INSTALLATION and MAINTENANCE INSTRUCTIONS

WIRE ROPE FESTOON KITS with STEEL TROLLEYS

WARNING

Failure to read, understand, and follow these installation instructions may result in damage to festoon or personal injury.

Figure 1

STEEL FESTOON TROLLEY

INSTALLATION

STEP 1– Mount tension brackets or other suitable device for holding stretched wire rope. See Figure 2, right, and

Installation Diagrams, following pages.

WARNING

Wire rope mounts must be able to withstand minimum

1050 lbs.(473kg) lateral force. Improper mounts could give way, causing damage or personal injury.

STEP 10– Affix cable or hose to end clamp and tow clamp and complete hook-up. Test festoon by moving thru full

Active Travel. Adjust loop depth as required for best operation. Tighten clamps to secure cable or hose.

TENSION BRACKET

(Optional)

SECURELY FASTEN.

BRACKET MUST BE

ABLE TO WITHSTAND

1050 lbs. (473 kg)

LATERAL FORCE.

STEP 2– Install eye-bolt and end clamp to tension bracket on

fixed cable end of system. See Figure 2. Eye-bolt should protrude maximum 0.25"(6mm) thru nut (Fig. 3).

STEP 3– Cut cable or hose to length shown on tables, following pages. Before cutting, add length needed for end connections.

STEP 4–Refer to Installation Diagrams on following pages.

Lay-out trolleys on floor. Install cable or hose in trolley hangers allowing for: 1–Planned loop depth. 2–One additional loop between first intermediate trolley and end clamp. 3–One additional loop between last trolley and tow clamp. 4–Length at each end for hook up. Tighten clamps until just snug.

STEP 5– Thread wire rope through trolleys.

STEP 6–Thread wire rope through eye-bolt on moving cable

end of system. Install thimble in loop. Secure wire rope with two

(2) cable clamps. Do not install rubber bumper. It goes on fixed

cable end only. Turn one hex nut onto eye-bolt and install flat washer. See Figure 3.

STEP 7– Lift wire rope, including trolleys and cable or hose, into position. Insert eye-bolt on wire rope thru tension bracket on

moving cable end and secure with flat washer and hex nut.

STEP 8– Slide rubber bumper onto other end of wire rope.

Thread wire rope through eye-bolt installed in step 2. Install thimble in loop. Pull wire rope as tight as possible. Secure wire rope with two (2) cable clamps. See Figure 2.

STEP 9– Tighten wire rope by turning nuts on eye-bolts. See

Figure 3. Use formula, Figure 4, to determine tension and sag.

T

END CLAMP

(Fixed cable end only)

TIGHTEN THIS

NUT TO TENSION

WIRE ROPE

EYE BOLT

Figure 2

THIMBLE

WIRE ROPE

CLAMPS

BUMPER

LOOSEN THIS NUT BEFORE

TENSIONING WIRE ROPE

.25" (6mm) MAXIMUM PRIOR TO

TENSIONING WIRE ROPE

Figure 3

Use this formula to calculate wire rope tension or sag.

T= W x L

8 x S

T= Tension (lbs.) W= Total Weight (lbs.)

L= Length (ft.) S= Sag (ft.)

WIRE ROPE

W

L

Figure 4

S

WIRE ROPE

T

FLAT CABLE FESTOON INSTALLATION DIAGRAM

TENSION

BRACKET

(Optional)

Storage Distance (SD)

RUBBER

BUMPER

INTERMEDIATE

TROLLEYS

System Length (SL)

Active Travel (AT)

WIRE ROPE

TENSION

BRACKET

(Optional)

END

CLAMP

FIXED CABLE

END OF SYSTEM

TOW ARM

(Optional)

TOW

CLAMP

MOVING

CABLE

(MC)

Loop

Depth

(LD)

MOVING CABLE

END OF SYSTEM

WIRE ROPE

CLAMPS

&

THIMBLE

(Both Ends)

FLAT CABLE

Length per chart plus cable needed for hookup at each end

FLAT

CABLE KITS

ACTIVE

TRAVEL

“AT”

LOOP DEPTH

For planning purposes.

(2)

36"

KIT

NO.

Maximum cable size:

0.65" x 2.0"

(17 x 51mm)

19' 9"

24' 8"

29' 8"

34' 7"

39' 6"

44' 6"

49' 5"

54' 4"

WF-03-36

(3 trolleys)

WF-04-36

(4 trolleys)

WF-05-36

(5 trolleys)

WF-06-36

(6 trolleys)

WF-07-36

(7 trolleys)

WF-08-36

(8 trolleys)

WF-09-36

(8 trolleys)

WF-10-36

(10 trolleys)

SYSTEM

LENGTH

“SL”

LOOP DEPTH

For planning purposes.

(2)

36"

STORAGE

DISTANCE

“SD”

MINIMUM.

May be greater with stiff cable or short loop.

(1) MINIMUM

CABLE

REQUIRED

LOOP DEPTH

For planning purposes.

(2)

36"

22' 10"

28' 0"

33' 4"

38' 7"

43' 9"

49' 0"

54' 3"

59' 6"

2' 1"

2' 4"

2' 8"

2' 11"

3' 3"

3' 6"

3' 9"

4' 1"

24'

29'

35'

41'

47'

52'

58'

64'

(1) KIT NUMBER EXPLANATION

Example: FF08 – 03

Flat cable festoon – Three trolleys

(1) Cable length listed in chart is enough for ACTIVE TRAVEL only, measured centerline to centerline; see diagram above.

ADD cable or hose to each end as required for hook-up to your system.

(2) Active travel, system length and minimum cable values on charts are for 36" loop depth only and are provided as guide. Kits include necessary components for festoon system with 36" loop depth at system length shown. Vary loop depth or cable length to suit application. Shorter loop depth = shorter active travel.

Legend

AT = Active Travel

SD = Storage Distance

SL = System Length

LD = Loop Depth

TENSION

BRACKET

(Optional)

END

CLAMP

FIXED CABLE

END OF SYSTEM

ROUND CABLE FESTOON INSTALLATION DIAGRAM

System Length (SL)

Storage Distance (SD)

RUBBER

BUMPER

INTERMEDIATE

TROLLEYS

Active Travel (AT)

WIRE ROPE

TOW ARM

(Optional)

TOW CLAMP

Loop

Depth

(LD)

MOVING

CABLE

(MC)

MOVING CABLE

END OF SYSTEM

TENSION

BRACKET

(Optional)

WIRE ROPE

CLAMPS

&

THIMBLE

(Both Ends)

ROUND CABLE

OR HOSE

Length per chart plus cable required for hookup at each end

ROUND

CABLE & HOSE KITS

ACTIVE

TRAVEL

“AT”

LOOP DEPTH

For planning purposes.

(2)

36"

KIT

NO.

Refer to note below* for saddle sizes.

SYSTEM

LENGTH

“SL”

LOOP DEPTH

For planning purposes.

(2)

36"

STORAGE

DISTANCE

“SD”

(1) MINIMUM

CABLE/HOSE

REQUIRED

MINIMUM.

May be greater with stiff cable or short loop.

LOOP DEPTH

For planning purposes.

(2)

36"

17' 9" WR-03-36 20' 10" 2' 1" 26'

22' 2" WR-04-36

25' 7" 2' 4" 32'

26' 7" WR-05-36 30' 3" 2' 8" 38'

31' 1" WR-06-36 35' 0" 2' 11" 45'

35' 6" WR-07-36

39' 11" WR-08-36

39' 9"

44' 6"

3' 3"

3' 6"

51'

57'

KIT NUMBER EXPLANATION

Example: FR04 – 03

Round cable/hose festoon – Three trolleys

Size 4 saddle*

(1) Cable/hose length listed in chart is enough for ACTIVE TRAVEL only, measured centerline to centerline; see diagram above. ADD cable or hose to each end as required for hook-up to your system.

(2) Active travel, system length and minimum cable values on charts are for 30" or 48" loop depths only and are provided as guide. Kits include necessary components for festoon system with 48" loop depth at system length shown. Vary loop depth or cable/hose length to suit application. Shorter loop depth = shorter active travel.

*

Saddle sizes:

FR04 = 0.30" (7mm) to 0.59" (15mm) OD cable/hose.

FR05 = 0.60" (15mm) to 0.94" (24mm) OD cable/hose.

PARTS LIST

FLAT

CABLE FESTOON COMPONENTS

1.25

(32)

1.0(25) dia.

3.3 (84)

1.5

(38)

1.7 (43)

3.5

(90)

2.1 (54)

3.25 (83)

3.7 (94)

1

(25)

0.66

(17) max.

STEEL TROLLEY

#W25–FC–32

Description: Zinc plated steel with dual nylon wheels.

Zinc plated steel cable clamp.

2 (51) dia.

2.3

(59)

3.25 (83)

TOW

ARM

0.66

(17) max.

2.1

(54)

0.9 (24)

2.1

(54)

2 (51) dia.

TOW CLAMP

#W25–FT–02

Description: Steel with zinc plating.

3.25 (83)

1.6

(41)

0.562

(14) dia.

0.6

(16)

3

(76)

4.9

(124)

0.8

(21)

2.1

(54)

1

(25)

0.66

(17) max.

2 (51) dia.

END CLAMP

#W25–FE–02

Description: Steel with zinc plating.

ROUND

CABLE & HOSE FESTOON COMPONENTS

0.75 (51) dia.

3.3(84)

1.5

(38)

3.5 (89)

3.25 (83)

1.25

(32)

B

Dia.

Range

“A”

TROLLEY

D

MODEL

NUMBER

*CABLE

O.D. “A” in. (mm)

“B” in.

(mm)

“D” in.

(mm)

W25-RC-11

W25-RC-12

W25-RC-13

0.31–0.59

(7–15)

0.60–0.94

(15–24)

0.95–1.25

(24–32)

2.75

(70)

2.94

(75)

3.2

(81)

2.75

(70)

3.86

(98)

5.0

(127)

Description: Zinc plated steel with dual nylon wheels. zinc plated steel cable clamp.

TOW ARM

0.9

(24)

B

Dia.

Range

“A”

D

TOW CLAMP

MODEL

NUMBER

*CABLE

O.D. “A” in. (mm)

“B” in.

(mm)

“D” in.

(mm)

W25-RT-11

W25-RT-12

W25-RT-13

0.31–0.59

(7–15)

0.60–0.94

(15–24)

0.95–1.25

(24–32)

1.25

(32)

1.44

(37)

1.7

(43)

2.75

(70)

3.86

(98)

5.0

(127)

Description: Steel with zinc plating.

Tension Bracket #W25–BR–01

Anchor ends of wire rope and fixed end of festoon.

3.5 (89)

3.25 (83)

1.6

(41)

0.6

(16)

B

0.562

(14) dia.

Dia.

Range

“A”

D

END CLAMP

MODEL

NUMBER

*CABLE

O.D. “A” in. (mm)

“B” in.

(mm)

“D” in.

(mm)

W25-RE-11

W25-RE-12

W25-RE-13

0.31–0.59

(7–15)

0.60–0.94

(15–24)

0.95–1.25

(24–32)

4.06

(103)

4.25

(108)

4.5

(114)

2.75

(70)

3.86

(98)

5.0

(127)

Description: Steel with zinc plating.

Tow Arm #W25–TA–01

Use on moving end of festoon with Tow Clamp (above).

0.8

(21)

3

(76)

2

(51)

6 (152)

5

(127)

0.406(10) DIA.

(4) HOLES

1.5

(38)

2.5

(64)

3

(76)

18 (457)

3

(76)

3

(76)

0.562(14) DIA.

(4) HOLES

8 (203)

®

HUBBELL

Workplace Solutions

Printed in USA

1.5

(38)

0.75

(19)

4 (102)

3

(76)

0.406 (10) dia.

(4) HOLES

1.2

(30)

18 (457)

600 South Clark St.

Mayville, WI 53050

Phone: 920-3874120 • Fax: 920-387-4189

Bulletin No. 618046.b