Installation, Service & Parts
Contents
1. DESCRIPTION CUSTOMER PART NO CASCADE PART NO ORDERING SERIAL NUMBER PURCHASE ORDER DATE Do you have guestions you need answered right now Call your nearest Cascade Parts Department AMERICAS Cascade Corporation U S Headguarters 2201 NE 2015 Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade Italia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR Italy Tel 39 045 89891 11 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 9771 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 461 7 3373 7333 cascade Cascade Corporation 1995 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 905 629 7777 Fax 905 629 7785 Cascade Africa Pty Ltd PO Box 625 Isando 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade Korea 121B 9L Namdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel 82 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 64 9 273 9137 9 95 Cascad2. MANUAL INSTALLATION SERVICE and PARTS 9 N 1 Cable Hose Reel Manual Number 211996 cascade Cascade is a Registered Trademark of Cascade Corporation CONTENTS INSTALLATION CD 1 SERVICE SEAL AND SPRING ASSEMBLY REPLACEMENT 4 INNER CABLE 7 OUTER CABLE HOSE REPLACEMENT roris t 9 TROUBLESHOOTING 11 ELECTRICAL TROUBLESHOOTING GUIDE erre nennen enneonnnnns 12 CABLE HOSE LENGTH CALCULATIONS esee 13 PARTS LISTS A EREE E 14 16 INTRODUCTION This booklet contains the complete PARTS INSTALLATION To order replacement parts contact the Cascade Parts Sales and SERVICE information for the 9 N 1 Cable Hose Reels The at manual also includes TROUBLESHOOTING GUIDES located Cascade Corporation on page 11 and 12 If you have additional questions call the 2901 NE 201st nearest Cascade Service Department listed on the back cover Troutdale OR 97060 9799 Telephone 1 800 CAS CADE 503 669 6300 Fax 503 669 6338 i 211996 Rev 0 IMPORTANT Do not allow the reel to rotate its shaft at this time Doing so will prewind the spring The wire attaching the caution tag to the ree must stay in place until the reel is to be prewound and cable hose connected to the junction block 1 Determine a locat
3. 2 When H is less than 2 x D the correct cable length is D 38 inches Example 286 96 286 96 190 38 228 Correct cable hose length CABLE HOSE PREPARATION DETAIL CABLE HOSE LENGTH CALCULATIONS 80011 1 REEL END JUNCTION BLOCK END WORKSHEET 1 enter mast s lift height here 2 D enter distance between junction block and center of reel with carriage completely lowered 3 Multiply D by 2 4 If line 1 is less than line 3 the cable hose length should be D line 2 4 38 inches 38 Cable Hose Length 211996 Rev O If line 1 is equal to or larger than line 3 the cable hose length should be H line 1 D line 2 4 38 inches 38 Cable Hose Length 13 B qan js SY N orque to 52 57 ft Ibs 25 OOOA 8 at 9 g QE T x D i eee aT amp VW RIGHT HAND REEL SHOWN AD A Lm WZ 4 So 5 14 211996 Rev 0 PUBH Adwassy c mm S1989 961 5 asou SC LX ON p i Gi 2 1 J9usew xo pueH 351 ILII 9 155 1 pue joo Buiduuuo 1 sapnjou pam ALPEN m 699112 NY 93 58 ejqe ui pepnjouj ON 0491 LZ 95 58 ejqeo
4. Cable Hose jumps off reel during Incorrect prewind of spring Prewind spring see page 3 steps 21 operation through 24 Cable Hose not aligned with junction Align junction block with cable hose reel block See Figure 5 page 2 Cable Hose binds during operation Cable Hose reel spring is broken Replace the spring Back up ring in hub working Replace the back up rings between shaft and hub Scored seal areas Replace the damaged hub and or use an emery cloth to remove the nicks from the shaft Electrical malfunction The same pattern for cable connections Make sure pin and cable connectors use has not been used at all locations the same pattern at all locations Electrical short in the reel cable truck See Electrical Troubleshooting Guide page 12 or attachment cable Cable Hose Reel leaks at hub Damaged O ring seals in the rotating Replace all seals When a cable hose reel ub requires replacement of any one of the O rings or back up rings it is important that all the seals be replaced If all the O rings and back up rings are not replaced at the same time the reel will only have to be disas sembled again in a short period of time to replace the older seals The seal kit offered by Cascade includes all of the O rings and back up rings necessary to rebuild one hose reel Order appropriate Seal Kit Loose or damaged fittings Tighten or replace damaged fittings Scored seal areas Replace the damaged shaft and or use
5. Figure 5 REEL FLANGES CARRIAGE JUNCTION BLOCK CENTERED BETWEEN REEL FLANGES Torque Capscrews to 12 15 ft lbs 316 Drill Tap 375 16 UNC 2 Holes Mi Thread Depth 12 Install the junction block on the carriage using the capscrews and lockwashers supplied with the junction block 13 Determine the length of the cable hoses required as shown in the Cable Hose Length Calculations see page 13 NOTE This step may be by passed if you have been supplied with a pre assembled cable hose of the correct length 14 Connect the hoses to the reel hub fittings See Figure 6 Put the end of the cable inside of the outer flange area Figure 6 15 To install the outer cable hose on the reel remove the two hub nuts securing the rotating cover to the outer flange Remove the rotating cover See Figure 7 16 Join the outer cable connectors to the inner cable con nectors using the established connection pattern See Figure 7 2 17 Fit the cable clamps to the outer cable and secure them as shown in Figure 7 18 Install the rotating cover and hub nuts The inner cable must be laying flat in the flange depression and not pinched Tighten the hub nuts Figure 7 HUB NUTS Torque to 70 75 in Ibs HUB FITTINGS ROTATING INNER CABLE CONNECTORS OUTER CABLE CONNECTORS HR0003 itl if equipped Figure 8 CABLE HOSE REEL IDENTIFICATION Viewed from the flange side of the reel RIGHT HAND REEL
6. cable housing to the inner reel flange See Figure 20 5 Pull the reel flanges off the hub studs Rotate the flanges slightly to free the inner cable connectors 6 Remove the mounting brackets and split the mounting blocks from the shaft See Figure 20 7 Separate the spring assembly from the inner cable housing Slide the inner cable housing off the shaft See Figure 20 CAUTION Do not allow the cable housing to tate independently of its hub Damage to the inner cable CABLE HOSE will occur if they are rotated Use tape or wire to hold END HROO06 li both from rotating If either has been rotated refer to the Inner Cable Housing Timing instruction on page 8 Figure 19 CABLE HOSE Figure 20 TRUCK CABLE CONNECTORS INNER CABLE CONNECTORS ROTATING COVER SPRING ASSEMBLY INNER CABLE CONNECTORS OUTER CABLE CONNECTORS MOUNTING po di BRACKET SPLIT MOUNTING BLOCKS NOTCH FOR INNER CABLE INNER CABLE HOUSING FIXED COVER TRUCK CABLE CLAMP RIGHT HAND REEL SHOWN 211996 Rev O 7 INNER CABLE REPLACEMENT NOTE if a new Inner Cable Housing is being installed delete this step and proceed to Reel Reassembly 1 Insert a small diameter Allen wrench under the lip of the divider plate Grip the Allen wrench with a pair of vise grips Pull outward to remove the divider plate See Figure 21 Figure 21 DIVIDER SMALL DIAMETER ALLEN WRENCH 2 Remove the cable harness
7. correctly reconnect the cables as shown in the diagram and proceed to Step 2 ELECTRICAL TROUBLESHOOTING GUIDE REEL OUTER CABLE li 2 Connect cable connectors A to cable connectors D to isolate the reel inner cable Operate the attachment NOTE Do not operate the mast a If none of the attachment functions operate the reel outer cable is faulty and should be replaced For re placement instructions refer to page 9 If some attachment functions respond and others do not the pins and or sockets in the connectors are at fault and should be replaced Recheck attachment operation after repair If all attachment functions operate correctly reconnect the cables as shown in the diagram and proceed to Step 3 3 Connect cable connectors C to cable connectors F to isolate the reel outer cable Operate the attachment NOTE Do not operate the mast a If none of the attachment functions operate the reel inner cable is faulty and should be replaced For re placement instructions refer to page 7 If some attachment functions respond and others do not the pins and or sockets in the connectors are at fault and should be replaced Recheck attachment operation after repair 211996 Rev 0 Total lift height D Distance from centerline of reel to junction block 1 When H is equal to or greater than 2 x D the correct cable hose length is H D 38 inches
8. emery cloth to remove the nicks from the shaft Inner Cable Housing wire Excessive mast height Cable Hose reel cannot be used in this breaks inside housing application The maximum turn capacity is being exceeded Cable Hose reel wound backwards Replace Inner Cable Housing Wind reel in direction indicated in Inner Cable Housing Replacement Instructions Service life of wire has been exceeded Replace Inner Cable Housing 211996 Rev 0 1 TRUCK BATTERY REEL Ree CABLE Use the accompanying electrical diagram and the following instructions to locate an electrical short When using an ohm meter to check for continuity follow the instructions with your meter Make sure the electrical power is disconnected when checking continuity 1 Connect cable connectors A to cable connectors F to isolate the entire cable reel Operate the attachment NOTE Do not operate the mast a If none of the attachment functions operate 12 eDisconnect cable connectors A from cable connectors F eUse an ohmmeter to check the continuity of the attachment cable between connectors F and 3 If the cable checks OK the truck cable is faulty and should be replaced Refer to your truck Service Manual some attachment functions respond and others do not the pins and or sockets in the connectors are at fault and should be replaced Recheck attachment operation after repair If all attachment functions operate
9. the new spring assembly onto the shaft Secure the spring end on the spring retainer by turning the spring on the shaft Make sure the notch in the spring assembly is aligned with the inner cable See Figure 14 REEL REASSEMBLY 1 2 Figure 14 Lubricate the shaft seals and bore of the hub with hydraulic oil Install the back up rings into the hub grooves Install the split rings on each side of the center O ring Place a por tion of ring in the groove then bend as required to install See Figure 15 Install the O ring seals NOTE When servicing the inner cable housing or install ing a new shaft seal kit the cable harness inside the inner cable housing should be lubricated with TRI FLON spray lube Cascade Part No 669779 See Inner Cable Replacement for assembly instructions on page 7 INNER REEL FLANGE SCRIBE MARK HUB O RINGS SPLIT RINGS AND BACK UP RINGS STUD BRACKET AND SPACER NOTCH FOR INNER CABLE INNER CABLE RIGHT HAND REEL SHOWN 211996 Rev 0 Figure 15 O Rings Back up Ring Back up Ring Solid i Solid Back up Rings Split RIGHT HAND REEL See Figure 8 page 2 a Rotate the hub slowly as you slide it onto the shaft b Install the hub outer snap ring See Figure 12 page 4 c Placethe reel flanges onto the hub aligning the scribe mark on the inner cable container to the scribe mark on the inner reel flange LEFT HAND REEL See Figure 8 page 2 a With the st
10. 3 Place the new cable harness in the housing Fit the cable at its 90 bend under the spring plate and around the pin See Figure 22 Figure 22 LEFT HAND REEL SHOWN 4 Wind the cable around the hub in the direction shown in Figure 23 A Right or Left hand reel is determined as viewed from the flange side of the reel See Figure 8 page 2 Figure 23 HOUSING INDENTATIONS 5 Place the divider plate inside the housing Push the plate edge past the three housing indentations INNER CABLE HOUSING TIMING 1 Determine if the reel is a right hand or left hand model as viewed from the flange side of the reel See Figure 8 page 2 2 Position the cable container with the hub cable harness toward you See Figure 24 3 Hold the housing from rotating Wind the hub until tight Right Hand Reel Wind hub counterclockwise Left Hand Reel Wind hub clockwise 4 Rotate the hub back 1 revolution This provides one safety turn in the wiring to prevent internal damage 5 Use tape or wire to secure the hub to the housing This will prevent either from rotating The Inner Cable Hous ing is ready for further ree assembly Figure 24 INNER CABLE HOUSING CLOCKWISE ROTATION SHOWN REEL REASSEMBLY 1 Fit the new inner cable housing over the shaft do not rotate and over the spring assembly Be sure to fit the inner cable into the notch in the spring assembly See Figure 20 page 7 CAUTION Do not allow the inn
11. LEFT HAND REEL 0004 8 19 Wind the outer cable hose completely onto the reel in the direction indicated viewed from the flange side Right Hand Reel Wind cable hose clockwise Left Hand Reel Wind cable hose counterclockwise A Right or Left hand reel is determined as viewed from the flange side of the reel See Figure 8 211996 Rev 0 20 Remove the caution tag and wire 21 Prewind the reel spring by grasping the end of the outer cable hose and turning the reel a minimum of 3 turns in the direction indicated viewed from the flange side Right Hand Reel Wind reel clockwise Left Hand Reel Wind reel counterclockwise CAUTION Rotation in a wrong direction will damage the inner cable and reel spring lf more tension is required the reel can be prewound additional turns The maximum turn capacities are 16 total turns Total turns Prewind turns Working turns CAUTION Exceeding turn capacity of the reel will damage the inner cable and reel spring CABLE CONNECTORS Torque Capscrews to 12 15 ft Ibs CAPSCREW CLAMP BAR HROOOS ilt 211996 Rev 0 22 23 24 25 With the reel prewound pull the hose ends down to the junction block Fasten the hoses with the clamp bar and capscrew See Figure 9 WARNING Do not let the reel unwind when connecting the cable hose to the junction block Connect the cable from the cable hose to the junction block Clamp the outer cable to th
12. acket 7 Remove the seals from the hub Avoid scratching grooves Clean the hub and shaft with solvent sealing surface the shaft is nickel plated If minor surface imperfections are noted use emery cloth 320 Grit to lightly smooth up if sharp edges or grooves are found shaft replacement is neces sary See Figure 13 eHub grooves must be free of sharp nicks or projec tions to prevent cutting of the outside diameter of the O ring during installation See Figure 13 Figure 13 INSPECT HUB SURFACES INSPEC SHAFT SEALING SURFACES 211996 Rev 0 SPRING ASSEMBLY REPLACEMENT NOTE If the spring assembly does not reguire replace ment delete this step and proceed to Reel Assembly Disengage the spring from the spring retainer on the shaft See Figure 14 CAUTION Do not allow the inner cable housing to tate independently of its hub Damage to the inner cable will occur if they are rotated Use tape or wire to hold both from rotating See Figure 14 If either has been ro tated refer to the Inner Cable Housing Timing instruc tions on page 8 Hold the reel assembly by the outside of the inner cable housing over a work bench with the shaft downward Tap the shaft end on the bench Slide the spring assembly out of the inner cable housing and off the shaft If the spring retainer has been damaged remove the spring retainer snap ring and install a new spring retainer See figure 14 Slide
13. apscrew See Figure 29 10 Figure 29 13 14 15 SWE CABLE CONNECTORS Torque Capscrews to 12 15 ft Ibs CAPSCREW CLAMP BAR HROOOS itl Connect the cable from the cable hose to the junction block Clamp the outer cable to the projection between the hoses with a hose clamp See Figure 29 Position the hose clamp so it can be tightened through the hole in the side of the junction block Route the inner cable through the junction block as shown Fasten the male cable con nectors to the large projection with a hose clamp Form the hose clamp around the connectors Do not overtighten the clamp The female cable connectors must fit in the male connectors Join the connectors Connect the attachment hoses to the junction block Be sure the hoses and their functions do not become inter changed See Figure 30 Operate the carriage up and down a few times to make sure the cable hose tracks smoothly and no interference exists Figure 30 FUNCTION A FUNCTION B FUNCTIONB FUNCTION A HRO0010 ill 211996 Rev O TROUBLESHOOTING GUIDE PROBLEM PROBLEM CAUSE SOLUTION Excessive wear on cable hose Cable Hose reel and junction block are Align the junction block and cable hose reel not in proper alignment properly They must be on the same center line and mounted squarely to each other See Figure 5 page 2 Cable Hose reel flanges damaged Repair or replace damaged parts
14. clamp Form the hose clamp around the connectors Do not overtighten the clamp The female cable connectors must fit in the male connectors Join the connectors Connect the attachment hoses to the junction block Be sure the hoses and their functions do not become inter changed See Figure 18 Operate the carriage up and down a few times to make sure the cable hose tracks smoothly and no interference exists Figure 18 FUNCTION A FUNCTION B FUNCTION FUNCTION A HR0010 ill 211996 Rev 0 INNER CABLE REPLACEMENT DISCONNECTING THE REEL 3 Remove the fiked cover from the mounting block and dis 1 Disconnect the connectors at the junction block connect the cable connectors See Figure 4 page 1 2 Remove the cable hose from the junction block 4 Disconnect the truck valve hoses from the shaft 5 Remove the capscrews and lockwashers fastening the WARNING Hold hoses firmly while discon reel to the mounting pad Remove the reel from the mast A necting cable hose from the junction block Allow the reel spring to unwind slowly REEL DISASSEMBLY while maintaining tension on the loose 1 Remove the nuts from the hub studs and lift off the rotat cable hose end See Figure 19 ing cover See Figure 20 2 Disconnect the reel outer cable connectors from the inner cable connectors See Figure 20 3 Disconnect the hoses from the reel hub fittings 4 Remove the four nuts and washers attaching the inner
15. e do Brasil Rua Joao Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105 8800 Fax 55 13 2105 8899 Cascade Xiamen No 668 Yangguang Rd Xinyang Industrial Zone Haicang Xiamen City Fujian Province P R China 361026 Tel 86 592 651 2500 Fax 86 592 651 2571 Sunstream Industries Pte Ltd 18 Tuas South Street 5 Singapore 637796 Tel 65 6795 7555 Fax 65 6863 1368 Cascade India Material Handling Private Limited No 34 Global Trade Centre 1 1 Rambaugh Colony Lal Bahadur Shastri Road Navi Peth Pune 411 030 Maharashtra India Phone 91 020 2432 5490 Fax 491 020 2433 0881 Part No 211996
16. e projection between the hoses with a hose clamp See Figure 9 Position the hose clamp so it can be tightened through the hole in the side of the junction block Route the inner cable through the junction block as shown Fasten the male cable con nector to the large projection with a hose clamp Form the hose clamp around the connectors Do not overtighten the clamp The female cable connectors must fit in the male connectors Join the connectors Connect the attachment hoses to the junction block Be sure the hoses and their functions do not become inter changed See Figure 10 Operate the carriage up and down a few times to make sure the cable hose tracks smoothly and no interference exists Figure 10 FUNCTION A FUNCTION B FUNCTION A HR0010 iil SEAL AND SPRING ASSEMBLY REPLACEMENT DISCONNECTING THE REEL 1 Disconnect the cable connectors at the junction block WARNING Hold hoses firmly while discon necting cable hose from the junction block Allow the reel spring to unwind slowly while maintaining tension on the loose cable end See Figure 11 2 Remove the cable hose from the junction block Figure 11 CABLE HOSE REEL LOOSE CABLE HOSE END 0006 3 Remove the fixed cover from the mounting block Dis connect the inner cable connectors from the truck cable connectors See Figure 4 4 Disconnect the truck valve hoses from the shaft 5 Remove the capscrews and lockwashers fas
17. er cable connectors Fit the cable clamps if equipped to the outer cable and secure them on each side of the rotating cover See Fig ure 28 Install rotating cover and hub nuts The inner cable must be laying flat in the flange depression and not pinched Tighten nuts to a torque of 70 75 in Ibs See Figure 28 Wind the new cable hose completely onto the reel in the direction indicated viewed from the flange side Right Hand Reel Wind cable hose clockwise Left Hand Reel Wind cable hose counterclockwsie A Right or Left hand reel is determined as viewed from the flange side of the reel See Figure 8 page 2 Prewind reel spring by grasping the end of the outer cable hose and turning the reel a minimum of 3 turns in the direction indicated viewed from the flange side Right Hand Reel Wind reel clockwise Left Hand Reel Wind reel counterclockwise CAUTION Rotation in a direction opposite than described will damage the inner cable and reel spring If more tension is required the reel can be prewound ad ditional turns The maximum turn capacities are 16 total turns Total Turns z Prewind turns Working turns CAUTION Exceeding turn capacity of the reel will dam age the inner cable and reel spring WARNING Do not let the reel unwind when connecting the cable hose to the junction block With the reel prewound pull the hose ends down to the junction block Fasten the hoses with the clamp bar and c
18. er cable housing to ro tate independently of its hub Damage to the inner cable will occur if they are rotated Use tape or wire to hold both from rotating If either has been rotated refer to the Inner Cable Housing Timing instructions in the pre ceding section IMPORTANT The spring assembly must be in its neutral position when fitted into the inner cable housing 2 Install the split mounting blocks and mounting brackets See Figure 20 page 7 3 Fit the reel flanges onto the hub studs Install the capscrews washers and nuts to fasten the reel flanges to the inner cable housing 4 Connect inner and outer cable connectors 5 Install the rotating cover and hub nuts The inner cable must be laying flat in the flange depression and not pinched Tighten the nuts 6 Remount the reel on the truck 7 Reconnect the inner cable connectors to the truck cable at the mounting block See Figure 20 page 7 8 Attach the clamp to the truck cable and secure the clamp to the mounting block 9 Install the fixed cover CAUTION Overtightening the capscrews will damage the fixed cover 211996 Rev 0 10 11 12 13 15 16 Connect the truck valve hoses to the shaft Make sure the cable hose is tightly wound on the reel in the direction indicated viewed from the flange side Right Hand Reel Cable hose wound clockwise Left Hand Reel Cable hose wound counterclockwise A right or left hand reel is deter
19. ews and lockwashers supplied with the reel See Figure 3 Figure 3 WARNING Ae on vertical seam only MOUNTING PAD MOUNTING BRACKETS LOCKWASHER MOUNTING CAPSCREW Torque to 52 57 ft Ibs 4 Remove the fixed cover from the mounting block on the backside of the reel See Figure 4 5 Join the cable connectors of the inner cable to the cable connectors of the truck cable 6 Remove the clamp from the mounting block and fit it around the truck cable Reinstall the clamp on the reel mounting block See Figure 4 Figure 4 TRUCK CABLE CONNECTORS INNER CABLE CONNECTORS INNER CABLE REEL MOUNTING A FIXED BLOCKS COVER 7 Install the fixed cover on the mounting block Tighten the screws CAUTION Overtightening the screws will damage the fixed cover 8 Connect the truck valve hoses to the reel shaft 9 Raise the carriage to a position approximately even with the top of the reel The junction block should be posi tioned so that it is centered between the reel flanges See Figure 5 Using the junction block as a guide mark the location of the junction block mounting holes on the back side of the carriage Make sure the junction block is posi tioned vertically 10 Lower the truck carriage to the floor 11 Drill and tap both holes at the location marked on the carriage Figure 5 shows the diameter and drilling infor mation for the two holes The thread depth should be drilled a minimum of 1 2 inch
20. ge side Right Hand Reel Cable hose wound clockwise Left Hand Reel Cable hose wound counterclockwise Prewind the reel spring by grasping the end of the outer cable hose and turning the reel a minimum of 3 turns in the direction indicated viewed from the flange side Right Hand Reel Wind reel clockwise Left Hand Reel Wind reel counterclockwise CAUTION Rotation in a direction opposite than described will damage the inner cable and reel spring If more tension is required the reel can be prewound ad ditional turns The maximum turn capacities are 16 total turns Total turns z Prewind turns 4 Working turns CAUTION Exceeding turn capacity of the reel will dam age the inner cable and reel spring With the reel prewound pull the hose ends down to the junction block Fasten the hoses with the clamp bar and capscrew See Figure 16 WARNING Do not let the reel unwind when connecting the cable hose to the junction block Figure 17 13 CABLE CONNECTORS Torque Capscrews to 12 15 ft Ibs CAPSCREW CHAMEBAR HRO005 ill Connect the cable from the cable hose to the junction block Clamp the outer cable to the projection between the hoses with a hose clamp See Figure 17 Position the hose clamp so it can be tightened through the hole in the side of the junction block Route the inner cable through the junction block as shown Fasten the male cable con nectors to the large projection with a hose
21. ion for the mounting pad keeping in mind the following points a Locate the mounting pad on the mast channel or truck cowling See Figure 1 The reel flanges must not interfere with eThe truck overhead guard when the mast is tilted all the way back if the reel is mounted on the mast eThe truck carriage as it moves past the reel if the reel is mounted on the mast eThe mast channel members when the mast is tilted all the way back if the reel is mounted on the truck cowling Figure 1 CHECK CLEARANCES AT THESE LOCATIONS WHEN LOCATING THE REEL b The inner reel flange should be no more than 1 4 inch from the side of the mast and should be placed behind the mast channel rather than along side it See Figure 2 c The reel should not extend beyond the widest part of the truck to prevent possible damage to the reel during truck operation Figure 2 INNER REEL INNER FLANGE OUTER REEL FLANGE MOUNTING PAD MAST CHANNEL CABLE TUNNEL MAST FRONT d If you are not using the Cascade Mounting Pad make sure that your pad has a thickness of at least 5 8 inch 211996 Rev 0 INSTALLATION 2 Weld the mounting pad in place using a 3 16 inch fillet weld use E60XX rod with no preheat or postheat along the vertical sides of the mounting pad only See Figure 3 Cover the mast hoist chains to shield from weld splatter 3 Attach the reel mounting brackets to the mounting pad using the mounting capscr
22. mined as viewed from the flange side of the reel See Figure 8 page 2 Prewind the reel spring by grasping the end of the outer cable and turning the reel a minimum of 3 turns in the direction indicated viewed from the flange side Right Hand Reel Wind reel clockwise Left Hand Reel Wind reel counterclockwise CAUTION Rotation in a direction opposite than described will damage the inner cable and reel spring If more tension is required the reel can be prewound ad ditional turns The maximum turn capacities are 16 total turns Total turns Prewind turns Working turns CAUTION Exceeding turn capacity of the reel will dam age the inner cable and reel spring With the reel prewound pull the hose ends down to the junction block Fasten the hoses with the clamp bar and capscrew See Figure 25 WARNING Do not let the reel unwind when connecting the cable hose to the junction block Connect the cable from the cable hose to the junction block Clamp the outer cable to the projection between the hoses with a hose clamp See Figure 24 page 8 Position the hose clamp so it can be tightened through the hole in the side of the junction block Route the inner cable through the junction block as shown Fasten the male cable connectors to the large projection with a hose clamp Form the hose clamp around the connectors Do not overtighten the clamp The female cable connectors must fit in the male connectors Join the con
23. nectors Connect the attachment hoses to the junction block Be sure the hoses and their functions do not become inter changed See Figure 26 Operate the carriage up and down a few times to make sure the cable hose tracks smoothly and no interference exists Disconnect the old outer cable hose from the attachment cable at the junction block WARNING Hold hoses firmly while discon necting cable hose from the junction block Allow the reel spring to unwind slowly while maintaining tension on the loose cable hose end See Figure 27 Disconnect the old cable hose from the junction block Disconnect the hoses from the reel hub fittings See Figure 27 211996 Rev O OUTER CABLE HOSE REPLACEMENT Figure 25 CONNECTORS Torque Capscrews to 12 15 ft Ibs CAPSCREW CLAMP HROOO6 ill Figure 26 FUNCTION A FUNCTION B FUNCTION A HRO010 ill Figure 27 CABLE HOSE REEL LOOSE CABLE HOSE END HRO007 itl Remove the two hub nuts securing the rotating cover to flange Remove the rotating cover See Figure 28 Remove the cable clamps if eguipped Discard the old outer reel cable hose See Figure 28 Connect the new hoses to the reel hub fittings Figure 28 7 8 12 HUB NUTS Torque to 70 75 in Ibs HUB FITTINGS ROTATING INNER CABLE CONNECTORS CLAMPS if equipped OUTER CABLE CONNECTORS HRO003 ill Join the new outer cable connectors to the inn
24. tening the reel to the mounting pad Remove the reel from the mast REEL DISASSEMBLY 1 Remove the nuts from the hub studs and lift off the rotat ing cover See Figure 12 2 Disconnect the reel outer cable connectors from the in ner cable connectors See Figure 12 3 Disconnect the hoses from the reel hub fittings 4 Remove the four nuts and washers attaching the inner cable housing to the inner reel flange See Figure 12 5 Scribe a mark on the inner cable housing and the inner reel flange to aid in alignment during reassembly See Figure 12 6 RIGHT HAND REEL See Figure 8 a Pull both flanges with outer cable off the hub studs Rotate the flanges slightly to free the inner cable connectors See Figure 12 b Remove the hub outer snap ring c Pull the hub off the shaft d Leave the stud bracket and spacer on the hub NOTE Since the O rings in the hub produce friction it may be necessary to tap gently on the end of the shaft with a rubber mallet or hammer handle while pulling on the hub Figure 12 ROTATING COVER INNER CABLE CONNECTORS OUTER CABLE CONNECTORS SCRIBE MARK INNER CABLE HOUSING FLANGE INNER REEL FLANGE AD T WASHER 4 v STUD BRACKET RIGHT HAND REEL SHOWN AND SPACER NUT 4 LEFT HAND REEL See Figure 8 a Remove the hub outer snap ring See Figure 12 b Pull the hub off the shaft c Remove both flanges with outer cable and the stud br
25. ud bracket and spacer on the inside of the reel flanges slide the hub and reel flanges as one unit onto the shaft b Align the scribe mark on the inner cable housing to the scribe mark on the reel flanges c Install the hub outer snap ring See Figure 12 page 4 SPRING ASSEMBLY SPRING RETAINER SPRING RETAINER SNAP RING INNER CABLE HOUSING TEMPORARY E TEMPORARY Install the capscrews lockwashers and nuts to fasten the inner reel flange to the inner cable housing See Figure 14 page 5 Reconnect inner and outer cable connectors See Figure 16 Connect the hoses to the reel hub fittings Install the rotating cover and hub nuts The inner cable must be laying flat in the flange depression and not pinched Tighten the nuts to a torque of 70 75 in Ibs Remount the reel onto the truck a Reconnect the inner cable connectors to the truck cable at the mounting block See Figure 4 page 1 b Attach the clamp to the truck cable and secure the clamp to the mounting block See Figure 4 page 1 c Install the fixed cover CAUTION Overtightening the capscrews will damage the fixed cover Connect the truck valve hoses to the shaft Figure 16 10 11 HUB NUTS Torque to 70 75 in Ibs HUB FITTINGS ROTATING INNER CABLE CONNECTORS OUTER CABLE CONNECTORS HROO03 ill if equipped Make sure cable hose is tightly wound on the reel in the direction indicated viewed from the flan
26. ui Papnjou 5 i 2 1 win wir a4 451455 52 58 MN PIC EA m9 pueH 9 Aiquessy 8 05 Ajquassy 6uudg OS L X ON t L ON t L masosden 9 9 quuessy 2 NOlLdiu2S3a 2 9827 LEER NN ENEKE CG ETE 92 112 744 25 442 ON JON bunjo01 verti 885712 82 6 65 9 1 0999 0 0999 5099 886559 066998 50491 15 Rev 0 211996 180002 211560 211540 Junction Block Assembly 2 448 4468 375x 750Lg 1 662128 662138 Clamp DESCRIPTION REEL END Hose Cable Assembly CATALOG HOSE LENGTH TOTAL ORDER NO NO 6 FITTING No 8 FITTING 211564 w 211565 240 2171 one eR 211472 211473 16 JUNCTION BLOCK END Fitting Group HC2R HC2L HC6R HC6L HC8R HC8L Models 6602 64061 o No8 O This group includes four straight O Ring fittings and two swivel 90 fitings These provide hose connections into and out of the reel All necessary electrical connectors are included with the reel 211996 Rev 0
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