Hose Reel Installation
Contents
1. e installation and Service Manual THINLINE 4 Port Hose Reel Manual Number 675395 R 1 O cascade Cascade is a Registered Trademark of Cascade Corporation THINLINE i Contents Page Introduction Section 1 o a aa ee i Truck Requirements 2 2 22 ee i Special Definitions ee i Installation Section 2 2 0 1 Hose Reel Installation icccccccccc eee 1 Cascade Masts oana aaa ee 1 All Other Masts ou oo aan en nea a e a E a a A Oa aa 1 Hose Installation 2 ee E 2 Hose Length Calculations Section3 0 00004 4 Periodic Maintenance Section 4 0 0 0 0 0 0008 eee 4 Troubleshooting Section5 e devas banat Ata 5 Service Section6 ie ware oera 2 2 2 2 0000022 eee 6 Hose Reel Removal 0 ee ee 6 Hose Replacement 2 0 00 000 eee ee danmi gh Flange and Hub Removal 2 2 200 000 0000 eee 8 Spring Assembly Replacement 2 000000 8 Hub Seal Replacement 2 0 a 9 Reversing the Reel Assembly 0 0000005 10 sein 1 Introduction This manual contains the installation periodic maintenance troubleshooting procedures and service information for the Cascade THINLINE 4 Port hose reels If you have ques tions call the Cascade Service Department at the location nearest you See the back cover for a list of the locations 1 Truck Requirements Pressure 3000 psi 210 bar maximum Volume Recommended flows No 4 2 5 gp2. 8800 Fax 55 13 2105 8899 Cascade Xiamen No 668 Yangguang Ra Xinyang Industrial Zone Haicang Xiamen City Fujian Province P R China 361026 Tel 86 592 651 2500 Fax 86 592 651 2571 Sunsiream 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 91 020 2433 0881 Part Number 675395 R 1
3. Spring Cover e ES Ms Inner Can Ke Z Right Hand Reel Spring Can 675395 Rev 1 Do you have questions you need answered right now Call your nearest Cascade Service Department AMERICAS Cascade Corporation U S Headquariers 2201 NE 201st 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 8989111 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Lid 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 9771 Fax 81 6 6420 9777 Cascade Australia Pty Lid 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 PS TM Cascade Corporation 1987 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 2 87 Cascade do Brasil Rua Jo o Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105
4. middle hole only Tighten the capscrew to a torque of 15 20 ft lbs 20 27 Nm All Other Masts o Select a mounting location for the hose reel The preferred location is near the upper mast crossbar Mark the required bracket position NOTE The hose reel must meet all minimum clearances shown below Disconnect the truck alternator O Weld the mounting bracket to the upright with 3 16 fillets using AWS E60XX weld rod No preheat or post heat is required Protect adjacent mast parts from weld splatter 675395 Rev 1 Pretapped holes Current Cascade Masts only Right hand hose reel shown Drill 3 8 dia this hole only Hose UP connection mounting block Hose DOWN connection Hose Restraint mounting Mounting Blocks block Good 1 4 6 5mm F Note any interferance with cylinder anchors Mounting Block Mounting Block seio 2 Installation Instructions 21 2 All Other Masts Continued Attach the hose reel to the mounting block with the capscrews supplied Tighten the capscrews to a torque of 30 35 ft lbs 40 47 N m Check the clearance as shown in step 3 Hose UP connection mounting block SSS O Use a square to find the reel centerline Position the qi hose restraint mounting block on the upper carriage bar OR centering the two outer holes with the hose reel as shown Sars O Weld the mounting bracket to the upper carriage bar cee BOWN with 3 16
5. an be prewound additional turns The maximum total turn capacity of the reel is No 4 15 13 turns No 6 13 13 turns No 6 16 13 turns Total Turns Prewind Turns Working Turns Caution Exceeding the total turn capacity of the reel will damage the reel spring Reconnect the hoses to the hose terminal Tighten the hose terminal capscrews to 15 20 ft lbs 20 27 N m O Raise and lower the mast carriage slowly to ensure adequate hose length and alignment on reel 675395 Rev 1 Right Hand Wind Counterclockwise Wind Clockwise Hose Restraint Install clamp with detent between first and second segment san6 Service 6 3 6 4 Flange and Hub Removal O Clamp the reel mounting block in a vice Remove the twinline hoses Remove the four 4 capscrews fastening the flanges and hub to the spring shaft assembly For re assembly tighten the capscrews to 10 14 ft lbs 13 19 Nem Remove the capscrew end cap and O ring from the shaft end For reassembly tighten the capscrews to 10 14 ft lbs 18 19N m Grasping both flanges and hub as an assembly slowly rotate as you lift off the shaft QO Separate the hub from the flanges Spring Assembly Replacement Remove the flanges and hub from the shaft as described in Section 6 3 2 Rotate the spring assembly to disengage the spring end from the spring declutching pin Slide the O rings and spring assembly off the shaft Do not damage
6. fillets using AWS E60XX weld rod No preheat or post heat is required Protect adjacent mast parts from weld splatter connection mounting block 21 3 Hose Installation Press and twist the hose assemblies into the hose restraint Spray hoses with WD 40 to make installation easier Install the fittings and hose ends inside fitting first to the hose reel hub Hold hoses while tightening to prevent from twisting NOTE install the hoses with the natural set in the direc tion of wind Left Hand Right Hand O Wind the hoses onto the hose reel in the direction shown in the illustration Wind Counterclockwise Wind Clockwise NOTE See Section 6 6 for Reel Assembly reversal 2 675995 Rev 1 sa Installation Instructions 2 1 3 Hose Installation Continued Q Raise the truck carriage to just below the hose reel O Prewind the hose reel the number of turns and direction shown in the chart below 2149m 1 Install clamp between first and second segments QO Attach the hose restraint to the mounting block with the clamp Install the clamp between the first and second hose restraint segments CASCADE MASTS Use the 3 8 NC x 75 capscrew supplied in the inner hole of the clamp sues 15 20 ft lbs 20 27 Nm CASCADE MASTS 3 8 NC x 75 Capscrew ene Hose Terminal Hose Up Connection Install the tubes and fittings i Up Kit 675287 to the mounting block and hose ends O Con
7. from the carriage Allow the reel spring to unwind slowly while maintaining tension on the loose hose ends Count the number of prewinds while unwinding the hose reel Disconnect the hoses from the reel hub It is not neces sary to remove the outer flange Remove the hoses from the reel Connect the new hoses to the reel hub fitting NOTE Thermoplastic twinline hose has a natural bend or set Wind the hose with the bend of the hose matching the flange bend Do not twist hose when tightening fittings Hold the fittings with a wrench when tightening O Wind the new hose assembly completely onto the reel in the direction indicated viewed from the flange side Right Hand Reel Wind hoses clockwise Left Hand Reel Wind hoses counterclockwise A Right or Left hand reel is determined as viewed from the flange side of the reel An R or L letter on the hub casting will designate the correct direction Q Remove the old hose from the hose restraint by twisting out Spray new hoses with WD 40 then install by twisting and pressing on Prewind the reel spring by grasping the end of the hose and turning the ree the specified number of complete turns in the direction indicated viewed from the flange side Right Hand Reel Wind reel clockwise Left Hand Reel Wind reel counterclockwise Normal prewinds No 4 15 5 turns No 6 13 5 turns No 6 16 5 turns If more tension is required the reel c
8. m 10 L min No 6 6 gom 25 L min CAUTION If the track flow through the reel exceeds 10 gpm 38L min call the Cascade Service Department location nearest you 12 Special Definitions A statement preceded by A WARNING is information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box CAUTION Astatement preceded by CAUTION is information that should be acted upon to prevent machine damage IMPORTANT Astatement preceded by IMPORTANT is information that posseses special significance NOTE Astatement preceded by NOTE is information that is handy to know and may make your job easier 675395 Rev 1 sein Installation Instructions 2 1 2 1 1 2 1 2 Hose Reel Installation Cascade Masts O Attach the hose reei mounting bracket to the mast crossbar Leave the capscrews finger tight until the hose reel is attached to the bracket and positioned for correct clearance with the mast upright 2 Attach the hose reel to the mounting bracket with the capscrews supplied Tighten the capscrews to a 30 35 ft lbs 40 47 N m Adjust the hose reel to 1 4 clearance between the reel inner flange and mast upright Tighten the mounting bracket capscrews to a torque of 15 20 ft lbs Drill out the threads in one of the hose restraint mounting block holes with a 3 8 dia drill as shown Attach the hose restraint mounting block to the mast upper carriage bar using the
9. mery 3 Teflon Ri cloth 320 Grit to smooth up If sharp edges or grooves J Om unos Remove o rings and back up rings are found shaft replacement is necessary 3 Square Rings eHub grooves must be fee of sharp nicks or projections to prevent cutting of the outside diameter of the o ring during installation eif the O ring seal nearest the spring assembly was damaged and allowed hydraulic oil to leak into the NO 4 HOSE REELS spring can drain the spring can before reassembly If Seal Kit Part No 674587 excessive oil is left in the spring assembly it will seep 8 Back up Rings out after reassembly and appear as though there is a serious oil leak le le 5 O rings NO 6 HOSE REELS Seal Kit Part No 674408 O Ring Install four new seals to the shaft end Durt Seal Align spring retainer Align the shaft spring retainer with side of to side of mounting mounting block without holes Install three Spig block without holes mounting capscrews Retainer Apply a liberal amount of petroleum jelly or hydraulic oil STP to the shaft seals and hub before reassembling O Install the back up rings and O ring seals O Reverse steps one 1 through four 4 for reassembly Mounting Block being careful to rotate the hub slowly as you push it onto Shaft End the shaft This will prevent damage to the seals and Seals make reassembly easier Also be sure O ring dust seals gl SS 3 are in their correct po
10. nect the hoses from the truck auxiliary valve to the hose reel mounting block NOTE The mounting block ports are marked for identification Q Tilt the mast back and forth Raise and lower the carriage Check for clearance problems Raise and lower the carriage 675395 Rev 1 3 Hose Length Calculation 3 1 Hose Length Calculations H Total lift height D Distance from centerline of reel to hose end with carriage fully lowered K CONSTANT 18 inches 460 mm for No 4 28 inches 710 mm for No 6 1 When H is equal to or greater than 2 x D the correct hose length is H D K 2 When H is less than 2 x D the correct hose length is D K Example inches H 286 D 96 K 28 A 286 96 190 28 218 correct hose length In this case use hose 675286 H Example mm H 7265mm D 2440mm K 710mm 7265 2440 4825 710 5535 correct hose length in this case use hose 675286 Y sein Periodic Maintenance 4 1 500 Hour Maintenance After each 500 hours of lift truck operation perform the following procedures O Tighten the mounting capscrews Use the torque specifications shown in Section 6 1 O Tighten all hydraulic hose fittings 675395 Rev 1 ss Troubleshooting Troubleshooting Guide PROBLEM PROBLEM CAUSE SOLUTION Excessive wear on hose Hose reel and hose terminal are Align the hose terminal and hose reel properly no
11. ot required that the reel assembly be removed from the truck All service procedures can be performed with the ree mounted on the mast For purposes of this manual all repairs will be done on the work bench Remove the twinline hoses from the hose terminal For reassembly tighten the hose terminal clamp capscrews to 15 20 ft lbs 20 27 N m WARNING Hold hoses firmly while disconnecting them from the carriage Allow the reel spring to unwind slowly while maintaining tension on the loose hose ends Note the number of prewinds while unwinding the hose reel Disconnect the truck valve hoses from the hose reel mounting block Tag the hoses for reassembly Remove the capscrews and self locking nuts fastening the reel to the mounting bracket Remove the reel from the mast For reassembly tighten the capscr ws to 30 35 ft lbs 40 47 N m Determine whether the reel is a right or left hand model viewed from the fiange side of the reel This must be noted for future reference If the reel is left handed an L will show on the hub casting If the reel is right handed an R will show on the hub casting Mounting Bracket Left Hand Ree Right Side shown Right hand hose reel shown Right Hand Reel 675395 Rev 1 san Service 6 2 Hose Replacement Disconnect the twinline hoses from the hose terminal WARNING Hold hoses firmly while disconnecting them
12. sitions Torauet 2 32 38 ft Ibs 675395 Rev 1 43 81 Nem 9 O Service 6 6 10 Reversing the Reel Assembly The reel assembly can be converted from a right hand reel to a left hand reel or from left to right as follows Remove the hose reel flanges and hub as described in Section 6 3 Remove four nuts and bolts that retain the spring can cover For reassembly tighten the capscrews to a torque of 30 40 in Ibs 3 4 N m WARNING Once the spring cover is removed the spring itself should never be allowed to be turned to any position other than flat without manually covering the spring The spring is banded but can come out by gravity or bouncing O Turn the spring can assembly making sure that can and cover stay together Lift off the spring can leaving the cover and inner can on the work bench Flip over spring can WARNING Do not remove spring from inner can O Use the spring cover to slide the inner can into the spring can Align the spring can notch with the inner can washer The spring winding will be exposed for a right hand reel and covered for a left hand reel O Reverse the spring retainer by removing the spiral snap ring and rotating the retainer 180 Replace the snap ring For reassembly reverse the above procedures Remove O Ring o Rotate to disengage de spring Lift off spring assembly CAUTION Do not damage ree shaft Inner Can
13. t in proper alignment They must be on the same centerline and mounted squarely to each other Hose reel flanges damaged Repair or replace damaged parts Hose jumps off reel Hose reel not aligned with hose Align hose terminal with hose reel during operation terminal Incorrect prewind of spring Prewind spring Hose binds during operation Hose reel spring is broken Replace the spring Flanges are bent Straighten or replace fianges See Page 9 Hose reel leaks at hub Worn or cut seals in the rotating hub Replace all rings When a hose reel requires immediate replacement of any one of the O rings or back up rings it is important that all the rings be replaced If all the rings are not replaced at the same time the reel will only have to be disassembled again in a short period of time to replace the older rings The seal kit offered by Cascade includes all of the O rings and back up rings necessary to rebuild one hose reel Order Seal Kit No 674408 Loose or damaged fittings Tighten or replace damaged fittings Scored seal areas Replace the damaged shaft or use an emery cloth 320 grit to remove the nicks from the shaft or hub Hose reel leaks at mounting Truck flow volume exceeds hose reel Install Flow Control Valve Part No 671825 block and shaft rating to reduce flow to 10 GPM 38 L min maximum 27096e 192 5 675395 Rev 1 5 sim Service 6 1 Hose Reel Removal NOTE To service the hub and flanges it is n
14. the shaft O D O Remove four nuts and bolts that retain the spring can cover Q Place the inner can into the spring can The spring winding will be exposed tor a right hand reel or covered for a left hand reel Align the spring can notch with the inner can washer O Replace the spring can cover Install the four cap screws and nuts Tighten to a torque of 30 40 in ibs 3 4 Nem Right Hand Reel Align notch with washer Inner Can Left Hand Reel Spring Can 675395 Rev 1 si O Service 6 5 Torque to 10 14 ft lbs O Ring Dust Seal 13 19 Nem g Dust Ssa Hub Seal Replacement Remove the flanges and hub as described in Section 6 3 Remove the O ring and back up ring seals from the hub bore Remove the seals by prying them out with the tool in Cascade O ring Extractor Kit part no 674424 ora hook type dental tool NOTE Do not scratch or damage groove surfaces Rotate the spring assembly to disengage the spring end from the spring declutching pin Slide the O ring dust seals and spring assembly off the shaft Do not damage the shaft O D WARNING Do not disassemble the spring assembly Remove the capscrews fastening the shaft and mounting block O Clean the hub and shaft with a non corrosive solvent HUB SEAL DETAILS Inspect the following areas 2 Back up Rings eThe sealing surface on the shaft is nickel plated If i 2 O rings minor surface imperfections are noted use e
Download Pdf Manuals
Related Search