dirt from between the cells cautiously with a soft brush or
similar to avoid damaging the cells. A clean condenser works efficiently and keeps the cabin air
comfortably cool.
2. Make sure that the refrigerant or hydraulic hoses do not come in contact with any sharp edges or
hot surfaces.
3. Check both the compressor fastening and the tightness of the hydraulic motor and hoses on a
monthly basis. Operate the unit also during winter at least once a week for approximately five
minutes. This ensures the compressor remains lubricated and the moving parts remain clean and
do not become oxidised.
4. Never disconnect the hose connectors except in an emergency. If a hose connector is
disconnected, the refrigerant flows out of the system and the system has to be refilled.
5. Keep the heater’s fresh air-filter and the internal air circulation filter clean.
6. Do not weld or steam-clean anything in the vicinity of the air conditioning lines or components.
The fresh-air filter on the outer wall of the cabin removes dust from the incoming air.
1 Detachable cover
4
2 Coarse filter 3
3 Fastening plate 2
4 Two separate fine filters 1
5 Housing
The air filter must be cleaned with compressed air
(the coarse filter may also be washed in soap
solution) and replaced regularly. The
5
maintenance interval depends on the quality of
the external air.
ID: 28197
ID: 28198
ID: 12203
ID: 28201
Only the following oil grades may be used in the Sanden compressors (refrigerant R-134a):
1. Sanden PAG SP-20 and SP-10 or a corresponding PAG (polyalkylene glycol) ISO-100 (high-
viscosity) or ISO-46 (low-viscosity) oil.
2. Corresponding ISO-100 and 46 ‘Ester’ oils can also be used in the compressor, e.g. Castrol
Icematic 100 and 46 or equivalent.
Naturally, the amount of oil to be added depends on the size of the parts, i.e. the capacity of the
system, so some variation from the values given above will occur.
Amount of oil added into the compressor at the factory: SD7H15 – 1.35 dl, sufficient for systems
containing less than 1050 g of refrigerant.
If the amount of refrigerant in the system exceeds that mentioned above, the amount of oil needed
is calculated as follows:
SD7H15: (0.06 x refrigerant quantity (g) + 60) : 0.9 = amount needed (cm 3)
For example, amount of refrigerant (1400 (g) x 0.06 + 60) : 0.9 = 160 cm 3 = 1.6 dl
Oil to be added: 1.60 – 1.35 = 0.25 dl
In the service meter set, blue indicates the suction side and red indicates the pressure side.
1 Vacuum pump
2 Service valves
3 Pressure side hose
4 Suction side hose 5
5 Service meter set and valves
4
2 1
ID: 28202
Do as follows:
1. Attach the blue filling valve of the service meter set to the suction side service valve (13 mm) of
the system, and the red filling valve to the pressure side service valve (16 mm).
2. (a.) Attach one end of the yellow (middle) hose of the service meter set to the refrigerant tank, and
the other end to the measuring cylinder valve. Open the liquid valve of the refrigerant tank or turn the
refrigerant tank upside down (with the valve facing downward). Bleed the air from the yellow hose by
loosening the end on the cylinder side cautiously. Open the cylinder valve and add liquid refrigerant
to the measuring cylinder. If the liquid refrigerant does not flow properly to the cylinder, heat the
refrigerant tank e.g. by immersing it in hot water or by letting some gas out from the valve on the top
end of the measuring cylinder. When the cylinder is filled with at least the minimum amount of
refrigerant, close the cylinder and refrigerant tank valves fully. Disconnect the yellow hose at both
ends, and then attach one end to the service meter. Switch on the measuring cylinder heating.
3. Screw the middle (yellow) hose of the service meter set to the vacuum pump. Open both filling
valves by carefully turning clockwise all the way to the bottom if you are not using quick connectors.
4. Turn on the vacuum pump. First open the blue valve of the service meter and check that the
pressure starts to drop slowly on the blue meter, and after a while also on the red meter. If not, turn
off the vacuum pump, close the filling valves, and make sure they are properly connected to the
service valves. Restart the vacuum pump and repeat the procedure (if the pressure on the red meter
still does not drop, the system might be clogged). Once the pressure on both meters has started to
drop, open the red valve of the service meter.
Create a vacuum in the system for at least 40 minutes, depending on the length of the hoses (less
than 6 m = at least 40 min. – 25 m = at least 80 min.).
5. First, close both service meter valves; then shut down the vacuum pump. Let the system remain
in this state for at least 15 minutes (if you are using a vacuum gauge with a wider scale, e.g. 1000–
0.0 mbar – 5 min.). If the underpressure has remained unchanged, go to step 6. (a.) or (b.). If the
underpressure has decreased during this time, there is a leak in the system. Repair the leak, and
start again from step 4 (if the system is still not tight, the leak must be located as described in steps
6–8, and then the procedure restarted from step 3.)
6. (a.) Disconnect the yellow hose from the vacuum pump, attach it to the valve below the measuring
cylinder, and open the cylinder valve. Bleed the air from the yellow hose by carefully loosening the
end on the service meter side. Set the measuring cylinder scale correctly in keeping with the pressure
gauge reading, and set the gauge line to the level of the liquid. Write down the reading, and determine
the sight glass reading which indicates how much refrigerant must be added to the system.
(b.) Place the refrigerant tank on the scale upside down (valve facing downward). Disconnect the
yellow hose from the vacuum pump and connect it to the refrigerant tank. Open the tank valve (if the
tank is equipped with two valves, do not turn it upside down, but open the red liquid valve). Bleed the
air from the yellow hose by carefully loosening the end on the service meter side. Reset the scale,
or write down the scale reading if it cannot be reset, and determine the scale reading at which the
system will be full.
7. Open the red (pressure side) valve of the service meter. Add approximately half of the total
amount of refrigerant into the system. Ensure that the pressure increases on both meters. Close the
red valve. If the pressure does not increase in the blue valve, or if it increases very slowly, there is a
clog in the system that must be cleared.
8. Check the system for leaks. Move the leak detector sensor very slowly at each of the connecting
points. Check also the cells and connections made by the manufacturer. Check the seal of the
compressor shaft. The refrigerant is heavier than air, so it sinks if there is leakage. Leak detection
spray (soap solution) is also a viable means of finding leaks, especially in warm conditions (near a
hot engine), because heat can cause the electronic leak detector to give false readings.
IF INFORMATION ON THE AMOUNT OF REFRIGERANT FOR THE SYSTEM IS NOT AVAILABLE
or if you are adding refrigerant, FOLLOW THE INSTRUCTIONS BELOW. Otherwise, go to step 11.
9. Start the vehicle's engine. Set the air conditioner to full capacity (fan at maximum speed and
thermostat at full power). Check via the sight glass that the refrigerant is flowing in the system. If the
sight glass is completely clear and no flow is visible, there is a clog in the system. In that case, switch
off the air conditioning immediately (checking first, however, that the compressor has been switched
on). Locate the clog and clear it. Place a thermometer in the air blast nozzle of the vaporiser. Use the
air conditioner until the pressures and the vaporiser blast air temperature are stable.
10. Check the reading of the pressure gauge (red) and the temperature of the vaporiser air blast. If
you are using a scale, add the refrigerant to the system as gas (with the tank valve facing up or through
the ‘GAS-VAPOR’ valve). Open theblue (suction side) valve of the service meter (very little and
very carefully when adding liquid refrigerant from the measuring cylinder, in order to avoid liquid
refrigerant entering the compressor). Add 50–100 g (depending on the hose lengths) of refrigerant
into the system, and close the suction side (blue) valve. The pressure side pressure (red meter)
should rise slightly, and the vaporiser air blast temperature should fall. Wait for the pressure and
temperature to stabilise, then again add 50–100 g of refrigerant into the system from the suction side
(blue valve).
Draw a curve, such as that shown below, to describe the ratio between the pressure and the amount
of refrigerant. Continue filling 50–100 g at a time. When the pressure on the pressure side (red meter)
no longer increases (and the air blast temperature no longer decreases), close the blue valve of the
service meter.
2
ID: 18113
13. The pressure on the suction side should be 0.1–2.0 bar (blue meter), and the pressure on the
pressure side should be 7.0–18.0 bar (red meter) when the engine operating speed is approximately
1500 rpm. Check the vaporiser blast air temperature at the minimum fan speed. The temperature
should be 2–8 °C. If necessary, ‘fine-tune’ the thermostat (via the small screw) to adjust the
temperature.
14. Close the filling valves of the service meter set by turning them anti-clockwise, and remove them
from the service valves of the system. Check that there are no leaks in the service valves, and attach
protective caps on them.
ALWAYS write down the amount of refrigerant added (e.g. in the
NOTE! warranty information or in the place reserved on the
manufacturer's type plate).
When replacing the dryer, take into consideration that the cover plugs of the new dryer must be
removed and the hoses installed immediately before filling the system! The dryer material loses its
effect if it comes into contact with air for more than 30 min. For this reason, the dryer must always
be replaced whenever the system is drained completely.
If the coupler between the air conditioning compressor and hydraulic motor must be detached during
maintenance or repair work, the following points must be observed:
1. When reinstalling the coupler, make sure that there is no end strain in the connection, as this
might damage the compressor and the engine.
2. The clearance between the coupler elements must be 2 mm +/– 0.5 mm.
ID: 28204
Numbering of the air conditioning system protector switches and circuit breakers
F253 = Switchboard
F500 = Condenser fan circuit breaker
F501 = Air conditioner circuit breaker
F510 = Heater circuit breaker
FAULT CAUSE
Fan is not working. – The automatic fuse of the main switchgear has
tripped.
– The air conditioner fuse has blown.
– The fan switch is broken.
– The fan motor is broken or jammed.
Air conditioning is not working. – The automatic fuse of the main switchgear has
tripped.
– The pressure of the refrigerant in the system
has decreased.
– The air conditioner fuse has blown.
– The compressor is not rotating.
– The system is frozen. Check the operation of
the expansion valve and the condition of the
dryer.
Air conditioning lacks efficiency. – The automatic fuse of the main switchgear has
tripped.
– The heater is on.
– The water valve is leaking.
– The intake air filter is clogged.
– The condenser cell is dirty.
– The vaporiser cell is dirty.
– The refrigerant is low.
– The expansion valve is frozen.
– The dryer is clogged or frozen.
Heating is not working. – The automatic fuse of the main switchgear has
tripped.
– The automatic fuse of the main switchgear has
tripped (feed for the heating resistor).
– The air conditioner fuse has blown.
– The water valve is broken.
Operation is noisy. – The fan motor (in the cabin) is faulty.
– There is not enough oil in the compressor, or
the compressor is faulty (bearing fault).
– There is not enough refrigerant in the system
(noisy vaporiser).
– There is excess humidity in the system (noisy
expansion valve).
– The air filter is clogged.
ID: 22388
ID: 22389
PROTECÇÃO CONTRA
INCÊNDIO PARA VEÍCULOS
Ansul Incorporated One Stanton Street, Marinette, WI 54143-2542, U.S.A. Tel +1 (715) 735-7411 Fax +1 (715) 732-3477
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Colector
de Descarga Ãrea do Tubo
da Bomba Hidráulica
Bloco do Motor
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Precauçães de segurança
O sistema contra incêndio descrito neste material Se forem feitas modificaçães ao equipamento a
é apenas um sistema de supressão e nãê foi ser protegido ou se o sistema de detecção e/ou de
concebido nem se destina a extinguir todos os supressão de incêndio for desligado por qualquer
incêndios, especialmente quando estiverem razão, assegure imediatamente a inspecção e o
presentes quantidades incomuns de materiais ensaio do equipamento contra incêndio por um
combustíveis e um amplo suprimento de distribuidor autorizado de sistemas para veículos
oxigénio. É extremamente importante que um Ansul.
equipamento contra fogo alternativo esteja
O Sistema de Supressão de Incêndio Ansul é feito
disponível caso o fogo não seja totalmente
sob encomenda para proteger áreas de risco
extinto pelo sistema.
específicas no seu veículo. Foi concebido
Proceda com extrema cautela para evitar a
cuidadosamente para ser fiável e construído de
acumulação de detritos, materiais combustíveis e
acordo com os mais altos padrães de qualidade.
fluidos que possam intensificar o fogo ou que o
Cada componente foi ensaiado para assegurar
façam alastrar para áreas onde não havia antes um
durabilidade e desempenho fiável.
potencial de incêndio.
Com uma manutenção apropriada, o Sistema de
Supressão de Incêndio Ansul deverá
proporcionar-lhe anos de protecção contra
incêndio.
Ansul Incorporated One Stanton Street, Marinette, WI 54143-2542, U.S.A. Tel +1 (715) 735-7411 Fax +1 (715) 732-3477
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Suporte soldado
ou aparafusado firmemente
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2. Aplique os travães
4. Evacue o veículo
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Ansul‚ uma marca comercial registada e CHECKFIRE é um marca comercial. © 1996 Ansul Incorporated
Part no 418 384
Ansul Incorporated One Stanton Street, Marinette, WI 54143-2542, U.S.A. Tel +1 (715) 735-7411 Fax +1 (715) 732-3477