Sherman + Reilly CRS User manual

CONDUCTOR
REEL STAND
SHERMAN & REILLY, INC.
P.O. Box 11267 •400 West 33rd Street
Chattanooga, TN 37401 USA
Phone 423•756•5300
Fax No. 423•756•2948
Toll-Free 800•251•7780
Web Site www.sherman-reilly.com
© Copyright November 16, 2011 Sherman & Reilly, nc.
OWNER’S MANUAL
• OPERAT ON
• SERV CE
• PARTS

November 16, 2011 I
Section 1 • INTRODUCTION
mportant nformation...............................................................1.1
Section 2 • SAFETY
WarningTerms.....................................................................2.1
OperatorSafetyPrecautions ...........................................................2.1
EmployerSafetyRequirements.........................................................2.2
Section 3 • OPERATION
Pre-Operation nspection............................................................. 3.1
Reel nstallation/Removal.............................................................3.2
Payout Brake & Hydraulic Retriever (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Section 4 • SERVICE
GeneralService.....................................................................4.1
mportant nformation...............................................................4.1
PowerPack ........................................................................4.1
SafetyPrecautions...................................................................4.2
Section 5 • PARTS
20"PayoutBrakeAssembly............................................................5.1
ReelShaftAssembly,20KModels.......................................................5.2
20"BrakeAssembly .................................................................5.3
ReelShaftAssembly .................................................................5.4
PillowBlockAssembly ...............................................................5.6
“OldStyle”PayoutBrakeAssembly .....................................................5.7
RetrieverDriveAssembly .............................................................5.8
TABLE OF CONTENTS

II
TABLE OF CONTENTS

1.1
t is very important to all of us at Sherman & Reilly
that all equipment is operated in a safe manner. We
have taken every precaution to guard against the pos-
sibility of an accident. To properly, safely operate this
unit, it is necessary and important that operators and
service people read and understand the information in
this manual. ANYONE working around the unit
should read the safety precautions in the manuals.
Be aware each warning and precaution is to help pro-
tect against needless injury. Taking unnecessary risks
and ignoring warnings is the primary cause of person-
al injury and fatal accidents in the work place. f you
have any questions regarding operation or safety of a
procedure or situation, contact the Sherman & Reilly
Customer Service Manager at 1-800-251-7780.
This manual was prepared to help the operator use the
Conductor Reel Stand in a safe manner. Responsibility
for safety during operation and service rests with the
person(s) doing the work. Be alert, observe, and prac-
tice all safety measures, including OSHA requirements
and ANS standards, to help prevent the possibility of
an accident.
This manual is of no value if the operator does not read
and understand the instructions and precautions before
starting and trying to operate the unit. The operator
must be aware of the unit’s capacities and limitations. t
is the operator’s responsibility to watch for situations
and conditions which could affect the normal perfor-
mance of the unit and safety in the work area.
Publication of this manual and the safety precautions
in it does not in any way represent an all inclusive list.
t is the operator’s responsibility to make sure the unit
is operated in accordance with all state and local safe-
ty requirements and codes,
including all applicable OSHA
(Occupational Safety and
Health Act) and ANS
(American National Standards
nstitute) regulations.
Sherman & Reilly strongly recommends that only per-
sons literate and understanding the English language be
considered as operators or service personnel.
INTRODUCTION
IMPORTANT INFORMATION

1.2
INTRODUCTION

Do not place any part of the body into a potential
pinch point. The unit must be turned off and locked
out in accordance with OSHA re ulations before
attemptin to correct a problem, workin on the unit,
or performin re ularly scheduled service.
Do not attempt to operate Sherman & Reilly
equipment without proper instruction, including
reading and understanding the manual.
Obey and enforce all warnings including OSHA
requirements and ANS standards.
Always wear proper safety equipment as
required by employer.
Never bypass safety switches or operate
equipment with faulty safety devices.
Be sure all guards and access covers are
secure in place when the unit is being operated.
Be aware of people in the work area who may be at risk
during operation.
Know all emergency shutdown procedures.
Do not obstruct controls or fire extinguisher.
Make sure fire extinguisher is fully charged.
Never operate equipment while under the influence of any
substance which could impair operator ability or judge-
ment. This presents a safety hazard in the work place.
Always use employer approved grounding proce-
dures when operating the unit.
Do not operate equipment if work ability is impaired
by fatigue, illness, or other causes.
Keep all body parts, head, and limbs away from all
moving parts.
Know location and function of all controls, gauges,
instruments, and protective devices.
Never use controls or hoses for hand holds.
Do not exceed unit specifications and lim-
itations for weight.
Know where to get help in the event of an
emergency or injury.
Do not make physical contact with rope or cable as it
leaves the reel.
DANGER
2.1
WARNING TERMS
Signal words in this manual call the operator’s atten-
tion to safety concerns.
The word DANGER indicates the information relates
to a specific immediate hazard which, if disregarded,
will result in severe personal injury or death.
The word WARNING indicates the information
relates to a specific immediate hazard or unsafe prac-
tice which, if disregarded, could result in personal
injury or death.
The word CAUTION indicates the information per-
tains to a potential hazard or unsafe practice which, if
disregarded, may result in minor personal injury or
equipment damage.
The word NOTE indicates the information is impor-
tant to the correct operation or maintenance of the
unit.
NOTE
CAUTION
WARNING
DANGER
SAFETY
WARNING TERMS/SAFETY PRECAUTIONS
OPERATOR SAFETY PRECAUTIONS

EMPLOYER SAFETY REQUIREMENTS
SAFETY
2.2
This guideline is intended to assist owners/employers
to ensure equipment is serviced and operated in a safe
manner. Each job site may have additional situations
and conditions which need consideration.
Monitor the operators to be sure they observe and
practice safety procedures and operate the support
equipment as outlined in this manual. Establish a reg-
ular inspection program which includes malfunction
reports, inspection, and service records. This inspec-
tion should cover the unit condition, adjustment, and
ensure all safeguards are in place and functional. Make
sure that any malfunction or breakdown that will
affect the safe operation of the equipment is properly
corrected or repaired before returning unit to service.
The employer shall provide training and instruction in
safe methods of work before assigning workers to oper-
ate, service, or repair the equipment. A record of train-
ing dates, employee names, and level of training should
be maintained. Only persons literate and understanding
the English language should be considered to use the
Sherman & Reilly Conductor Reel Stand.
Employer shall utilize a lock-out/tag-out procedure
which complies with part 1910.147 of Title 29 of the
Code of Federal Regulations (OSHA). The procedure
will include control of all keys.
The employer will specifically inspect all safety equip-
ment and protective devices on the equipment to
ensure they are not bypassed or disabled. Operation
of the equipment will not be permitted unless all safe-
ty devices are functional and in place. The employer
shall meet the appropriate protection requirements
for the workers.

PRE-OPERATION INSPECTION
OPERATION
It is recommended pre-operation inspection be done
before leavin the yard or ara e.
As you continue the inspection, look for structural
dama e, bent or broken parts, cracked or broken
welds, missin pins and retainers.
Gnspect pillow block bearings and housings.
Gnspect disc brake assemblies.
GCheck reel locks for damage.
Gnspect retriever assembly (when applicable).
On units with a Power Pack asoline en ine powered
system, refer to the en ine manufacturer’s manual for
pre-operation checks and maintenance of the en ine.
NOTE
NOTE
NOTE
3.1
Reel Lock
Pillow Block Bearing
Optional Retriever
Reel Shaft
Disc Brake

REEL INSTALLATION/REMOVAL
3.2
OPERATION
The procedure for installing or removing a reel is the
same for all types of reels.
Make sure there is adequate overhead clearance
with no obstructions before attemptin to remove or
install a reel.
GDisengage the payout brake coupler from the reel
shaft.
On units with optional hydraulic retriever, the
retriever must be disen a ed.
Make sure the reel lockin
pin is unlocked.
GRemove the locking pins
and unlatch the pillow
block housing on both sides. Rotate the top of the
housing to the full open position and make sure the
latch is folded back out of the way.
GUse a spreader bar on the chains to the lifting device
to lift the reel and drive bar assembly up out of the
pillow block housing.
Lift strai ht up keepin the bar level with the unit
to prevent the bearin s from bindin in the pillow
block housin s and possibly causin dama e to the
unit.
CAUTION
NOTE
NOTE
CAUTION
“OPTIONAL”
RETRIEVER
COUPLER
COUPLER

3.3
GRemove the bearing from the end of the drive bar,
loosen the set screws and remove the lifting
eye/tapered cone.
The conductor reel should be placed so that the con-
ductor will feed off the bottom of the reel, throu h
the fairlead window, to the front of the unit.
GSlide the drive bar into the reel to be
installed. Adjust the drive pins if necessary.
GSlide the reel lifting eye/tapered cone onto
the drive bar.
Two (2) sizes of tapered cone liftin collars are pro-
vided. Be sure to use the proper size based on the
diameter of the arbor hole.
The tapered cone is turned in and slid into the
arbor hole on wooden reels when necessary to stabi-
lize the reel.
GAlign the reel lifting eye with the lifting eye on the
drive bar and tighten the set screws.
GSlide the bearing into place on the drive bar.
GAttach the lifting device chains with a spreader bar
to the reel and drive bar lifting eyes.
GPosition the reel over the pillow block housings and
lower the reel into place.
Lower the reel strai ht and level with the unit to
keep the bearin s from bindin in the pillow block
housin s as the reel is lowered into position.
GRemove the lifting device, close, latch and secure
the pillow block housings with the locking pins.
GRotate the reel by hand to make sure it moves freely
and turns correctly.
NOTE
NOTE
NOTE
NOTE
OPERATION
REEL INSTALLATION/REMOVAL
REEL
SHAFT
LIFTING EYE
TAPERED CONE
BEARING
LOC ING
COLLAR

3.4
PAYOUT BRA E
The payout brake is used to add tension to the reel and
provide even control of the conductor during stringing
operations. The tension is provided by an adjustable disc
brake assembly. Adjustment may be manual or hydraulic.
To add tension, rotate the control clockwise. To release
tension, rotate the control counter-clockwise. A pinned
locking collar is used to disengage the brake from the reel
shaft during the loading and unloading procedure.
Make sure the payout brake is disconnected before
attemptin to remove the reel shaft.
HYDRAULIC RETRIEVER
(Optional)
The retriever device is intended for rewinding only
short sections of conductor on the reel. The unit is
engaged by connecting the drive shaft to the reel shaft
with a sliding coupling.
This unit was desi ned to retrieve loose cable or
rope and should not be used as a “puller”.
CAUTION
CAUTION
OPERATION
PAYOUT BRA E & HYDRAULIC RETRIEVER

4.1
IMPORTANT INFORMATION
The service uidelines outlined in this manual are
effective methods. These uidelines are not all inclu-
sive. Anyone who performs service or repair on a
Sherman & Reilly unit must be completely satisfied
that no one’s safety will be jeopardized and take
responsibility for these actions.
f there are any questions about safety, procedure or
precautions, contact Sherman & Reilly at 1-800-
251-7780 before attempting to do the work.
Service should be sched-
uled to allow adequate
time so the procedure can
be completed correctly. t
must be done by skilled,
trained service personnel
with a good basic knowl-
edge of equipment, proce-
dures, and safety practices.
Accurate records should be kept of all service and
repairs.
WARNING
Close attention to proper preventive measures and ser-
vice procedures will ensure and extend trouble-free
operation of equipment. Proper lubrication and atten-
tion to the bearings, brake pads and structural compo-
nents are vital. The objective of scheduled service
should be to anticipate and prevent operational prob-
lems before they require extended shutdown for
repairs.
SERVICE
GENERAL SERVICE
POWER PAC SERVICE
GReplace broken or missing parts with Sherman &
Reilly factory authorized parts.
GKeep all fluids at their proper level.
GClean the unit regularly and keep it as clean as pos-
sible during operation.

SAFETY PRECAUTIONS
4.2
GMake sure the unit is locked out in accordance with
OSHA requirements.
GMake sure that all precautions are taken to support
components before loosening or removing bolts.
GMake sure nothing will move or drop when loosen-
ing a connection.
GUse oil-dry or some absorbent material to soak up
any fluid spills to keep working surfaces from
becoming slippery.
GBe sure everyone involved in the maintenance, ser-
vice or repair process understands what is being
done and all of the safety precautions which need to
be taken during the procedure.
GTake all fire prevention safety mea-
sures before using a welder or cut-
ting device, including grinders.
Have a fully charged fire extin-
guisher near the location of the
work.
GMake sure all lifting devices, chains, slings, and
hooks are in good condition and have the rated
capacity to do the job. Use guide lines when neces-
sary for control during the lifting process.
GAlways wear proper protective
clothing and equipment when per-
forming service: gloves, safety glass-
es, etc.
SERVICE

5.1
PARTS
20" PAYOUT BRA E ASSEMBLY
Part # Description Qty.
305414 20" Caliper Assembly 1
530361 Ventilated Brake Disc 530361 1
550182 Detent Pin 1
558660 Brake Pads “replacement” 1
700237 T-Handle Assembly #7 1
A1548 Bushing 5-093-004 2
A2036-2 Support 1
A2037 Support 1
A2087 Spacer Washer 2
B1398 Coupler 1
C2130 POB Shaft 1
D2493 Guard 20" POB 1
D2493
A2037
C2130
A2087
A1548
558660
D1418-368 700237
A2036-2
550182
B1398
A1548
A2087
530361

5.2
PARTS
REEL SHAFT ASSEMBLY, 20 MODELS
1608-378
551448
552037
Part # Description Qty.
1608-378 Brake Drive Shaft 1
1608-378 Brake Locking Pin 1
530361 20" Ventilated Brake Disc 530361 1
551448 Bearing, 2 Bolt 1
552037 Bearing, 4 Bolt 1
A2352-C Reel Shaft Lifting Collar, 315⁄16"1
A2359-C Tapered cone, 4" shaft, 5" arbor 1
B1474-3 Shaft Adapter, 4" shaft, 5" arbor 1
530361
1608-378
A2352-C
A2359C
B1474-3

5.3
PARTS
20" BRA E ASSEMBLY
Part # Description Qty.
305414 Caliper Assembly, 20" 1
558660 Brake Pad (Set of 2), 20" 1
700237 T Handle Assembly 1
558660
700237
305414
STANDARD “T” HANDLE

5.4
PARTS
REEL SHAFT ASSEMBLY
*
B1474-1
B1474-2
B1474-3
530447
C1635-2
550104
551776
555030
551402
530447
C1638-1
300663
550294
300664
D1840 A2352-A
A2352-B
A2352-C
***
550104
551495

5.5
PARTS
REEL SHAFT ASSEMBLY
Part # Description Qty.
300663 Drive Pin 2
300664 Drive Pin Retaining Washer 2
530447 Bearing Housing, C1638-1 or C1638-2 2
550104 Bearing 1
550294 Detent Pin 1
551402 Snap Ring 1
551495 Bearing, 25⁄16"1
551776 Snap Ring 1
555030 Snap Ring 1
A2352-A Reel Shaft Lifting Collar, 25⁄8"1
A2352-B Reel Shaft Lifting Collar, 3" 1
A2352-C Reel Shaft Lifting Collar, 315⁄16"1
B1474-1 Shaft Adapter, 25⁄8" shaft, 5" arbor 1
B1474-2 Shaft Adapter, 3" shaft, 5" arbor 1
B1474-3 Shaft Adapter, 4" shaft, 5" arbor 1
D1840 Locking Collar 1
A2356 Tapered Cone, 25⁄8" shaft, 3" arbor 1-094-002
A2357 Tapered Cone, 3" shaft, 4" arbor, 1-095-002
A2359-A Tapered Cone, 25⁄8" shaft, 5" arbor, 1-094-002
A2359-B Tapered Cone, 3" shaft, 5" arbor, 1-095-002
A2359-C Tapered Cone, 4" shaft, 5" arbor, 1-095-002
A2813 Tapered Cone, 25⁄8" shaft, 4" arbor, 1-094-002

5.6
PARTS
PILLOW BLOC ASSEMBLY
Part # Description Qty.
370038 Reel Stop Pin 2
530274 Pillow Block Cap 2
530388 Pillow Block Base 2
550294 Detent Pin 2
550319 Toggle Clamp 2
550569 Spring Plunger 2
A1477-1 Pivot Pin 1
550319
550569
370038
530388
1-073-002
550294
A1477-1