Operation and Service Manual for Self
Contents
1. ERING amp REFRIGERATION HARDWARE Operation and Service Manual for Self Retracting GEN Ill Hose amp Cable Reels models after 1 June 2004 1 li 1 4 Overview The following operation service and repair manual has been designed to give the operator user a full understanding of the operational aspects of the hose and cable reels Table of Contents Quality and Certification Page Declaration of Conformity 3 Terms and conditions of warranty 3 Procedure for making warranty claims 3 Procedure for returning goods for repair 3 Listing of explanation symbols 4 Installation instructions Connection of the inlet hose 5 Mounting the reel 6 Fitting optional mounting brackets 7 How to use the reel 8 Maintenance and repair procedures Inserting the locking pin service tool 9 Checking for leaks 10 Checking for hose defects 10 Servicing seals and O rings 11 Adding or removing tension 12 13 Replacing mouth guard 14 Replacing O rings seals slip rings and swivels 15 Replacing hoses or cables 16 Replacing the tension locking system 17 Replacing the outer cases 18 Replacing a broken spring 18 Spare parts breakdowns General parts breakdown 19 Swivel parts high pressure 20 Slip ring parts 21 Tension locking system breakdown 22 Spring and drum assembly 23 Numerical part number listing 24 26 CE Declaration of Conformity Declaration of conformity2. X 3 8 NPT HOSE BARB 1 4 BSPT X 3 8 HOSE BARB 1 4 X 3 8 BSPM BOLT 1 4 X 1 1 4 PAN XRMTSZT NUT 1 4 HN7P OVAI INI FT SIDF PI ATF I ARGF UF OVAI INI FT SIDF PI ATF ARGF HFX RI ACK OVAI INI FT SIDF PI ATF I ARGF HEX OVAI INI FT SIDF PI ATF I ARGF RFD OVAI INI FT SIDF PI ATF I ARGF YFI I OW SWIVFI HOSF SHORT 3 8 X 3 8 RSP SWIVFI HOSF SHORT 1 2 X 3 8 RSP SWIVFI HOSF SHORT 1 2 X 3 8 NPT SWIVFI HOSF RARR SHORT 3 8 X 3 8 NPT 3 25 MM SWIVFI RODY 3 8 RSPP 3 25 MM SWIVFI RODY 1 2 RSPP 3 25 MM SWIVFI RODY 3 8 NPTS 3 25 MM SWIVFI RODY 1 2 NPTS GEN 3 22 MM SWIVFI RODY 3 8 RSPP GEN 3 22 MM HFX SWIVFI RODY 3 8 NPTS 3 25 MM HFX SWIVFI SHAFT 3 8 RSPP GEN 25 MM HEX SWIVEL SHAET 1 2 RSPP Numerical Part Numbers continued Item N Ordering Description 25 13 13 13 14 14 14 15 16 17 18 19 20 20 20 20 20 21 21 21 21 21 22 22 22 22 23 23 24 25 26 27 28 28 28 28 28 29 30 an 31 32 33 34 35 36 37 9 9 9 SGN5NB S SG0507 8 SGO 508 S SGnn71 5 0203 5 0204 lt lt 1 sqnsnn SGN5N9 SGN137 SGN403 R SGN4N3 RI SGN4N3 G SGnAO3 R SGN403 Y SGNN77 SG0078A sqnna1 SGNN94 SG0076A 5640078 SG0091A SG0094A 5060138 660215 560229 5640739 560503 5640753 SGN404 B SG
3. Do not open the drum assembly Note Use only Strata original components failure to do so will void warranty Numerical Part Numbers Item N Ordering Description 24 00 DDONNNNNNDDDADIADINAWBDN A AHH A 13 SG0405 B SG0405 BLK SG0405 G SG0405 R SG0405 Y SG0023A SG0408 SG01 12 SG0260 560017 560040 560041 560042 560060 560099 560221 560222 560226 SG0226B SG0250 560020 560048 560063 560064 560065 560 129 5 50132 SGO 146 SG0228 560236 560244 560248 560237 SG0238 SG0402 R SG0402 RI SG0402 G SG0402 R SG0402 Y SG0020 S SG0048 S SG0228 S SG0236 S SG0 504 R SG0 505 R SGN506 B SG0507 R SG0 508 R SGN509 R SGN504 S SG0505 S OVAL OUTER CASE BLUE OVAL OUTER CASE BLACK OVAL OUTER CASE GREEN OVAL OUTER CASE RED OVAL OUTER CASE YELLOW WALL ANGLE BRACKETS ALL REELS MOUTH GUARD NYLON CABLE TIE 194MM 8 X 3 4 PAN PR HI LO Z GOLD B POINT 10 MM HOSE BUMPER 12 MM HOSE BUMPER 8 MM HOSE BUMPER 6 MM HOSE BUMPER TWIN 11 MM HOSE BUMPER BRASS FERRULE 14 27 1 0 BRASS FERRULE BFM687 BRASS FERRULE BFM718 BRASS FERRULE BFM78119 84 X 15 88 BFM 718B FERRULES 19 84 X 12 70 BRASS FERRULE BFM478 HOSE BARB 3 8 X 3 8 BSPT HOSE BARB 1 2 X 3 8 BSPM HOSE BARB OXY FUEL GAS 5MM OXY NUT 5 8 UNF R H FEMALE ACCET NUT 5 8 UNF L H HOSE BARB 3 8 X 1 4 NTP HOSE BARB 1 2X1 2 NTP OXY AND ACET NUTS 3 8 BSP HOSE BARB 1 2 BARB 3 8 NPT HOSE BARB 3 8
4. Use only original components failure to do so will void warranty Note For Oxygen swivels and connections use only approved lubricants refer to your authorities Step n f SMS IC A z gt 3 lt 2 Wr Ce 1 ANN AN D IJ ES 2 ix gt s 4 4 4 27 d CN x gt PENA os NS L TYPICAL OXYGEN amp FEUL GAS SWVEL Replacing Hoses Cables Note Repairs to electrical cable reels should be carried out by authorised electricians only Follow the same procedure as replacing the swivel or slip ring once you have cut the hose from the swivel or removed the slip ring pull the hose or cable from the reel via the main 16 opening Note always check the length and diameter of your replacement hose or cable to ensure it is the same length and diameter as the hose or cable originally supplied on the reel Each model of reel is designed to retract a certain length and diameter of hose or cable only Longer lengths or larger diameters will damage the reel and void warranty Replace the hose or cable by feeding it through the mouth of the reel and then through the Opening in the drum and reconnect to the swivel or slip ring Refit the cable tie to hold the hose to the drum and refit the swivel and side plate Reconnect the inlet supply and check for leaks Electrical reels should be tested for earth leakage c
5. X RING SI IP RING SINGI F PHASF SI IP RING 3 X RING MAIN SPRING PFR TORSION SPRING I OCKING PAWI INNFR DRUM RFFI FRS PAIR 12 MM FASTFNER 73020012 M5 X 60MM PAN XR ZINC HIGH OW THRFAD DRUM AXI RFCOII A PAWI PLUSH ON FASTENFR 156RMIP MA OVAL TENSION SIDF PI ATF BI UF OVAI TENSION SIDF PI ATF RI ACK OVAL TENSION SIDF PI ATF OVAI TENSION SIDF PI ATF OVAL TENSION SIDF PI ATF YFI I OW Numerical Numbers continued 26 40 5640406 I OCKING TENSION 41 560407 RATCHET OCKING RING 27
6. cable rewind uncontrolled Means all positional locking system Means ensure you have full knowledge of the service or repair task being carried out possible hazards Note Please refer to your local authority for rules and regulations on the safe use of compressed liquids gases and fuel gases Installation Instructions Connection of the inlet supply hose s A flexible connection between the reel and the source of supply is required to prevent possible misalignment and binding Non flexible connections will void the warranty The pressure rating of the inlet hose must be equal to or greater than the rating of the reel Always check with your local authorities for appropriate rules and regulations for safe use and handling of compressed gases liquids and fuel gases Do not use lubricants or thread sealants on Oxygen connections unless such lubricants or sealants are approved by your authorities for use with Oxygen Using the appropriate approved hose and fittings connect the supply line to the inlet connection of the reel Ensure you use thread sealants where applicable and permitted Never over tighten or under tighten fittings Once connection has been made to the inlet of the reel ensure you make or fit a connection to the outlet of the reel the main hose then turn the supply valve on slowly and check for leaks Note Please refer to your local authority for rules and regulations on the safe use of compressed liquids gase
7. from CRH supplier available upon request Declaration relates to conformity with our suppliers design specifications and acceptance criteria and the provision of 98 37EC Machinery Directive Terms and Conditions of Warranty Please refer to CRH terms and conditions Procedure for making warranty claims Please refer to CRH terms and conditions Procedures for returning items for service or repair Please refer to CRH terms and conditions Catering amp Refrigeration Hardware Contact Details Melbourne Catering amp Refrigeration Hardware 1 3 Nelson Street Moorabbin VIC 3189 t 61 3 9532 1599 f 61 3 9532 2696 Sydney Catering amp Refrigeration Hardware Unit 1 11 Turbo Road Kings Park NSW 2148 t 61 2 9831 6477 f 61 29831 8284 Brisbane t 61 7 3284 0666 f 61 2 9831 8284 e info c rh com au www c rh com au SAFETY PRECAUTIONS Listing of explanation symbols Means warning Watch out There are possible hazards with this procedure Possible hazards are shown by this warning symbol Means warning moving parts keep away from moving parts and pinch points Means consult the service centre or become trained and read the service manual Means warning item under tension this area contains a tensioned spring Means warning Do not remove fasteners or attempt to service without contacting a service centre or becoming fully trained on the service and repair of hose reels Means warning Never let the hose or
8. the reel The hose must always be fully wound on the hose reel Adding tension With the hose fully recoiled in the reel remove the two most inner self tapping screws locked on the tension ring With a spanner or the tensioning service tool rotate the cap clockwise one full turn the tensioning cap is a ratchet system so you will note the clicking as you rotate the cap Always have the screws vertical when finished this way you will always know you have a full turn Whenever adding tension only ever add one full turn at a time Before replacing the screws pull the hose out check to ensure that all the hose comes out If you cannot pull the hose all the way out and there are remaining coils left on the reel this indicates that you have over tensioned the spring or that the spring has run out of power and we suggest that you contact your service centre If all is OK replace the two self tapping screws to lock the cap in position 12 Adding Removing Tension Cont Note Never add or remove tension when the hose is extended from the reel The hose must always be fully wound on the hose reel Removing tension Removing tension is done for one of two reasons one that you over tensioned your hose reel and cannot pull all the hose out and the second is that you are replacing the spring drum There should be no other reason to remove tension from the reel Using a C spanner or the service tool hold the centre locking cap an
9. 0404 RI SGN404 G SGN404 R SG0404 Y 5640111 560122 560124 560015 5640016 SG0018 SGN019 560025 560062 560232 5640318 SG0401 B SG04A01 RI SG0401 G SGN401 R SG0401 Y 3 25 MM SWIVFI SHAFT 3 8 NPTS GEN 3 25 MM SWIVFI SHAFT 1 2 NPTS GEN 3 22 MM SWIVFI SHAFT 3 A RSPP O RING RS115 O RING RS115 VITON O RING RS115 22MM FXTFRNAI CIRCI IP GEN 3 OXY amp FIIFI GAS SI GEN 3 OXY AND FIIFI SHAFT GEN 3 HP OXY amp FIIFI GAS RFEZFI ROI I PIN AMM OD X 36MM OVAL INI S PI ATF HP OXY FIIFI RI OVAL INI S PI ATF HP OXY FIIFI RI ACK OVAL S PI ATF HP OXY FIIFI GREEN OVAL FT S PI ATF OXY FIIFI RED OVAL S PI ATF HP OXY FIIFI YFI I OW OXY FXT NIPPI SFT 45 8 CIRCI IP 24 FXTFRNAI NEW OXY SHAFT FXT 3 8 RSP OXY FXT NIPPI FS 9 16 18 LINE OXY FXT NIPPI FS M16 1IS FXT ADAPTOR 5 8 UNF OXY FXT NIPPI FS 3 8 RSP FXT NIPPI 9 16 18 FXT NIPPI FS M18 15 HOSF 1 4 X 1 8 RSPM HOSF RARR 3 16 X 1 8 RSP M4 X 8MM PHII I IPS HEAD ROI T WASHER 7P 5 32 X 7 16 X 20G 02136406 GFN 3 HP SWIVFI SHAFT 5000 PSI HP GRFASF SWIVFI 490102 4 4 OVAL FCTRICAI S PI ATF UF OVAI FI FCTRICAI S PI ATF RI ACK OVAL FCTRICAI S PI ATF OVAI FI FCTRICAI S PI ATF OVAL FCTRICAI S PI ATF YFI I OW CARI F GI AND M20X15 3 PHASF 4
10. 300mm and then allow it to retract back whilst holding the hose If you want to stop the rewinding and lock it in position again pull some hose out until you hear the clicking and allow it to retract a little locking the hose in position Maintenance Repair Section Inserting the locking pin service tool In the interest of safety we have designed and constructed a special service tool a locking pin that when inserted through the outer cases it locks the drum from being able to rotate when carrying out service work We recommend that this tool be used to prevent damage to the reel or the service person By simply rotating the drum pulling the hose slowly and looking into the service pin hole shown below you will see the line up holes insert the pin right through the reel so that it protrudes out the opposite side Maintenance Procedures Checking for leaks Like all moving and rotating components there is a need to make regular maintenance checks Some of these checks are very simplistic and only require a visual inspection others require service work to be carried out on items such as seals and O rings For O ring and seal servicing refer to servicing O rings and seals further in your manual From time to time we recommend that the user checks for leaks liquid leaks are easily found however gas leaks require some form of leak test a soapy water test is the most simplistic Soapy water brushed around each joint wil
11. Typical extra high wall mount using the Swivel floor mounting bracket Under bench mounting using the fixed floor mounting bracket Use The Reel Once you have mounted your reel and made the inlet connection you are ready for operation In order to familiarise yourself with the function of the reel stand as close as possible to the reel pulling the hose slowly out you will note a clicking noise This is the locking pawl running over the locking teeth or ratchet teeth As soon as you hear this noise stop pulling and allow the hose to retract a little and it will lock in position If it won t lock allow the hose to retract back further then pull it again slowly until you hear the first one or two clicks stop pulling and allow the hose to retract a small amount and it will lock Now pull it out some more until you hear the next set of clicks and repeat the locking process The hose will lock about every 3 feet or 1metre increments but only after you have been pulling it with an outward movement The locking system is designed so that the hose will never lock when rewinding the hose Once you are familiar with the system you wont need to listen for the locking clicks as you will automatically know when and where it will lock Never let the hose fly back uncontrolled this can cause damage to property or person Always keep a firm hold of the hose as it is retracting back into the reel To rewind the hose pull it out about 1ft or
12. d remove the four outer screws Note There is tension on this cap and it will want to spin anticlockwise so hold tightly Once the screws are removed allow the cap to unwind in a controlled manner once the tension is released the cap will sit stationary This has now released all the tension Replace the four self tapping screws ensuring you locate the correct position between the inner rotating cap 13 and the side plate To add tension follow the steps above Adding tension if you have removed all the tension and are re tensioning add five full turns to start with and then one more at a time if necessary Repeat the steps as described in Adding tension TO REMOVE TENSION Repair Procedures Replacing the mouth guard The reel has been designed with a replaceable mouth guard to prevent wear to the case of the reel The amount of wear on the mouth guard is dependant on the amount of use To replace this pull some hose from the reel and lock it in position remove the four fasteners as shown below stretch the case open slightly to pop the mouth guard out Remove the hose bumper and slide the mouth guard off and fit the new one in reverse order Swivels Slip rings and O Rings Seals Note Repairs to electrical cable reels should be carried out by authorised electricians only The task of replacing the swivel is the same as replacing the O rings and seals Follow the procedure below Pull the hose all th
13. e way out of the reel and using the service locking tool described in use of service locking tool fix the service tool in position This locks the reel and makes it safe to carry out repairs Note Never open the tension side plate or adjust tension with the hose fully or partially extended All the hose or cable must be fully retracted onto the reel i e fully wound on the drum of the reel Disconnect the inlet supply from the inlet fitting on the reel or disconnect the supply cable for the electrical reels Remove the six self tapping screws in the inlet side plate Remove the side plate and the swivel You will note that the hose is connected to the inner drum with a cable tie Cut the cable tie but be careful not to cut the hose Once this is done it will allow you to pull the hose through the side plate cavity Pull the hose out far enough to get free access Remove the crimp clip or simply cut the hose off as close as possible to the hose barb For the electrical reels loosen the screws holding main cable Re connect the hose to the barb of the swivel using a suitable clamp Replace the swivel and refit the cable tie to hold the hose to the drum and refit the swivel and side plate Reconnect the inlet supply and check for leaks Electrical reels should be tested for earth leakage continuity and correct wiring connection Remove the service tool while holding the main cable or hose and allow the cable or hose to retract Note
14. l soon indicate a leak when bubbles appear Oxygen and Fuel gas reels should be checked regularly to prevent the possibility of fire due to leaking of flammable gases The soapy water test also applies here however a quick test to determine a leak or not is to pressurise the lines ensure the blow torch or appliance is turned off Without touching the regulators turn the main bottle valve off If you watch the pressure gauge on the regulator and it begins to drop this indicates there is a leak somewhere between the regulator and the blow torch or appliance If this occurs pressurise the system again and apply the soapy water test to find the leak Checking for hose defects High pressure systems will require a regular test procedure where the system is pressurised to a test pressure and maintained Most PVC hose reels do not require this test and a simple visual inspection will identify potential hose failures Pull all the hose from the reel and lock it in the final position sliding the hose through your hands look for cuts bruises cracks blistering or hardening of the hose s skin Should you find any of these conditions point these out to your workshop foreman or manager so that the appropriate action can be taken 10 Servicing Replacing Rings Seals As with normal and scheduled maintenance checks O rings and seals will need to be serviced or replaced from time to time The task of replacing the O rings and seals is quite
15. ly and follow the procedure for re tensioning the reel in the previous section To add tension follow the steps above Adding tension if you have removed all the tension and are re tensioning add five full turns to start with and then one more at a time if necessary Repeat the steps as described in Adding tension Replacing the Outer Case To replace the outer cases you must first follow the procedure for replacing the locking system once you have removed the tension and removed the tension side plate remove the 18 inlet side plate as you would if you were going to replace the swivel However do not disconnect the swivel from the hose Remove the screws around the outer case and split the two halves Refit the drum into the new case halves and replace the screws Refit the inlet side plate Refit the tension side plate and follow the procedure for replacing the tension locking system Replacing a Broken Spring Note Never open the spring drum assembly as it contains a coiled spring and could cause serious injury Due to safety factors we do not sell just the spring instead we sell a complete spring assembly called the spring drum assembly To replace the spring drum assembly follow the procedure for Replacing the outer cases Once you have got the drum out of the reel remove the hose and refit to the new drum Rebuild the reel in the same manor as described in replacing the outer cases Pa
16. ontinuity and correct wiring connection Remove the service tool while holding the main cable or hose and allow the cable or hose to retract Note Use only original components failure to do so will void warranty Note For Oxygen swivels and connections use only approved lubricants refer to your authorities LR 3 9 3 Replacing The Tension Locking System Note Never open the tension side plate or adjust tension with the hose fully or partially extended All the hose or cable must be fully retracted onto the reel i e fully wound on the drum of the reel 17 The first step is to remove tension from the reel Using C spanner or the service tool hold the centre locking cap and remove the four outer screws Note There is tension on this cap and it will want to spin anticlockwise so hold tightly Once the screws are removed allow the cap to unwind in a controlled manner once the tension is released the cap will sit stationary This has now released all the tension Remove the six self tapping screws holding the tension side plate Once you have removed the side plate check to see if the there is any damage to the locking teeth ratchet teeth located on the inner drum If the locking teeth ratchet teeth are damaged or broken you will need to replace the inner drum spring canister Refer replacing broken spring section at this point If these are all OK without damage refit the new side plate assemb
17. rts Break Down Typical Main Assembly DRAWING FIGURE Note Not all items are sold as individual parts complex assemblies and spring assemblies are sold in sub assembly kit form Note Use only original components failure to do so will void warranty Parts Break Down 20 Typical High Pressure Grease Swivel Note This item is sold as an assembly O ring service kits are sold separately please quote the model of hose reel you have Note Use only Strata original components failure to do so will void warranty Parts Break Down Typical Electrical Slip Ring Assembly 5 D LAS N SN Los SW gt lt X On 5 MJ om T i Ma M d FIGURE 5 Note This is sold as an assembly For slip rings please state what model reel you have Always disconnect the electrical supply before carrying out any service or maintenance work It is recommended that you use a certified electrical contractor to make any repairs Note Use only Strata original components failure to do so will void warranty Parts Break Down Typical Tension Side Plate Assembly 22 Note This item is sold as an assembly Note Use only Strata original components failure to do so will void warranty Typical drum and spring assembly Parts Break Down Typical Drum and Spring Assembly 23 FIGURE SUPPLIED AS AN ASSEMBLY ONLY Note This item is sold as an assembly
18. s and fuel gases Mounting the reel All Strata Self Retracting hose reels are fitted with an all position locking system which allows the reel to operate in all positions 360 by 360 degrees The reel is supplied as standard with a mounting system and brackets that allow ceiling mounting or wall mounting an optional floor or under bench mount can be purchased for other mounting positions see the following page for examples The optimum height for wall mounting is such that it allows the hose or cable to be pulled at an upward or a downward angle of no more than approx fifteen degrees angles exceeding this can create undue drag in operation and potentially cause premature wear to the mouth opening of the reel For wall mounting where heights above 3 metres are required we suggest the use of the swivel mounting optional floor bracket Bolt the bracket to the wall and fix the reel in position as you would for ceiling mounting Note the orientation of the wall brackets is important please follow drawings Typical Mounting Typical Mounting 1 Ceiling Mounting mme 8 1 4 Lea Fitting Optional Mounting Brackets Optional extra mounting brackets are available such as fixed floor mounting where you do not require the reel to swivel or extra high wall mounting where you require the reel to be mounted high up on a wall or swivel floor mounted and under bench mounting Swivel Floor Mount Fixed Floor Mount
19. simplistic and should only take a few minutes following the procedure below Pull the hose all the way out of the reel and using the service locking tool described in use of service locking tool fix the service tool in position This locks the reel and makes it safe to carry out repairs Note never open the tension side plate or adjust tension with the hose fully or partially extended All the hose must be fully wound onto the reel Disconnect the inlet supply from the inlet fitting on the reel Remove the six self tapping screws in the inlet side plate Remove the side plate and the swivel At the axle end of the swivel remove the circlip and slide the swivel sleeve off the swivel shaft This will expose the O rings and seals remove these with an appropriate tool Note Do not score or scratch the O ring or seal sealing surfaces Replace the O rings and seals and apply an appropriate lubricant Note Use only original seals and O rings failure to do so will void warranty Note For Oxygen swivels and connection use only approved lubricants refer to your authorities Re assemble the swivel and refit in position replace the self tapping screws holding the hose remove the service tool and rewind your hose Reconnect the inlet supply and check for leaks refer to checking for leaks earlier in the manual Step 2 TYPICAL OXYGEN amp FEUL GAS SW VEL Note Never add or remove tension when the hose is extended from
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