COXREELS 1125 Motorized Hose Cable Reels Instruction Manual

INSTALLATION AND MAINTENANCE MANUAL
FORM #PM-004-E REV E 09/13
MOTORIZED HOSE/CABLE REELS:
SERIES: 1125, 1125WC, 1175, 1185, 1195, 1275, 1600

1125 Motorized Hose Cable Reels

SERIES: 1125, 1125WC, 1175-6, 1185, 1195 SERIES: 1600 SERIES: 1275

COXREELS

The technical data and images which appear in this manual are for informational purposes only. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE CREATED BY THE DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN THIS MANUAL. COXREELS makes no warranty (and assumes no liability) as to function of equipment or operation of systems built according to customer design or of the ability of any of its products to interface, operate or function with any portions of customer systems not provided by COXREELS. COXREELS agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and material discovered and reported to COXREELS within two years after shipment of such goods to Buyer. Except where the nature of the defect is such that it is appropriate, in COXREELS’ judgment, to effect repairs on site, COXREELS’ obligation hereunder to remedy defects shall be limited to repairing or replacing (at COXREELS’ option) FOB point of original shipment, any part returned to COXREELS at the risk and cost of Buyer. Defective parts replaced shall become the property of COXREELS.
COXREELS shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service recommended. COXREELS is not responsible for defects which arise from improper installation, neglect, improper use of or from normal wear and tear.
COXREELS obligation shall be limited by the manufacturer’s warranty (and is not further warranted by COXREELS) for all parts procured from others according to published data, specifications or performance information not designed by COXREELS. COXREELS further agrees to replace or at COXREELS’ option to provide a refund of the sales price of any goods that do not conform to applicable specifications or which differ from that agreed to be supplied which non-conformity is discovered and forthwith reported to COXREELS within 30 days after shipment to the Buyer. COXREELS’ obligation to replace or refund the purchase price for nonconforming goods shall arise once Buyer returns such goods FOB point of original shipment by COXREELS at the risk and cost of Buyer.
Goods replaced by COXREELS shall become property of COXREELS. COXREELS liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage arising out of, connected with, or resulting from the manufacture, sale, delivery, resale, repair, replacement or use of any products or services shall in no case exceed the price paid for the product or services or any part thereof which give rise to the claim. In no event shall COXREELS be liable for consequential, special, incidental or other damages, nor shall COXREELS be liable in respect of personal injury or damage to property not the subject matter hereof unless attributable to gross misconduct of COXREELS, which shall mean an act or omission by COXREELS demonstrating reckless disregard of the foreseeable consequences thereof. COXREELS is not responsible for incorrect choice of models or where products are used in excess of their rated and recommended capacities and design functions or under abnormal conditions. COXREELS assumes no liability for loss of time, damage or injuries to property or persons resulting from the use of COXREELS products. Buyer shall hold COXREELS harmless from all liability, claims, suits and expenses in connection with loss or damage resulting from operation of products or utilization of services, respectively, of COXREELS and shall defend any suit or action which might arise there from in Buyer’s name – provided that COXREELS shall have the right to elect to defend any such suit or action for the account of Buyer. The foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer.
NOTE: All designs, specifications, and dimensional data contained in this publication are subject to change without notice.
WARNING – APPLICATION
THE PRODUCTS IN THIS INSTALLATION AND MAINTENANCE MANUAL HAVE BEEN TESTED UNDER CONTROLLED LABORAROTY CONDITIONS TO MEET SPECIFIC TEST CRITERIA. THESE TESTS ARE NOT INTENDED TO REFLECT THE PERFORMANCE OF THE PRODUCTS OR ANY OTHER MATERIAL IN ANY SPECIFIC APPLICATION, BUT ARE INTENDED TO PROVIDE THE USER WITHY APPLICATION GUIDELINES. THE PRODUCTS ARE INTENDED FOR USE BY KNOWLEDGEABLE PERSONS HAVING THE TECHNICAL SKILL NECESSARY TO EVALUATE THEIR SUITABILITY FOR SPECIFIC APPLICATIONS.
WARNING – USER RESPONSIBILITY
THE USER, THROUGH ITS OWN ANALYSIS AND TESTING, IS SOLELY RESPONSIBLE FOR MAKING THE FINAL SELECTION OF THE SYSTEM AND COMPONENTS AND ASSURING THAT ALL PERFORMANCE, ENDURANCE, MAINTENANCE, SAFETY AND WARNING REQUIREMENTS OF THE APPLICATION ARE MET.
TO THE EXTENT THAT COXREELS PROVIDE COMPONENT OR SYSTEM OPTIONS BASED UPON DATA OR SPECIFICATIONS PROVIDED BY THE USER, THE USER IS RESPONSIBLE FOR DETERMINING THAT SUCH DATA AND SPECIFICATIONS ARE SUITABLE AND SUFFICIENT FOR ALL APPLICATIONS AND REASONABLY FORESEEABLE USES OF THE COMPONENTS OR SYSTEM.
WARNING – SAFETY
  READ ALL SAFETY INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE, OR MAINTAIN THIS PRODUCT. ONLY QUALIFIED PERSONNEL SHOULD UNDERTAKE THE INSTALLATION AND COMMISSIONING OF THIS PRODUCT. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE.
FAILURE TO FOLLOW RECOMMENDED APPLICATION INFORMATION AND RECOMMENDED PROCEDURES FOR SELECTION, INSTALLATION, CARE, MAINTENANCE AND STORAGE OF REEL ASSEMBLY, SWIVEL, HOSE, COUPLINGS OR HOSE ASSEMBLIES MAY RESULT IN FAILURE TO PERFORM PROPERLY AND MAY RESULT IN DAMAGE TO PROPERTY AND SERIOUS BODILY INJURY.
FOLLOW GOOD MAINTENANCE PRACTICES – ESTABLISH A PROGRAM OF INSPECTION, TESTING AND REPLACEMENT OF REEL COMPONENTS FROM FACTORS INCLUDING: o SEVERITY OF APPLICATION, FREQUENCY OF EQUIPMENT USE, AND PAST PERFORMANCE OF REEL COMPONENTS
ONLY PROPERLY TRAINED PERSONS SHOULD INSPECT, TEST OR SERVICE REEL AND HOSE/CABLE ASSEMBLIES. PERIODIC UPDATING OF TRAINING IS RECOMMENDED. DOCUMENT MAINTENANCE, INSPECTIONS AND TESTING.
PROP 65 WARNING: Handling of brass material on this product exposes you to lead, a chemical known to the State of California to cause birth defects or other reproductive harm. “WASH HANDS AFTER USE”

SAFETY

PRESSURE WARNINGS

• This equipment should be properly installed before use in accordance with local codes and ordinances.
• The pressure from the hose reel should be disconnected from the hose reel before any service functions are performed.
• This hose reel must not be used for pressure greater that the rating listed in the COXREELS catalog / website www.coxreels.com.

OPERATIONAL WARNINGS

• Exercise care when handling the hose reel during normal operation.
• Do not use hose different from that for which the reel is intended. Changes in diameter, weight per foot, length of hose or flexibility (Minimum Bend Radius) will affect the operation of the reel.
• Mounting hardware and fasteners should be installed to maintain tightness under vibration and checked periodically to ensure tightness.
• Overhead installation mountings should be such that the reel is not supported by bolts in tension. A safety chain, cable, enclosure or netting is strongly recommended to minimize damage and/or possible injury in the event of a mounting failure.

MAINTENANCE WARNINGS

• Modification of the equipment may cause excessive wear and will void the warranty. Contact COXREELS regarding changes or modifications of equipment which could affect reliability or safety.

SPECIFICATIONS & LISTINGS

• The identified Series of Hose Reel products within this manual are not certified or listed by any independent certifying or regulatory body.
• This series of hose reels is intended for industrial use and are provided with permanent mounting means.

PRESSURE & TEMPERATURE RATING

• All reels covered in this manual with or without hose have specific P.S.I. ratings. (Please refer to the COXREELS catalog, website or contact Customer Service for Reel specific data). Reels should not be used at pressures greater that the rating of the hose.
• Multipurpose hose is installed with tube compounded for maximum oil resistance. Hose can be used for air, water, oil and many other chemical applications.
• Operational temperature ranges vary across the wide range of hose options. (Please refer to the COXREELS catalog, website or contact Customer Service for hose specific data). Hose reels should not be used at temperatures below or above the rating of the hose.
• The operational rating of a reel not equipped with hose is determined by the capacity of the installed hose. The pressure rating of the reel without hose must not be greater than the than the operational capacity of a reel. (Please refer to the COXREELS catalog, website or contact Customer Service for reel/hose specific data). Variations in the OD of higher rated hose will affect the operational capacity of the reel.

LABELS & MARKINGS
Hose Reels with and without hose

• The marking of the hose reel provide with or without hose includes the following
  o The label on the frame includes the COXREELS name and Logo, the product catalog number, the individual product serial number, PSI rating and what type and length of hose intended for use on the reel.
  o The maximum pressure rating for every hose reel supplied without house is marked on the COXREELS Identification Label. In absence of this information, refer to website, catalog, or customer service. Actual rating is determined by the installed hose and is not to exceed the indicated maximum operational rating. The pressure rating of the hose installed on reels provided without hose must be marked on the label upon installation.

PERSONAL SAFETY

• Ensure reel has been properly installed before connecting supply line.
• Before connecting to reel, be certain supply line does not exceed rated pressure of the hose reel or amperage rating on cable reel.
• Thoroughly review the “Hose Installation” instructions to properly install hose.
• Perform “Operational Check” per instructions to ensure reel is operating properly.
• If a leak should occur after applying pressure to the reel, immediately discontinue supply line pressure.
• Be aware of other persons and machinery in work area
• Do not wear loose fitting clothing when using reel
• Routinely check for loose, frayed, or broken wires before operating.

WARNING: Prevent static sparking. When working around flammables, ensure that the hose reel, hose, and equipment are properly grounded.

INSTALLATION

WARNING: READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE, OR MAINTAIN THIS PRODUCT. ONLY QUALIFIED PERSONNEL SHOULD UNDERTAKE THE INSTALLATION AND COMMISSIONING OF THIS PRODUCT. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE.
WARNING: REEL SHOULD NOT BE INSTALLED ABOVE 15 FEET MAXIMUM FROM THE FLOOR.
MOUNTING OF REEL

• Overhead installation mountings should be such that the reel is not supported by bolts in tension. A safety chain, cable, enclosure or netting is strongly recommended to minimize damage and/or possible injury in the event of a mounting failure.

• To mount reel to a solid structure use 7/16” or M12 bolts, washers, and nuts. Masonry bolts may be used depending on mounting application. Mounting hardware is NOT provided. Mounting patterns will vary depending on model.

• Fit mounting hardware to ceiling/wall/floor so reel can be fastened into position. Fit reel and tighten all hardware securely.
  INSTALLATION OF INLET HOSE

• Apply thread sealant to inlet hose and connect to the swivel joint on reel.
  CAUTION: IT IS IMPORTANT TO USE A “FLEXIBLE” INLET HOSE.
  DO NOT USE SOLID PIPING OR RESTRAIN INLET HOSE AS TO CAUSE ANY SIDE FORCE ON SWIVEL JOINT. THE WARRANTY IS VOID IF NOT PROPERLY INSTALLED.

• nstall inlet hose into swivel assembly by hand tightening, followed by ½ turn with wrench. DO NOT over tighten as it may damage swivel.

• Flush some product through the system before connecting inlet hose to the source. Connect end to supply source.
  INSTALLATION OF CABLE (1125WC SERIES)
  NOTE: Before proceeding, ensure that you are installing the proper size, length and type of hose that the reel is rated for. Consult factory if unsure of rating.
  CAUTION: ENSURE THAT THE CABLE CONNECTOR IS SECURELY CRIMPED, SOLDERED, OR CLAMPED TO CABLE.

• Place connector over stud (fig 3.0) and install brass nut (supplied).

• Using a wrench, firmly hold onto the nut under the connector while tightening the outer nut.

• Connect the supply line in the same manner.

INSTALLATION OF OUTLET HOSE
NOTE: Before proceeding, ensure that you are installing the proper size, length and type of hose that the reel is rated for. Consult factory if unsure of rating.

• Securely install hose reel prior to installing outlet hose.

• Apply thread sealant to male hose fitting and insert into the drum opening.
  Note: It is recommended that a swivel type connector be used to ease installation of outlet hose.

• Thread male hose fitting into outlet riser(s). Refer to figure 1.0 for single and figure 2.0 for double outlets. Note: Outlet riser is removable on 1195 series.

• Using a wrench, firmly hold on to riser fitting while tightening hose connector.
  CAUTION: FULLY EXTEND AND CHARGE HOSE BEFORE INITIALLY WINDING ON TO REEL. THIS PREVENTS FLATTENING OF HOSE AND EXCESSIVE PRESSURE ON DRUM WHEN HOSE IS FULLY CHARGED DURING OPERATION.

• Wind hose on to reel; operator should hand guide the hose on to reel to achieve maximum capacity.

• Flush fluid through system. Inspect hose, connections, and swivel for leaks. HOOK-UP ELECTRICAL MOTOR
  CAUTION: REMOVE ALL ELECTRICAL POWER WHEN WIRING. DO NOT HOT WIRE. OBSERVE ALL APPLICABLE NEC, OSHA, AND LOCAL CODES.

• Ensure motor location is conducive to mounting or operating requirements. Field modifications are not recommended.

• Ensure power supply and motor voltage ratings are compatible. Refer to figures 4.0, 5.0, and 6.0 for wiring diagrams.

• Install switch, solenoid, circuit breaker, etc. as required. Consult factory for optional components.

• Apply power, and inspect reel to determine proper operation.

HOOK-UP AIR MOTOR

CAUTION: DO NOT EXCEED 100 PSI MOTOR INLET PRESSURE. USE AN FRL OR CONTROL VALVE (IN LINE) TO ADJUST SPEED.

• A suitable sized filter/regulator/lubricator must be installed in the compressed air line within 3-6 ft. from the motor.

• Use pipes that are the same size as the motor ports for lengths up to 6 ft. from the main line and pipes that are larger for lengths that are longer than 6 ft. Remove plastic plugs from two ports in motor and follow steps for muffler or 4-way valve / muffler installation.

• A muffler (provided) must be connected to the outlet port on single rotation applications.

• When motor is going to be driven in both directions, a 4-way valve (not included) may be used by being connected to both ports of the motor. Muffler must then be connected to the air outlet pipe or valve port.

• Do not use thread tape to seal pipe threads. Use only the correct pipe sealant on the threads.

• This motor requires LUBRICATION. Use GAST lubricating oil part number UK5220 or equivalent. Fill reservoir to correct level.

• Apply air pressure, and inspect reel to determine proper operation.
  SWIVEL SEAL REPLACEMENT

• Remove inlet hose from swivel.

• Remove swivel from reel by unscrewing swivel from shaft. Disconnect hose from swivel.

• Remove retaining ring on swivel; pull out shaft from body.

• Replace the seals, lubricate and reassemble swivel.

• Fit hose to swivel then fit swivel to reel. Do not over-tighten.

• Reconnect inlet hose and test for leakage.

NOTE: Swivels designs vary depending on the reel model. Refer to repair procedure shipped with individual seal replacement kits or consult factory.
CAUTION: Release line pressure prior to making any repairs or adjustments to the reel.
CHAIN REPLACEMENT (1175-1195 Only)

• Remove motor as instructed. See “Motor Replacement”.
• Remove chain master-link.
• Install new chain. Adjust chain tension and install motor as instructed. See “Motor Replacement”.

MOTOR REPLACEMENT
CAUTION: Before replacing motor, remove electrical or fluid pressure from reel.

• Disconnect wiring/fluid line pressure from motor.
• Remove bolts securing motor and/or bracket to reel. See figures 7.0 or 8.0 depending on reel model.
• Install replacement motor. Align gears or chain/sprocket depending on reel model.

NOTE: 1125/1275 series are direct gear driven and 1175, 1185, 1195 & 1600 series are chain and sprocket driven.

• If gear driven reel, adjust motor into location and secure in position with best gear alignment. Noise level is noticeably higher when gear is not fully engaged.

NOTE: Improperly engaged gears will reduce gear life.
GEAR REPLACEMENT (1125/1275 Series Only)

• Remove motor as instructed above.

• Remove gear from shaft on motor by loosening set screws.

• Install new gear on to shaft. Install motor as described above.

• If chain driven reel, adjust tension on chain to allow between ¼ to ½” play in chain.
  NOTE: Over-tensioning of chain will reduce motor life.
  SLIP RING BRUSH REPLACEMENT (1125WC SERIES)

• Remove cable completely from drum of reel.

• Remove access panel on drum by removing four screws.

• Remove brush retaining nut to access worn brushes.

• Replace with new copper brushes.
  Reverse above procedure to re-assemble reel.

TROUBLE SHOOTING GUIDE

HOSE/CABLE WILL NOT FULLY FIT
ON TO DRUM OF REEL| a) Hose/cable is longer than specified.
b) Outside diameter of hose is larger than specification.
c) Hose/cable was not hand guided onto reel and wound up evenly on drum.| a) Cut down hose/cable to meet reels specified capacity.
b) Replace hose with a hose that meets the specified maximum outside diameter requirements.
c) Hand guide hose/cable on to drum as it is wound on to the reel.
IT IS VERY DIFFICULT TO PULL HOSE OFF REEL ON 115Vac REEL| Wiring for motor is reversed.| Refer to wiring diagram and correct motor wiring.
NO ELECTRICAL CURRENT AT OUTPUT END OF CABLE. (1125WC SERIES ONLY)| a) Cable is severed.
b) Slip ring brushes are worn.| a) Replace cable.
b) Replace slip ring brushes.
Note: Ensure current does not exceed rated amperage.
DRUM OF REEL IS CRUSHED OR DAMAGED.| Hose was not charged when initially installed on to reel.| Replace damaged drum. Contact factory. Install hose per instructions.
FLUID PATH (PLUMBING AND/OR
SWIVEL) IS LEAKING OR DAMAGED.| a) Maximum pressure rating for reel has been exceeded.
b) Application is not compatible with plumbing and/or swivel seal materials.| a) Replace or repair damaged components. Consult factory.
Check maximum pressure rating of reel.
b) Contact factory to determine chemical compatibility or environmental issues (i.e. temperature rating).
FLUID LEAKS FROM SWIVEL| Swivel seals are damaged or worn.| Replace swivel seals.  See “Swivel Seal Replacement”.
Caution:  Be sure leak is not at Hose Fitting!
SWIVEL ASSEMBLY IN NOT MOVING FREELY OR LOCKING UP| a) Inlet hose fitting has been over-tightened
b) Inlet hose is not flexible causing side force on swivel.| Remove and examine swivel assembly for damage. Replace as necessary.
Properly tighten inlet hose. Hand tighten fitting, plus ½ turn with wrench.

For assembly drawings, parts lists, or specific repair instructions, refer to web site at www.coxreels.com or consult factory.
Coxreels, Inc., 5865 S. Ash Ave., Tempe, Arizona, USA, 85283
Tel: 1-800-269-7335

References

• Hose, Cord & Cable Reels | Coxreels®
• Manual-Hub.com – Free PDF manuals!

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