INSTRUCTION MANUAL

FOR
CABLE REEL TYPE:
20.1 R612-201P K56OIFC1

WORKS ORDER N. 100841-2

Dated 03.15.2011
CAVOTEC CANADA INC.
 CAVOTEC SPECIMAS HYDRODYNAMIC SYSTEM

INDEX
TECHNICAL DESCRIPTION:
- Cable reel code key
- Installation drawing
- General information

General warnings and safety precautions chp 0 -rev.1

Introduction to the system chp 1 -rev.1

How the torque unit works chp 2 -rev.1

Cable reel assembly instructions chp 3.1 -rev.4

Drum assembly instructions chp 4.1 -rev.0

Torque output regulation, measuring and testing instructions chp 6.1 -rev.3

Maintenance instructions chp 7 -rev.8

Limit switch RAVIOLI chp 9 -rev.1

Hydraulic motor manual / Parts lists chp 10

CAVOTEC SPECIMAS
Works order nr. Date Edited By
100841-2 03.15.2011 J. ANDRIOTIS

Approved By
ING. ROSENWALD
 0 specimas
A M OF lIE CAVOTEC OP
CODE KEY

Cabi. r11 code key (.x.mpb)

120.6 M-1543/62 G KL60/2710/1/6F0/FC/R

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

- I

II L Heating resistor for slipring housing

Rotary limit switch
optic 6 channeL
Ground check ring In collector
Insulating distance - 100 mm
Slipring ring diameter - 270 mm
600 A ring / 60 % ED
of sliprings
K - collector
- Hot dip golvanised

between spokes = 62 mm
outer diameter - 4300
inner diameter - 1500
Type of drum - Monaspiral
pole - 6-pole
box type
(nominal torque l2Okgm)

Oab(e gid. code k•y (.x.mpl.)

I9PF/OT/A

II f I Belt lifting device (optional)

Over tension device
Flat rollers (optional)
Pendulum
Cable guide type

11/07/97 Rev.1 TB185 pagel

 GENERAL INFORMATION

This “operations manual” is intended as a guide to the mounting, use and maintenance of
Specimas “cable reel Specimas S.p.A. or its affiliated Companies accept no liability for
“

loss or damage suffered as a result of the use of this manual.

If in doubt, always refer to the original equipment manufacturer.

Refer at all time to the “General Warnings” chp. OH.

Warranty is not valid in any way if the cable reel has been used in the wrong way or the
technical specifications for use and installation of the cable reel has not been followed.

Only instructed maintenance people are allowed to be near the cable reel during
supervised maintenance.
 INTRODUCTION TO THE SYSTEM
Specimas cable reeling systems are composed of module groups. Each one performs a
specific function; the drawing shown below allows an easy identification of each
component, which is individually described in the following page.

Vista
A
View

121113(9

1. MOTOR electric, hydraulic, pneumatic

2. TORQUE UNIT worm reduction gear
automatic braking,
adjustable torque hydrodynamic coupling
Comprising irreversible worm reduction and built in
automatic brake.
Torque output adjustable through the hydrodynamic
clutch.
3. DRUM monospiral, threespiral, wide.
4. COLLECTOR or hydraulic swivel on hose reels
5. FIBER OPTIC ACCUMULATOR optional.
6. CABLE GUIDE optional switches for: slack cable, cable direction,
®
and cable overtension. With optional Panzerbelt
lifting device
7. CABLE normally not Specimas supply.

30/07/1 997 REV.1 Chp 1H page 1/4

Screws and bolts for drum assembly and adjustment are of stainless material (tie rods of
stainless steel, nuts of stainless steel or zinc plated brass).
Screws and bolts fixing the drum to the gearbox flange are of galvanized tensile steel.
When required for highly corrosive areas the drums can be completely manufactured from
stainless steel.
Special drums for vertical cable retrieve and extreme cable lengths are also manufactured.

4. COLLECTOR
The purpose of the collector is to allow the reeling of the cable onto the drum without
twisting the cable.
Specimas collectors are self-contained units and are fitted onto the torque unit by a dog-
hub connection and 4 supporting bolts.
The ring assembly utilizes air insulation between rings to eliminate risk of short circuit due
to contaminated insulation surfaces.
In an emergency situation, the collector can quickly be replaced.
All components of the collectors are designed and manufactured by Specimas.
Collectors can be equipped with the following optional equipment:
— Resistance heaters (standard in High Voltage units)
— Rotary travel limit switch (with 4 cams as standard)
Switch 1: used to detect center feeding point and by-pass any slack-cable signal
used. (drum full)
Switch 2: used to detect drum empty
Switch 3 and 4: used by client if needed.
Can be used to slow down crane speed over center feed point or to
slow
down crane speed before drum empty signal.
— Pilot ring
If a pilot core for earth sensing is incorporated in the reeling cable a pilot ring will be
inserted in the collector.

5. FIBER OPTIC ACCUMULATOR

If fiber optics are incorporated in the reeling cable a F.O. joint is attached on the rear of the
collector. Standard units are for 6 fibers and 40 drum revolutions with 62.5/125 um
multimode fiber.
Connectors type ST or FC are most commonly required.

6. CABLE GUIDE
This device is used both in horizontal and vertical applications.
In horizontal application it is essential in both modes of operation, i.e. reeling and
unreeling to ensure that regular laying of the cable is achieved.
Normally all cable reels are fitted with a cable guide.
The cable guide is normally fitted with devices to sense crane location in respect to center
feed point (left/right), slack cable and optionally overtension.
In vertical applications it normally depends on mounting type and drum type if a guide is
used or not. If the drum is not of a monospiral type (that is semi wide or wide), it is
recommended to use a guide below the drum to guide the cable centrally onto the drum
and absorb shock and sway from the cable.

30/07/1 997 REV.1 Chp 1H page 3/4

 HOW THE TORQUE UNIT WORKS

Figure 1

SPECIMAS reels are driven by torque units which work on a patented self braking
hydrodynamic clutch system.

The functions of the torque unit are:

- To provide a constant torque on the drum shaft.
- To gear the drum rotating speed to the reeling diameter of the cable.
— To brake the drum when stationary.
- To allow a controlled unreeling of the cable.
- To regulate the torque output accordingly to the requirements of each application.

The torque unit is powered by a motor rotating at constant speed. Normally a conventional
electric squirrel cage motor is used but also an air or hydraulic motor can be used.

The torque of the driving motor is transmitted to the drum shaft through a hydrodynamic
clutch which is combined with a worm gear reduction.
The output torque is only minimally affected by the rotating speed of the input and output
shaft. The output torque can be set from zero to maximum torque through a spring
arrangement of the clutch.

30/07/1 997 REV.1 Chp2H page 1/2

 CABLE REEL ASSEMBLY INSTRUCTIONS
COMPONENTS:

Torque unit 5b
2
3. Collector + optional travel limit switch 4
7
3a Cable gland (collector side) \ /
4. Adapter flange (for 5b) 1
5a. Electric motor
5b. Hydraulic or air powered motor -

6. Mounting base on crane (not supplied)

7a. Cable gland (drum side) 6 -

7b. Pull box for big diameter cable or flat cable 7b

8. Cable grip (optional) 9/\
9. Cable guide 8

The following points are only a general guide to the correct installation of the Specimas
cable reels. In fact, further on in the manual, you will find the specific instructions to the
operations only briefly described hereafter.

A. Fix the torque unit on the mounting base through the holes on the feet (see table in chp.
2) On torque units type 120.0, 200.0, 300.0, 550.0, 700.0 use high tensile steel bolts
(10.9).
Remove the tape applied on the oil breather hole on the torque regulating key.

B. Fit the motor and collector to the torque unit.(normally the collector and the motor are
fitted before delivery. Sometimes the motor is not assembled due to delivery space).

C. Assemble the drum according to the separate instructions. (see chp.4)

When lifting the assembled drum from the ground to be fixed on the torque unit it is not
allowed to lift in the outer rim. The drum must be lifted with lifting straps around the tie
rods on the inner ring of the drum.
When the drum is to be fixed to the torque unit’s flange the fixing bolts on the tie-rods
must be aligned with holes in the torque unit’s flange. To align the fixing flange with the
drum bolts the torque unit motor can be rotated by hand (turn the motor fan by hand).

29.03.06 REV.4 Chp3lH page 1/6

 High Voltage Collectors

T5—181
OaIattor ceedli E
Colctor A C D Ring *
z
Mox. tension — — —

3 kV / 3.6 kV 150 285 420 555 135 800+

—

kV / 7.2 kV iso 285 420 800.

—

190 360 530 690 170 900*

10 kV / 12 kV —

15 kV / 17.5 kV 240 340 555 780 225 1000.

—

290 565 630 1105 275 1400.

20 kV / 24 kV —

— 1000 mm tunghezza di sicurezza in piu all interno del frutto collettore

avvclto
- 1000 nei extrasafety lenghl coiled inside the collector ring assembly

Collectors from 500

Amp. and above

Collettore Tipo +rnlI.

A B C D
Collector Type Ri*g
h

K450 160 030 300 370 70

250
K460 220 265 310 355 270

K560 95 260 325 390 455 45

190 235 280

K4120 95 45/60
190 250 310 370

1(4121 195 241 400 455 455 55/160

Se vengono usati anelli pilota misurare Ia Iunghezza dei conduttoti.

* If pilot cable rings are used mesure conductor lengths.

29.03.06 REV.4 Chp3lH page 3/6

 Horizontal retrieval:
The most difficult working mode is reeling in and accelerating with drum nearly full.
In this working mode check that the cable leaves the cable guide with a slight slack; the
cable should hardly touch the last roller in the cable guide.
In this way the torque is correct and the reel is not pulling too hard on the cable.

Vertical retrieval:
The most difficult working mode is reeling up and accelerating. Cable amount on drum is
normally of less importance as this is compensated by the layering diameter on the drum
which changes with the amount of cable on the drum.
Position hook near ground level, hoist with full speed. During the acceleration phase the
cable should show a slight relaxation or even a slight slack.
This indicates that the torque is correct and not too high.
If the cable is always fully tight it is impossible to see how much the reel is pulling and
the extra pull on the cable will only go to a destructive force on the cable itself.
It is recommended to fix the cable to the hook with an elastic element spring or similar as
this movement is then easy to see in the spring movement.
The spring will also dampen dynamic forces from sway etc. on the cable.

I. After a few weeks to a month of operation it is normal that the torque must be re
adjusted.
This as the initial wear in of the clutch plates has occurred. After this re-adjustment might
be needed every 12 months depending on working load and intensity.
At the same time check screws, bolts, and electric connection.

29.03.06 REV.4 Chp3lH page 5/6

 RAC DRUM ASSEMBLY INSTRUCTION

RAC Drum Torque Unit

510- 612- 614- 914- 916- 1018 10.0- 20.0- 40.0

The drum assembly is normally carried out in the Specimas workshop.

For the assembly of the drum on the torque unit operate as follows:

1. Position the drum on the torque unit flange.

2. Fix the drum through the bolts to the torque unit shaft.

NOTE! All the necessary dimensions are shown on the table below.

RAC Type u.d.c. 0 Fix Nr. of Bolts Bolts Type

510 10.0 210 6 M10x40

10.0 210 6 M10x40

612-614 20.0 210 12 M10x40

10.0 210 6 M10x40

914-916 20.0 210 12 M10x40

40.0 210 12 M10x70

1018 40.0 210 12 M10x70

19/01/1995 REV.0 Chp4lH page 1/1

 MAINTENANCE INSTRUCTIONS
Cavotec Specimas cable and hose reels are designed so that maintenance is reduced to a
minimum. However, in order to guarantee correct and continuous function of the reel, it is
necessary to follow a few simple rules, hereafter described.

ATTENTION: Clean carefully, with ONLY a dry rag (no water or solvents), collector
insulators and brushgear before initial cable reel start.

AFTER FIRST OPERATING WEEK:

Drum
— Check the tightness of all bolts and nuts including the ones fixing the torque unit onto its
support, the collector, the drum and the motor to the torque unit.
— In the case the drum is a monospiral type check that the spacing between the wheels
at the inner ring is cable diameter + 10% (max. 4mm) and at the outer diameter
corresponds to cable diameter + 2-3 mm.

Collector (if any)

— Check tightness 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.

AT REGULAR INTERVALS (TWO MONTHS):

The frequency of these regular checks will also depend on the severity of the environment
in which the reel is working and on the duty cycle intensity.

Collector (if any)

— Check the tightness 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.

Rotary ioint (if any)

— Change the gasket jy if there are some dribbles. The ball bearings do not need any
maintenance, since they normally are life-lubricated; on the contrary there will be special
instructions about the lubrication.

10.07.06 REV.8 Chp 7H page 1/3

Drum
— Check the tightness of all bolts and nuts including the ones fixing the torque unit onto its
support, the collector, the drum and the motor to the torque unit.
— In thecase the drum is a monospiral type, check that the spacing between the wheels
at the inner ring is cable diameter + 10% (max. 4mm) and at the outer diameter
corresponds to cable diameter + 2-3 mm.

— Limit switch (if any) check cam positions and that switches are operating.

— Heaters (if any) : check that they are operating.

Read carefully the chapter 0-General warnings and safety precautions.

Torque Oil capacity

unit (Kg)

10.0 1,7

20.0 2,2

40.0 16,0

120.0 27,0

200.0 67,0

300.0 67,0

550.0 98,0

700.0 98,0

10.07.06 REV.8 Chp 7H page 3/3

4. Set the cam designated to the drum empty indication.
If the cable reel is a high speed reel for horizontal or vertical retrieve it is
recommended to use a wider cam for the drum empty signal.
This will ensure that the crane will not over-ride the end signal and be able to
start again.

5. Move the crane to any other location along the track where a switch has to be
set. Set the appropriate cam at the location.
Note the cam widths as these could be special.

6. Do a test run to check all the switch settings.

Note: Specially for Stromag rotary travel limit switches:

Do not adjust the black screw on the switch after setting each individual cam.
The black screw sets the complete block of cams and will then offset all the
previous settings with the same amount.

30/07/97 REV.1 Chp. 9H page 2/2

 Catalogue HY1 1-2500/UK Heavy-duty aluminium pumps and motors
Ordering Code Series PGP, PGM 500

Gear Type Unit Displace- Rotation Shaft Flange Shaft Side Side Rear Rear
Design ment Suction Pressure Suction Pressur€

U
Port Port Port 2) Port 2)
I I I I
Code Type I
P Pump
M Motor
F Flow divider

Unit
ocie
Pump Motor
Standard Motor w/o
A Single unit
checks
Standard Motor w.
B Multiple unit
two checks
Standard Motor w.
C — one anti cavitation
check (ACC)
Standard Motor w.
D —

one ACC + restrictor

Single distributor
M
—

Unit
Multiple distributor Code Shaft
N
—

Unit 9T, 16/32DP, 32L, SAE “A’

Single split gear
Al
—
sptne
Unit
liT, 16/32DP, 38.2L, SAE 19-4
-- Multiple split gear —
ci spline
unit
13T, Wl8xl.25, 24L, DIN
Ony for displacement codes 0060 to 0280 F2
5480 spline
015.88, 4.OKey, no thread,
Displacement Kl
32L, SAE “A”, parallel
Code ccm
017.0, 7.7L, 3.OKey, M12x1.5,
Si
0040 4.0 taper 1:5
0060 6.0 016.65, 12.OL, 3.2Key,
S2
0080 8.0 M12x1.5, taper 1:8
0100 10.0 016.65, 12.OL, 4.OKey,
S4
0110 11.0 M12x1.5, taper 1:8
0140 14.0 8x6.5 short shaft,
V5
tang drive
0160 16.0
0190 19.0
0230 23.0
0270 27.0
0280 28.0
0310 31.0
0330 33.0

2) Only coded
for the last
section.

For products of short-term delivery Only for

motors
please consult page 1-121

PGP-PGM500 600 GB PM6 5MM

Parker Hannifin GmbH

1-116 Hydraulic Controls Division
‘-Parker Hydraulics Kaarst, Germany
 Catalogue HY1 1-2500/UK Heavy-duty aluminium pumps and motors
Performance Data Series PGP, PGM 500

Fluid Temperature = 45± 2°C

Viscosity = /s
2
36mm
Inlet Pressure = 0.9 + 0.1 bar absolute
PGP/PGM 511 -4.0 CC PGP 511 - 10.0CC
‘16 32- — . — — —
‘20-E’40
15 . 30 19 - 38 ——

— I I
II I I
14 28 0
18 - 36
El:
— Flow n=3600 rev/mm— —— —
17- 2i
UE
13 - 26 0.
&16 32
12 24
15- 30 I
11 22 14- 2-., ————— —
10. 20 13- 26
12- 24
/
9.0- 18
F ow n=4000 rev/mm 11- 22 I
8.0. 16
10- 20
— ——
-

ower n=3600 rev/mm

7.0. 14 —

9.0- 18
LPower n=4OOOOrev/mh —
0’
6.0- 12 8.0- 16 Flc wn=150 n

5.0.

4.0

3.0
. 8.0

6.0
10

H1H
Row n=1 500 rev/
I. Power n=1 500 rev/mm
7.0-
6.0
5.0
4.0 8.0-
“,

— —I — ‘F
0’

—
I
::=:
—

7’
/
I. Powern=1500 rov/mio
II
2.0 - 4.0 3.0 C-(i —

/ Flow n=50 rev/mi

I,.
— —
1.0 - 2.0 lo n=OOev/ in
2.0
1.0
4.0
2.0 —
/
— — -—— —

0. 0
0 50 100 150
. Power n=500 rev/mm
200 250 300
0
0
— —
50
I. Power n=500 rev/mm
100 150 200 250
—

300
Pressure [ban Pressure [bar]

- PGP1PGM511 -19.0CC PGP/PGM 511 -33 CC

J. ,40
30 -
-
eo -
C
E
. 38 — I I I I
I I
1 a - a -
a
-

Ffr’w n=3000 r v/n in

-

a
I
-—
Fl w =2200 rev! in
——
0
a. - u 56 0 36
34
f

68
—

——
— — — —

——— ——
— — — —

26 -
D — — — — —

52
- / .
a.
32 64 ——— — — ——— ——— —

24 48 30 60 ———— — — — — — — — —

22

20
44

40
:__

H— —--—--—‘ —
28
26-
24-
-

:
18 36 22-
.erfloore.fz
- I. Pow r n=3000 rev/mm
16- 32 20 -

I. Power n=2200 rev/mn

28
flown=150rni7 —
18- 36 — — — — — ——— ———
: — ——4
14
16-
12 24
14-
10- 20 12- 24 - Power n=150 rev/mu —

8.0 - 16
— / —— 7 1. Powe n= 500 rev/mm
10- 20-
16-
—

8.0-
6.0

4.0-
12

8.C
6.0-
4.0-
12
8.
4.C
-E 7Fow=500rrv!mEH_

I. Power n=500 rev/mm

2.0- 4.0
- 2.0 -

0 —
I. Power n=500 rev/mm
I I I I I 0 0
0 — — —
— —

0 50 100 150 200 250 300

0 50 100 150 200 250 300 Pressure [bar]
PGP-PGM5OU600_GB.PM6.SMM Pressure [ban
Parker Hannifin GmbH
1-124 Hydraulic Controls Division
“-Parker Hydraulics Kaarst, Germany
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 Lista Pezzi/Parts List
Codice/Part No: S05-0061 4-201
Lista/List Rev:
Data/Date: 28-set-04
Descrizione: Tamb. R612-201
Description: Drum R612-201 +protection cover for cable gland
Disegno/Drawing No: AT-066
Disegno/Drawing Rev: C
Peso/Weight (kg): 72,0 kg

. Peso
. . . .

Pos. Codice/Part No. Descrizione Description Disegno/Dwg No. Rev

(kg)
1 SR5-00912-300 Bandella RAC 600-200 L=198 RAC inner ring 600/200 1 8,6 PS-912 F
2 SR5-80614-OEO Ruotaest. R612 RAG ext. wheel 612 28,3 PS-910 E
3 SR5-80614-0l0 Ruota in R612 RAG mt. wheel 612 23,0 PS-911 F
SR5-00913-000 Flangia RAG 680 RAG flange 680 — 4,7 PS-913 B
4
Tirante M10 x 345 Galvanizzato Tie rod M10 x 345 Galvanised 10 0,2 —
5 S45-I000G-345
Plain washerM 10 60 0,0 —
6 S47-6592G-010 Rosetta piana M 10
Dado autobloc. M 10 Lock nut M 10 36 0,0 —
7 S49-7473G-010
Vite TE M 10x30 Hexag.screw M 10x30 4 0,0 —
8 S40-73910-030
9 S40-73910-040 Vite TE M 10x40 Hexag.screw M 10x40 12 0,0
S49-5588G-010 DadoMlO NutMlO 4 0,0 —
10

AT-066 R61 4-30 1 xIs Page 1 of I

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CAVOTEC SPECIMAS SPA.
502 6R510-201 A MINUFAOT1JNG COMPANY OF THE CAVOTEC GROIP

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Serve anche per K 560 - K 4120 - K 4121 K 4240 (1W &o.ang sow mow”, and,, SnOt, 00(00 ,spomnad cocoa an,
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Ship to:
CAvoTE C
DELIVERY NOTE

Customer No.:
25007
Order Date:
Date:
03-15-11
Order No.:
Page:
I

03-15-11 100859-1
Procon Mining Your reference: Our reference:

2203 8Th Street 103.131203.123198 1800050

Nisku,ABT9E7Y9
Order Customer:
Procon Mining and Tunnelling Ltd.
# 108-4664 Lougheed Highway
Terms of delivery: Burnaby, BC V5C 5T5
EXW: Markham, ON Canada

Delivery by: Terms of payment:

Purolator Collect Net 30 Days

Marking:
Purolator #4715387

POS ARTICLE NO -
I QTY ORDER I QTY DELIVERED

005 S02-00524-005 I Pcs I Pcs

Collector K524 prep. for
FCi Ravasi MF2C, AISI 304

CAVOTEC CANADA INC

Toronto Office Cavotec Sales Office:
Inspired 860 Denison St. #6 Toronto
Engineering Markham, ON L3R 4H1 Canada
Tel: 1-905-415-2233
Fax: 1-905-415-2238
 QCAVOTEC
DELIVERY NOTE I
Customer No.: Date: Page:
25007 03-15-11
Ship to: Order Date: Order No.:
03-15-11 100859-1
Procon Mining Your reference: Our reference:

2203 8Th Street 103.131 203.1231 98 1800050

Nisku, AB T9E 7Y9
Order Customer:
Procon Mining and Tunnelling Ltd.
# 108-4664 Lougheed Highway
Terms of delivery: Burnaby, BC V5C 5T5
EXW: Markham, ON Canada

Delivery by: Terms of payment:

Purolator Collect Net 30 Days

Marking:
Purolator # 4715387

POS ARTICLE NO -
I QTY ORDER I QTY DELIVERED

005 S02-00524-005 1 Pcs 1 Pcs

Collector K524 prep. for
FCi Ravasi MF2C, AISI 304

CAVOTEC CANADA INC

Toronto Office - cavotec Sales Office:
Inspired 860 Denison St. #6 Toronto
Engineering Markham, ON L3R 4H1 Canada
Tel: 1-905-415-2233
Fax: 1-905-415-2238