Operation & Maintenance Manual

Cable Drum

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TABLE OF CONTENTS
SUBJECT

PAGE

Principle of operation

Technical data rating plate

Accident prevention measures

Cable drum commissioning

Adjustment of cable limitation (two strain relief windings)

Adjustment of drive torque control (half full and full position)

Adjustment of the maximum permissible cable deflection

Adjustment of the tight and slack cable control device

Dryer packs in the cable drum body

Drive motor rotor resistance

Drive motor connections

11

Travel motion control

13

Maintenance of the cable drum

15

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Access to the high voltage area for authorized personnel only.

The local safety regulations must be observed.
Before start any work on the high voltage system, make sure
that the main power supply from the power station is
interrupted. Contact your supervisor for further safety
instructions.

Principle of Operation
Legend for Illustration Z 25058
(5M6)
Brake motor, for more information refer to the separate manuals
Operating Instructions Brake Motor and Manual Brake Release
Attachment in the Appendix.
(5S3)
Rotation direction indicator (switch)
(5R1)
Resistor for brake motor torque adjustment
(5S4)
Gear type cam switch for resistor controlling and monitoring of
the last two cable windings
(5S6)
Pendulum control cam switch, to detect slack or tight cable
(5S8, 5S9) Proximity switch to detect cable deflection to the right and left side
(5S1)
Service switch for cable drum control
Positions of rotary switch (C)
1 Winding off the cable
2 Stop drum rotation
3 Automatic operation
4 Winding up the cable
IMPORTANT: The cable drum control switch (5S1) is intended to be used by
authorized service personnel only. Contact your supervisor for further
instructions. For operating the rotary switch (C) insert key (A) into lock (B).
For normal operation set switch (C) to position (3) automatic operation.
Purpose and principle of operation

The cable drum is utilized to automatically wind up or wind off a suitable cable or
support cable, which ensures power supply for a mobile excavator. The cable drum is
driven by a transmission brake motor with slip ring rotor (5M6). Torque control of this
drive is effected by a rotor resistor (5R1) with 4 taps, which is accordingly activated
by a camshaft switch (5S4).
Using a rotation sense transmitter (5S3) incorporated into the driving chain, operation of
the control device is monitored, and the drum body's sense of rotation is determined.
The cable to be wound up is properly arranged by the control device, and then wound
up on the drum.
A camshaft switch (5S6) mounted to the oscillating crank controls cable pulling and
ensures in this way a monitoring of tight and slack cable modes.
Two proximity switches (5S8 and 5S9) incorporated in the oscillating crank control
the elongation of the pendulum, ensuring in this way a maximum slanting direction of
cable pulling of up to 30 to either side. Voltage and signal transmission from the
drum cable to the firmly installed cable on the excavator is carried out by a slip ring
body incorporated in the drum body.

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Technical data - Rating plate

The rating plate is mounted to the removable protection hood of the drum body (nondrive side).
This rating plate contains the most important data of the cable drum.
Typical rating plate
Manufacturer:
Elektrotechnische
Elektrotechnische
Gerte Gerte
- Ehrenberg
Bhlitz Bhlitz
- Ehrenberg
GmbH GmbH
Ludwig-Hupfeld-Strae
6, D-04178
Ludwig-Hupfeld-Strae 6, D-04178
LeipzigLeipzig
Telephone:
D-341/4481-0,
Fax:
D-341/4481-200
Telephone: D-341/4481-0, Fax: D-341/4481-200
-------------------------------------------------------------------------------------------------------------------------------

Cable drum
Serial
Number:
70.209 / PC8000 - .....
Cable
drum
Serial Number

-------------------------------------------------------------------------------------------------------------------------------

Nominalvoltage
voltageSRK:
SRK:3 3x x400
400A A+ +PE,
PE,1010kV,
kV100% ED
Nominal
200A,A,1 1kV,
kV100% ED
1 1x x200
Drive:
480
V,
60
Hz,
40%ED
ED
Drive: 480 V, 60 Hz, 40%
Drivingspeed:
speed:4242m/min
m/min
Driving
Cable:
DIA
=
81
mm,
m
=
12,3
kg/l m,
l = 210
in two
Layers
Cable: D = 81 mm, m = 12,3 kg/ m,
= 210
m inmtwo
Layers
In order to ensure a safe operation of the cable drum, observe the
performance parameters contained on the rating plate. When using a
cable with different features, the control device and the corresponding drive
must be adapted accordingly. Please contact us for further questions.
Accident prevention measures
All movable or quickly rotating parts directly mounted to the cable drum, such as
chain drives, are cased in an appropriate manner.
The removable casings of the drum body are equipped with safety switches which
must be connected in such way that the slip ring body voltage is cut off when
removing the casing. Any bridging of the switches is not allowed.
The last two windings on the drum shell serve as strain relief of the cable and must
not be winded off during operation. The switch 5S4 controls this condition and cuts
off forward travel of the excavator when the last two windings of the cable are left on
the drum.

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Drum commissioning
Apply and connect cable:
The drum body must be located in such away that the cable entry (1), illustration
(Z25057) in the drum shell is on top, and the control device with the oscillating crank
is on the left rim. The chain link (2) must be in the outermost left position. This can be
carried out by turning the drive motor by means of the crank or manual brake release
device, for more information refer to the separate manual Operating Instructions
Brake Release Attachment in the Appendix. Remove the cover of the drum body and
adjust the sealing rubber of the screwed cable gland to the cable diameter.
Equip the cable with prefabricated cable end terminations, and route it through the
guide rollers (3) of the control device and the screwed cable gland into the drum
shell. Fix the cable inside the drum on the existing clamps (strain relief) and the
individual cores to the copper rails of the current collectors. When making the
connection, look for ring and current collector identification markings.
After termination of this work tighten the screwed cable gland, and additionally seal
with sealing compound (such as SSW E 105). Clean the drum body after termination
of this work, and reinstall the cover removed before. Look to it that sealing rubbers
are tight.
Now put on two windings onto the drum shell by means of the drive motor or the
manual brake release device and adjust cable limitation at the gear type cam switch
5S4, see (5) in the illustration.
NOTE:

Ex works the cable drum is pre-adjusted. Prior to putting the cable drum into
operation, re-checking of the adjustment is necessary.

Adjustment of cable limitation at the gear type cam switch 5S4, see (5) in the
illustration (Z 25057)
With the two windings on the cable drum adjust the switching element 11-12 of the
cam switch (5) in such a way that in this position the contact opens (cable limitation)
and remains open when winding up further cable windings.
NOTE: The two windings serve as strain relief and must not be winded off during
operation.
Re-check the switching point of element 11-12. Remove the manual brake release
device from the drive motor. For further winding up of the cable the drive motor can
now be driven electrically.
Adjustment of cable drum HALF-FULL position (first cable layer on the drum)
With the first layer on the cable drum adjust the switching element 21-22 of the cam
switch (5) in such a way that in this position the contact opens (torque increase) and
remains open when winding up further cable windings.
Adjustment of cable drum FULL position (both cable layers on the drum)
With both layers on the cable drum adjust the switching element 31-32 of the cam
switch (5) in such a way that in this position the contact opens (cable drum full).

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NOTE:
The lowest torque will be required for winding off. The lowest torque is activated
on the basis of an information from the rotation sense monitoring device (5S3),
which delivers a signal when the cable drum is pulled in the direction of windingoff (forward travel of the excavator).
Check before commissioning, that the control device moves to the right during
winding-up of the cable. Make sure the cable is wound up without kinks assist by
hand if necessary.
Adjustment of the maximum permissible deflection of cable pulling:
The maximum lateral deflection of the cable is 30. This condition is monitored by
two proximity switches (5S8 and 5S9), see (4) in the illustration (Z 25057) mounted
to the oscillating crank. Adjust the metal sheets (8) of the pendulum in such way
that the sensor triggers at a deflection of 30 to the right and to the left. The
switching point of the proximity switches is indicated by a LED. Make sure, that the
cable cannot be over run through the tracks of the excavator.
Adjustment of the tight and slack cable control device:
The camshaft switch (5S6), see (6) in the illustration controls the tight and slack
cable condition. In order to reach idle time of the drum cable that are as long as
possible, correct cable pulling is necessary. Deviations from this condition can be
caused by excessive driving speeds or defective drive motor torque control devices.
Tight cable adjustment:
Adjust the switching element 11-12 of the camshaft switch (6) in such a way
that the contact opens when the oscillating crank with pendulum (7) is moved
up more than 25-30. When the oscillating crank with pendulum moves down in
direction of Slack Cable the switching element must remain in closed position.
Slack cable adjustment:
Adjust the switching element 21-22 of the camshaft switch (6) in such a way
that the contact opens when the oscillating crank with pendulum (7) is moved
down more than 25-30. When the oscillating crank with pendulum moves up in
direction of Tight Cable the switching element must remain in closed position.
Dryer packs in cable drum body
A cage for taking up six dryer packs is located inside the drum body, see illustration
(Z 25056) on page 14. Before operating the cable drum, remove the access cover on
the non drive end of the drum body and check to make sure that the six dryer packs
are inserted in the cage. If the dryer packs are not yet inserted, remove the plastic
wrapping from the packs and insert them into the cage. Attach the access cover.
Drive motor rotor resistance:
This resistor serves as protective resistor for the stop period sliding rotor brake
motor. The protective degree is IP 23. The resistor heats up to approximately 125C
during operation, the air temperature at the outlet being up to 175C. Make sure
that there is enough air exchange with the outer environment.

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Connecting the drive motor:

The cable drum is driven by a three phase stop period cage rotor motor. The motor
works on the sliding rotor principle, and thus constitutes the simplest type of
connection between motor and brake. The motor is always connected in a way as to
create a torque in the sense of winding up. The motor automatically adapts to all
driving speeds of the device until standstill, and is pulled through upon cable
winding-off in opposite direction of its rotation sense. When the mains is switched
off, the brake working on the sliding rotor principle prevents winding-off of the cable.
Observe the data contained on the rating plate, when connecting the motor. For
more information refer to the Service Manual of the Excavator and to the electrical
diagram. Observe also the instructions in the separate manual Operating
Instructions Brake Motor in the Appendix.

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Travel motion control, illustration Z 25059

General:
The cable drum is equipped with safety switches for the protection of the power
supply cable during travelling and turning operations. Movements which could
damage the power cable are automatically switched off.
Cable condition

Monitored by

Travel response

Switch
1. Too tight

5S6

crawler left and crawler right

forward motion stopped

2. Too slack

5S6

crawler left and crawler right

reverse motion stopped

3. Too strong deflection

to the left

5S8

4. Too strong deflection

to the right

5S9

5. Maximum permissible
cable length on the
drum

5S4

6. The last two cable

windings serving as
strain relief are left on
the drum

5S4

NOTE:

crawler left
reverse motion stopped
crawler right
reverse motion stopped
crawler left and crawler right
reverse motion stopped
crawler left and crawler right
forward motion stopped

The ground contact sensing bar (9), illustration (Z 25057) prevents

the cable drum from hitting the ground or obstacles by stopping
reverse travel of the excavator.

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Maintenance

Maintenance Points
see illustration Z25056

After the first 100

After every
After every
and 250
500 operating 1000 operating
operating hours
hours
hours

Lubricate bearings of the

X

oscillating crank via grease

fittings

Lubricate bearings of the

X

oscillating crank rollers and

slip ring unit ball bearing via
grease fittings

Lubricate main drive

chains and drive chain of
the oscillating crank

Check and adjust

tension of the oscillating
crank drive chain

Check and adjust

tension of the main drive
chains

Check and retighten bolt

connections in the slip ring
unit

Check and retighten bolt

connections in the terminal
box

Check guide rollers of

the oscillating crank for
wear and correct alignment
Change oil in drive gear
box

Change oil in angular

gear box
(11) Change dryer packs

X
Change the oil after every 10000
operating hours
Change the oil after every 10000
operating hours
Change the six dryer packs whenever the cable drum
has been opened
(continued on next page)

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Recommended Lubricants
Grease fittings

MPG K3K-20 or KE2K-50 or equivalent greases

Chains

Adhesive spray lubricant Molykote or equivalent

Gear boxes

Gear oil ISO VG: CLP 220 or equivalent

Remarks to the Maintenance Chart:

For lubrication of the slip ring unit ball bearing (2) remove the cover from the
drum body on the drive end side.
The six dryer packs located in a cage (11) inside the drum body should be
replaced whenever the drum has been opened. Used dryer packs can be reused one time after drying. For access to the dryer packs remove the cover on
the non drive end of the drum body.
Additional Maintenance to be carried out by authorized service staff
The slip ring unit (6) inside the drum body should be checked after every 1000
operating hours by authorized service staff as follows:
Check slip rings, brushes, current collectors and insulators for wear and
damage. Replace all worn or damaged parts without delay.
Make sure that all bolt connections are in good condition.
Check self-locking nuts for sufficient clamping torque. Replace nuts which
have lost their clamping torque.

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