Hosereels Electric Rewind Installation and Maintenance Manual SDM09E-Hosereel
Index Section Page 1.0 Introduction 1.1 Scope of this manual 2 1.2 Description 3 1.3 Inspection 4 2.0 Installation 2.1 Installing the hosereel 5 2.2 Connecting the hose 5 2.3 Installing the electric rewind motor 6&7 2.4 Handwheel friction brake 7 2.5 3 way brake 8 2.6 Installing ancillary devices 9&10 3.0 Operation 3.1 Deploying the hose 11 3.2 Rewinding the hose with the manual rewind handle 11 3.3 Rewinding the hose with the electric rewind motor 12 3.4 Operating ancillary devices 12 4.0 Maintenance 4.1 Monthly maintenance 13 4.2 Six monthly maintenance 13 4.3 Corrective maintenance 13 4.3.1 Adjusting the 3 way brake 13 4.3.2 Cleaning or replacing the centrifugal clutch shoes 14 4.3.3 Removing the centrifugal clutch from motor 14 4.3.4 Removing / replacing the electric rewind motor 15 4.3.5 Replacing the motor brushes 16 4.4 Swingjoint / fluid path assemblies 17 4.5 Problem solving 20 Appendices 1 Layout drawing of hosereel with electric rewind motor 21 2 ¾ and 1 fluid path layouts 22 3 ¾, 1 and 1¼ Swingjoint assemblies 23 4 1½ Swingjoint / fluid path assemblies 24 5 2 Swingjoint / fluid path assemblies 25 Figures Tables 1 Typical hosereel with electric rewind motor 2 Lifting the hosereel 3 Typical wiring diagram 4 Handwheel friction brake 5 3 - way brake position 6 Fixed roller guides 7 Hinged roller guides 8 Earth continuity device 9 Swing out platform 10 Alternative clutch shoe positions 11 Typical swingjoint / fluid path assembly (1½ and 2 ) 1 Electrical data 2 Problem solving SDM09E-Hosereel Page 1
1.0 INTRODUCTION 1.1 Scope of this manual WARNING CAUTION WARNINGS ARE GIVEN WHERE FAILURE TO OBSERVE THE INSTRUCTION COULD RESULT IN INJURY TO PERSONNEL. Cautions are given where failure to observe the instruction could result in damage to the equipment or associated equipment. This manual provides the end-user of Collins Youldon hosereels with full details of the equipment, its installation, use, maintenance and basic repair / spares information. Proper installation and regular maintenance is essential for long and trouble free use. In the unlikely event of any operational problem, or for the supply of spare parts, and any technical or usage queries please call our Sales Office on 01480 832200 and they will be pleased to help. As soon as you take delivery of a hosereel, please complete the boxes below. This will enable us to respond quickly to any enquiry. A The serial number and model number of the reel from the plate on the cross stay at the front of the hosereel. B The nominal width of the hosereel drum (measured between the drum disks) 203mm 305mm 406mm 457mm 508mm 610mm 711mm 813mm C The diameter of the drum disks 432mm 482mm 508mm 584mm 736mm D Rewind motor Electric 12Vdc / 24Vdc 1-PH / 3PH AC E F Internal diameter of the fluid path Date of purchase 19mm 25mm 32mm 38mm 51mm ¾ 1 1¼ 1½ 2 Collins Youldon has a policy of continual product improvement, and reserves the right to modify the design, or materials used, at any time in the future. SDM09E-Hosereel Page 2
1 Drum assembly 2 Drive gears and chains 3 Centreshaft inlet connection 4 Frame 5 Electric motor 6 Hose roller guides (if fitted) 7 Idler reduction gear / 3-way brake 8 Serial number plate 10 Swingjoint 11 Flexible connection Figure 1 Typical hosereel with electric rewind motor (For more details of individual parts refer to Appendix 1) 1.2 Description 1.2.1 The basic hosereel consists of a centrally positioned drum assembly supported by two bearings on the frame of the hosereel, see figure 1. 1.2.2 The hose may be rewound manually with a cranked handle or by the electric motor. The emergency crank rewind shaft operates a crown wheel and pinion set at 90 degrees or 25 degrees to the hosereel front. All hosereels with electric rewind motors are fitted with a centrifugal clutch which provides protection to personnel and to the motor in the event of a hose snag during rewind. 1.2.3 The main frame of the hosereel is made up of two end plates joined by two tie plates. The swingjoint and gooseneck assembly are positioned at one end of the hosereel. The rewind mechanism may be at either end of the drum assembly. The gooseneck, depending on the size of the fluid path, may be an integral part of the centre shaft or use separate castings. 1.2.4 This manual describes Collins Youldon hosereels with electric motor rewind. Other types of hosereel include: manual rewind, hydraulic motor rewind, air motor rewind, and the HR30 series of catherine reels with various power rewind options. There is a separate manual for each type. 1.2.5 All hosereels are supplied powder painted in a range of standard colours, or in grey primer epoxy powder coat finish for painting to individual customer requirements. Alternatively they can be galvanised or supplied in stainless steel. 1.2.6 Collins Youldon inspect and test all parts of the hosereel fluid path before despatch. SDM09E-Hosereel Page 3
1.3 Inspection 1.3.1 Remove all packaging materials and inspect the hosereel on receipt. If there is any damage, please notify your supplier and the carrier in writing within 3 days, stating the serial number of the hosereel and your order number. 1.3.2 If the hosereel is received undamaged, packaging materials may be disposed of in accordance with local Environmental Health and Safety regulations. 1.3.3 The total weight of the hosereel requires more than one person to lift or move it and in some installations lifting equipment may be required. Lifting instructions are given below. WARNING THE CENTRE OF GRAVITY IS NOT QUITE CENTRAL TO THE HOSEREEL AND MUST BE DETERMINED BEFORE LIFTING. WE RECOMMEND THAT A MINIMUM OF TWO PERSONS ASSIST DURING THE MOVEMENT OR INSTALLATION OF THE HOSEREEL. CAUTIONS 1 The centre of gravity is not central to the hosereel; we recommend that a minimum of two persons assist during the movement or installation. 2 The hosereel must only be lifted by the drum (as shown below), or by the frame. Figure 2 - Lifting the hosereel SDM09E-Hosereel Page 4
2.0 INSTALLATION CAUTIONS 1 Care must be taken to avoid distortion of the frame when fitted. 2 Care must be taken not to exert undue force on the swingjoint when the inlet connection is made. 3 The inlet connection to the hosereel must be through a flexible hose. 4 Care must be taken to protect the gears, bearings and chains from dirt and water. 5 The maximum working pressure marked on the serial number label must not be exceeded. 6 Check that the minimum bend radius of the hose is compatible with the diameter of the drum of the hosereel. The drum diameter should be twice the minimum bend radius. 7 If the installation is such that transmission parts are exposed, then additional guarding may be required. 2.1 Installing the hosereel 2.1.1 Bolt the hosereel frame onto a flat, firm surface. A distorted frame will affect the mesh of the rewind gears. We recommend the use of four flexible mounting pads to minimise distortion. Where a hosereel is supplied without a frame it is essential that the mounting is square and the rewind gears are correctly aligned. Do not bridge the hosereel frame across two separate chassis rails. 2.1.2 Fully engage the manual rewind handle to make sure that there is sufficient space around the hosereel for rotation of the handle. 2.1.3 The inlet connection to the swingjoint must be through a flexible hose. Make sure that the hose is flexible enough to avoid strain or twisting and does not exert any side load on the swingjoint 2.1.4 External swingjoints are loosely fitted to the hosereel for transport purposes. These must be removed and refitted using an appropriate thread sealant. 2.1.5 To protect the gears, bearings and chains from dirt and water, install vehicle mounted hosereels in a cabinet wherever possible. As a minimum, a splashguard should be fitted to protect the reel from spray from the road wheels. 2.1.6 Allow sufficient space around the hosereel so that it can be easily serviced and maintained. 2.2 Connecting the hose 2.2.1 When using the hosereel for hose with an inside diameter of 38mm (1½ ) or 50mm (2"), the gooseneck should be removed. Fit the hose to the gooseneck and then refit the gooseneck to the hosereel. When refitting the gooseneck, ensure that the gooseneck/spindle seal is correctly positioned in the groove in the centre spindle. 2.2.2 If the hose is too close to the drum at the gooseneck connection point, the drum may be dished locally with a hide mallet. No harm will be done and the hose should then be a snug fit with a smooth profile around the drum. SDM09E-Hosereel Page 5
2.3 Installing the electric rewind motor WARNINGS 1 A COMPETENT ELECTRICIAN MUST DESIGN AND INSTALL THIS ELECTRICAL INSTALLATION. (DC motors require a 2-cable connection directly from the supply). 2 THIS PRODUCT MAY BE COVERED BY EC LEGISLATION. PLEASE REFER TO THE DOCUMENTATION SUPPLIED WITH THE HOSEREEL. THERE MAY BE ADDITIONAL LOCAL LEGISLATION WHICH MUST ALSO BE FOLLOWED. 3 A CURRENT OF 100 milliamps PASSING THROUGH THE HUMAN BODY FOR ONE SECOND CAN KILL. THIS CAN OCCUR AT VOLTAGES AS LOW AS 35V AC OR 50V DC. NOTE (i) Motor supply cables must be large enough to carry the current requirement of the motor. (ii) Motor overload protection must be fitted (circuit breaker with anti surge fuse). (iii) For safety, the switch should be spring return type. 2.3.1 Connect the hosereel to a suitable electrical supply as follows; switch off or isolate the power supply and complete the electrical installation as shown in the wiring diagram, figure 3. WARNINGS 1 BEFORE YOU CONTINUE WITH THE INSTALLATION SEQUENCE MAKE SURE THAT ALL OTHER PERSONS ARE STANDING AWAY FROM THE HOSEREEL. 2 MAKE SURE THAT GUARDS ARE CORRECTLY FITTED BEFORE PROCEEDING. 3 CHECK THAT THE CENTRIFUGAL CLUTCH WILL SLIP TO PROTECT THE OPERATOR IN CASE OF HOSE SNAG. CAUTIONS 1 Make sure that there are no tools or other objects on the surface of the hosereel. 2 Energise the power supply and check the direction of rotation of the drum. For DC motors, this can be changed by reversing the motor supply cables. For AC motors, refer to wiring diagram in terminal box. 3 Ensure that all cable entry points are sealed to prevent the ingress of moisture. NOTE: DC motors are not continuously rated and should only be energised to rewind the hose. Motor M Operators Control Box Motor Switch Solenoid Overload Protection (see Table 1) 5 AMP Fuse Ignition Switch Master Switch Figure 3 - Typical wiring diagram for a dc motor SDM09E-Hosereel Battery Page 6
Table 1 - Electrical Data Motor voltage Full load current Minimum cable size 12V dc 2/3 hp 75 amp (15 mm 2 ) 24V dc 2/3 hp 38 amp (6 mm 2 ) 12V dc 1/3 hp 35 amp (6 mm 2 ) 24V dc 1/3 hp 18 amp (2.5 mm 2 ) 230V ac ½ hp 3.6 amp (0.75mm 2 ) 415V ac ½ hp 1.2 amp (0.5mm 2 ) Note: These sizes allow for a cable length of approximately 7 metres and a voltage drop of 5%. 2.4 Handwheel friction brake 2.4.1 This brake is fitted to most hosereels as standard. Other types of brake are detailed in sections 2.5. 2.4.2 Rotating the handwheel clockwise will increase the strength of the brake. The brake should be partially released when deploying the hose, whilst still providing sufficient friction to prevent overrun of the drum. To rewind the hose the brake should be released further. When the hose is stored the brake should be fully tightened to ensure that the drum cannot rotate during transit. 12 TEETH 7700.0R.A 90 RH HANDWIND 90 LH HANDWIND 7700.0L.A SWING COVER SIDEWAYS TO GAIN ACCESS TO REWIND SHAFT 26 REWIND LH ANGLED 7705.0L.A RH ANGLED 7705.0R.A Figure 4 Handwheel friction brake SDM09E-Hosereel Page 7
2.5 3-way brake This brake may be factory-fitted to any Collins Youldon hosereel. Locked position (1) Braked position (2) Rewind position (3) The brake is fully applied. This position should be selected during transit or when the hose is in use if a positive lock on the drum is required. The brake is partially applied in order to control the drum during deployment of the hose. The brake is not applied. This position should be selected when the hose is being rewound. 2.5.1 To adjust the strength of the brake: 2.5.1.1 Move the brake lever to the rewind position. 2.5.1.2 Apply sufficient pressure to the end of the brake rod so that the spring compresses and allows the nut to rotate. Tighten the nut to increase braking or loosen the nut to decrease the strength of the brake. 2.5.1.3 The adjustments should be made gradually. After each adjustment, put the brake lever to the braked (middle) position and test the efficiency of the brake. The brake should be fully locked when the lever is in the locked position. 1 LOCK 1 LOCK 2 BRAKE 2 BRAKE 3 REWIND 3 REWIND Brake at non-inlet end Brake at inlet / drive end Figure 5-3-way brake SDM09E-Hosereel Page 8
2.6 Installing ancillary devices Additional equipment may have been supplied with the hosereel. This may include but not be limited to the following: 2.6.1 Fixed 4 way roller guides These are designed to reduce hose wear. Make sure that the hose will run smoothly off the hosereel drum and between the rollers. 4 - WAY TOP FIXED ROLLER GUIDES 4 - WAY FRONT FIXED ROLLER GUIDES 2.6.2 Hinged roller guides Figure 6 Fixed roller guides These are designed to reduce damage to cabinet door seals and bodywork. Where indicated they are supplied as a separate kit item with full installation instructions. ROLLERS HINGED BACK FOR STORAGE ROLLERS HINGED OUT FOR DEPLOYMENT ROLLERS HINGED BACK FOR STORAGE Plan View ROLLERS HINGED OUT FOR DEPLOYMENT TOP TILT OUT ROLLER GUIDES FRONT HINGE OUT ROLLER GUIDE KIT Figure 7 Hinged roller guides 2.6.3 Inverted Mounting Kit If the hosereel is to be mounted upside down an inverted mounting kit must be factory-fitted. The installation must be adequate for the weight of the hosereel, hose and product. Collins Youldon hosereels are not designed for mounting on a vertical surface. SDM09E-Hosereel Page 9
114mm [1 1/2"] 2.6.4 Earth Continuity Device Where an earth continuity device is fitted to the hosereel the installer must provide a continuity path as appropriate. 4.7mm PLASTIC BEARING. FRAME. Figure 8 Earth continuity device 2.6.5 Swing out platforms The installer must provide rigid mounting points for the bearings. Support will also be required under the end of the platform when it is in the parked position. PLAN VIEW SEE DETAIL OF MOUNTING PAD 114mm [1 1/2"] 4 HOLES Ø14.3mm [9/16"] Figure 9 Swing out platform 2.6.6 Remote rewind If the hosereel is supplied with remote rewind adequate guarding must be fitted to all moving parts and the rewind mechanism must be correctly aligned. SDM09E-Hosereel Page 10
3.0 OPERATION WARNINGS 1 ALL PERSONS ARE TO COMPLY WITH THE INSTALLERS INSTRUCTIONS AND ANY LOCAL LEGISLATION OR HEALTH AND SAFETY REQUIREMENTS. 2 MAKE SURE ALL GUARDS ARE CORRECTLY FITTED BEFORE PROCEEDING. 3.1 Deploying the hose 3.1.1 Make sure that the manual rewind handle is removed and the brake is correctly set, section 2.4. If roller guides are fitted please refer to section 3.4. 3.1.2 The operator should pull the hose from the hosereel with a smooth even movement. 3.1.3 The centrifugal clutch allows the hosereel drum to rotate without turning the motor. 3.1.4 Motors should not be used to deploy the hose. 3.2 Rewinding the hose with the manual rewind handle WARNINGS 1 IF A HOSE ROLLER GUIDE IS FITTED, TAKE CARE NOT TO TRAP HANDS BETWEEN THE HOSE AND THE ROLLERS. 2 BEFORE COMMENCING THE REWIND OPERATION, MAKE SURE THAT ALL OTHER PERSONS ARE STANDING AWAY FROM THE HOSEREEL AND THE HOSE. CAUTIONS 1 Ensure that there are no tools or other loose objects near the hose or hosereel. 2 If the hose snags or the rewind seizes do not force the handle to turn, this may cause the teeth on the gears to jump, become damaged, or distort the frame. 3 When rewinding the hose, do not drag the nozzle along the ground. 3.2.1 Return the nozzle to a position adjacent to the hosereel. 3.2.2 Swing open the handwind cover and fit the manual rewind handle to the slotted drive shaft on the front of the hosereel. 3.2.3 Check that the brake is correctly set to allow free rotation of the drum, section 2.4. 3.2.4 Check the direction of rotation and turn the rewind handle, using gloved hands to guide the hose evenly across the drum of the hosereel. 3.2.5 When all the hose has been rewound onto the drum, set the brake to prevent the hosereel from turning. 3.2.6 Finally, ensure that the nozzle and rewind handle are stored safely and the handwind cover is swung closed. SDM09E-Hosereel Page 11
3.3 Rewinding the hose with the electric rewind motor 3.3.1 Observe the warnings and cautions under section 3.2 above. 3.3.2 Bring the nozzle to a position adjacent to the hosereel. 3.3.3 Make sure the manual rewind handle is not fitted and the brake is correctly set, section 2.4. 3.3.4 Activate the motor switch to start the rewind operation. Allow the hose to run freely between gloved hands and guide it evenly across the drum of the hosereel. 3.3.5 In the event of an emergency switch off the motor. If the hose snags during rewind the clutch will slip if correctly set, see section 4.3.2.6. 3.3.6 When the hose is almost completely rewound, switch off the motor. 3.3.7 Activate and release the motor switch as required to rewind the remainder of the hose onto the drum. 3.3.8 When all the hose has been rewound on to the drum, set the brake to prevent the hosereel drum turning. 3.3.9 Finally, ensure that the nozzle is stored safely. 3.4 Operating ancillary devices 3.4.1 Fixed 4 way roller guides The hose should be fed smoothly between the roller guides when deploying and rewinding. Care must be taken not to trap hands between the rollers. 3.4.2 Hinged roller guides Before deploying the hose, the roller guide(s) should be swung into the open position. After use, and when the hose has been fully rewound, the rollers must be returned to the parked position 3.4.3 Top tilt out roller guides 3.4.3.1 To deploy the rollers first operate the latches at each end before pulling forward the rollers. In the case of inverted hosereels a pull wire is provided to operate both levers simultaneously. Ensure the levers return to the latched position before deploying the hose. 3.4.3.2 After rewinding of the hose return the rollers to the parked position by unlatching both levers prior to pushing the rollers back. Ensure the levers return to the latched position. NOTE: DO NOT push the rollers to the parked position without first operating the levers, this may cause irreparable damage. 3.4.4 Swing out platforms The spring bolt should be released and the platform opened to the required position, securing with the appropriate spring bolt. After use the platform should be returned to the parked position and secured with the spring bolt. Depending on the installation, there may be additional instructions which should be followed. SDM09E-Hosereel Page 12
4.0 MAINTENANCE WARNINGS 1 BEFORE PROCEEDING, ISOLATE THE POWER SUPPLY TO ALL POWER REWIND HOSEREELS 2 A HOSE THAT LEAKS COULD CAUSE INJURY TO THE OPERATOR. 3 SPECIAL CARE IS REQUIRED WHEN CARRYING OUT MAINTENANCE OR REPAIR WORK ON INVERTED HOSEREELS. CAUTIONS 1 A weak hose could swell under pressure and could cause damage to the drum. 2 Where there is surface contamination of the hose and reel i.e. road traffic grime, or frequent hosing down, the reel may need to be greased more frequently than suggested. 4.1 Monthly maintenance 4.1.1 Grease the drum bearings and the spindle of the rewind mechanism through the grease nipples. 4.1.2 Lubricate the drive chain sparingly (if fitted). Do not contaminate the friction shoes of the brake. 4.1.3 Release the brake and check the reel for easy rotation. 4.1.4 Check the hose for damage and deterioration. Inspect for any swelling under pressure. 4.1.5 If fitted, check that the Earth Continuity Device is functioning correctly. 4.2 Six-monthly maintenance 4.2.1 Check that all fasteners are tight. 4.2.2 Check for excessive free side to side movement of the drum between the bearings on the frame. If necessary, adjust the position of the support bearing at the opposite end of the drum to the rewind assembly. 4.2.3 Remove the plastic guard and check the alignment of the handwind gear pinion and crown wheel. If adjustment is required, re-position the handwind spindle bracket and lubricate the gear teeth with grease. Make sure the nyloc nuts are tightened to at least 53Nm [40lb ft] and refit the guard. 4.2.4 Check the tension of the drive chain(s) over one complete revolution of the hosereel drum. Allow 12mm (+/-6mm) total side movement of chain at the midway position. Adjust as required by moving the rewind motor mounting plate. Lubricate the chain with a suitable lubricant. 4.3 Corrective maintenance 4.3.1 Adjusting the 3-way brake (if fitted) For full information on the 3-way brake see section 2.5. To adjust the strength of the brake: 4.3.1.1 Move the brake lever to the rewind position. 4.3.1.2 Apply sufficient pressure to the end of the brake rod so that the spring compresses and allows the nut to rotate. Tighten the nut to increase braking or loosen the nut to decrease the strength of the brake. 4.3.1.3 The adjustments should be made gradually. After each adjustment, put the brake lever to the braked (middle) position and test the efficiency of the brake. The brake should be fully locked when the lever is in the locked position. SDM09E-Hosereel Page 13
4.3.2 Cleaning or replacing centrifugal clutch shoes 4.3.2.1 Isolate the electrical supply. Check that the supply cable is long enough to allow the motor to be moved away from the hosereel frame. 4.3.2.2 Slacken the four motor mounting bolts and the four bolts on the idler reduction gear bracket. Remove the chain from the sprocket on the clutch and lift the motor and clutch away from the hosereel frame. 4.3.2.3 Remove the circlip from the end of the hub of the clutch and remove the clutch drum. Take care to retain any shims between the hub and the drum. 4.3.2.4 Remove the springs from the friction shoes. 4.3.2.5 Remove the shoes from the hub. If the shoes are contaminated with oil, wash the shoes and the hub in paraffin or a solvent type brake cleaner. The shaft of the clutch should be lightly lubricated with a dry lubricant such as Copaslip. Clutches with bronze bearings may be lightly oiled, but do not over lubricate, this may contaminate the shoes in service. 4.3.2.6 Reassemble the clutch with the shoes in the required position, figure 10. WARNING WE DO NOT RECOMMEND SETTING THE CLUTCH TO POSITION 1 AS THE TORQUE TRANSMITTED DOES NOT AFFORD SUFFICIENT PROTECTION TO OPERATOR OR MOTOR. 4.3.2.7 Refit the motor to the frame, adjust the tension of the drive chains, the long one first (drum to idler), tighten the idler bracket bolts, then the short one (idler to motor), and tighten the motor mounting bolts. The tension of the chains should have 12mm (+/-6mm) total side movement at the midway position. 4.3.2.8 The new clutch must be bedded-in by switching on the motor, engaging the clutch and preventing the hosereel from rotating by pulling back on the hose. This will allow the clutch faces to rub together. On a new clutch this operation should achieve maximum torque after approximately two minutes. Occasionally it may require up to 4 minutes. DO NOT exceed this time as motors are not continuously rated and to do so could damage the motor beyond repair. The motor should be allowed to cool every 30 seconds or so. NOTES 1 The clutch may be assembled with the shoes located in one of four alternative positions on the clutch hub. Each position gives the clutch different engagement and drive characteristics. The choice of clutch setting depends upon the types of equipment being driven and the bore/length of the hose). 2 Position 1 is the strongest setting. The direction of rotation is important (see arrows on figure 10 as viewed from the motor into the open side of the clutch). 4.3.3 Removing the centrifugal clutch from the motor 4.3.3.1 Remove the circlip from the end of the hub of the clutch and remove the clutch drum. Take care to retain any shims between the hub and the drum. 4.3.3.2 Use a hexagon key to loosen the two grub screws in the hub. 4.3.3.3 Ease the hub from the motor shaft. If the hub is tight, try driving a wedge (screwdriver blade or similar) between the hub and the motor boss. Take care not to lose the Woodruff key. 4.3.3.4 When re-fitting apply anti-seize compound to the motor shaft ensure the chain is correctly aligned. SDM09E-Hosereel Page 14
DIRECTION OF VIEW CLOCKWISE Position 1 Position 2 Position 3 Position 4 (Strongest) (Factory normal setting) (Weakest) ANTI-CLOCKWISE Position 1 Position 2 Position 3 Position 4 (Strongest) (Factory normal setting) (Weakest) Figure 10 - Alternative clutch shoe positions 4.3.4 Removing / replacing the electric rewind motor 4.3.4.1 Isolate the electrical supply. Disconnect the supply to allow the motor to be moved away from the hosereel frame. 4.3.4.2 Slacken the four motor mounting bolts and the four bolts on the idler reduction gear bracket. Remove the chain from the sprocket on the clutch and lift the motor and clutch away from the hosereel frame. 4.3.4.3 Remove the clutch as detailed in 4.3.3 SDM09E-Hosereel Page 15
4.3.4.4 Ensure that the voltage of the replacement motor is the same as the motor being removed, by referring to the rating plates of both motors. 4.3.4.5 Refit the clutch as detailed in 4.3.3 4.3.4.6 Refit the motor to the frame, adjust the tension of the drive chains, the long one first (drum to idler), tighten the idler bracket bolts, then the short one (idler to motor), and tighten the motor mounting bolts. The tension of the chains should have 12mm (+/-6mm) total side movement at the midway position. 4.3.5 Replacing the motor brushes WARNING THIS WORK SHOULD BE CARRIED OUT BY A COMPETENT ELECTRICAL TECHNICIAN. 4.3.5.1 Remove the motor and clutch as detailed in 4.3.4 and 4.3.3, and then proceed as follows. 4.3.5.2 Mark the position of the endplates to the stator body so that the relative positions can be aligned on reassembly. Undo the 4 long bolts that hold the two motor endplates together. WARNING THE MOTOR USES POWERFUL PERMANENT MAGNETS IN ITS CONSTRUCTION. ON REMOVAL OF THE ARMATURE FROM THE STATOR THERE WILL BE A FORCE PULLING THE ARMATURE BACK INTO THE STATOR. KEEP FINGERS AWAY FROM THE GAP BETWEEN ENDPLATE AND STATOR BODY TO PREVENT FINGER CRUSHING. 4.3.5.3 Carefully pull off the endplate at the shaft end, then the outer stator barrel from the armature and opposite endplate. 4.3.5.4 The brushes will be found inside the endplate with the cable entry. Withdraw the brushes from their holder by pulling back the spring then the brush. The armature should now be checked. Ensure the commutator is smooth and clean. If necessary dress it lightly/carefully with fine wet and dry emery paper. Check there is no build up of metal or carbon between each segment, clean out with a sharp edge if necessary, taking care not to scratch the faces of the segments. 4.3.5.5 Fit the new brushes in the rocker housing and withdraw them clear of the inside face and hold them in this position using the springs against the side of each brush. Ensure they will clear the commutator on re-assembly. 4.3.5.6 Lay the endplate flat on the bench, check the brushes are still clear, and insert the armature, commutator end first, into the endplate. Ensure the shaft/bearing are fully home in the endplate. 4.3.5.7 Release the springs, gently push the brushes into their holders and replace the springs on the end of the brushes to hold them in place against the commutator. WARNING KEEP FINGERS AWAY FROM THE GAP BETWEEN ENDPLATE AND STATOR BODY TO PREVENT FINGER CRUSHING 4.3.5.8 Fit the stator barrel over the armature, keeping fingers clear of the space between endplate and stator. The two parts will snap together. 4.3.5.9 Fit the opposite endplate over the shaft extension and ensure both endplates are full engaged into the stator barrel. Check the position of the endplate with the cable entry is re-aligned by reference to the previously added marks. 4.3.5.10 Re-fit the 4 fixing bolts, align the shaft end endplate with the cable entry endplate and tighten them evenly and securely. 4.3.5.11 Re-fit the clutch to the motor and the motor to the frame as detailed in 4.3.3 and 4.3.4. SDM09E-Hosereel Page 16
4.4 Swingjoint / Fluid Path Assemblies Collins Youldon hosereels have two basic type of swingjoint / fluid path assembly. ¾, 1 and 1¼ swingjoints are external to the hosereel, see appendix 3 for more detail. These swingjoints can be replaced or serviced without removing the delivery hose from the reel. 1½ and 2 fluid paths are formed from several cast items, see figure 12 and appendices 4 and 5. The inlet and seals of these assemblies can be easily replaced without removing the delivery hose from the reel; however replacement of the spindle and/or shaft will require removal of the drum from the frame. Leaking product may be due to a worn inlet seal or component. The inlet seal may need occasional replacement but if the hosereel frame is twisted this will lead to irregular wear of swingjoint components. Before replacing worn parts ensure that the frame alignment is correct, see Installation section 2.1.1 and contact our Sales Department for advice. 4.4.1 Replacing swingjoint seals ¾, 1 and 1¼ hosereels Equipment A pair of external circlip pliers and 2 new seals. 4.4.1.1 Drain the hose and if necessary remove the inlet hose.. 4.4.1.2 Remove the circlip and washer from the end of the stem and pull off the sleeve. 4.4.1.3 Remove the seals inside the sleeve, as you pick the seals out take care not to scratch the bottom of the groove where the seals fits. 4.4.1.4 Wipe all the parts clean, fit new seals into the grooves, put the sleeve back on the stem. 4.4.1.5 Refit the washer and circlip. Replace the inlet hose if it was removed at 4.4.1.1. 4.4.2 Replacing the swingjoint -¾, 1, 1½ LPG and 1½ high pressure hosereels 4.4.2.1 Disconnect the flexible hose from the swingjoint. 4.4.2.2 Disconnect the swingjoint from the hosereel. 4.4.2.3 Fit the new swingjoint to the hosereel using an appropriate thread sealant. 4.4.2.4 Reconnect the flexible hose to the swingjoint using an appropriate thread sealant and check for leaks. 4.4.3 Replacing Inlet o-ring or Chevron seal in 1½ and 2 swingjoints Equipment: 13mm A/F spanner and a new seal (check type is correct for your model of hosereel). 4.4.3.1 Drain the delivery hose and remove the inlet hose from the hosereel inlet. 4.4.3.2 Remove the 3 bolts and shakeproof washers securing the inlet and pull off the inlet to expose the seal. 4.4.3.3 Remove the old seal from the end of the spindle, taking care not to scratch any of the sealing faces. 4.4.3.4 Wipe all parts clean and fit the new seal. O-ring seals locate into the groove on the spindle, chevron seals locate in the inlet. 4.4.3.5 Apply a little grease to the mating parts of the seal and carefully push the inlet back into position, locate with the 3 bolts previously removed, taking care not to damage the seal. 4.4.3.6 Refit 3 bolts and tighten firmly, reconnect the hose to the inlet using an appropriate thread sealant and check for leaks. SDM09E-Hosereel Page 17
NOTE: If leakage still occurs after replacement of the seals it is possible that other components of the swingjoint are worn and may need replacement. Please identify your hosereel, see section 1.1 and contact our Sales department for further assistance. 2 6 4 3 1 5 Figure 12 Typical swingjoint / fluid path assembly (1½ and 2 ) Key to parts 1 Spindle 2 Gooseneck 3 Bearing housing 4 Inlet 5 Shaft 6 Chevron seal (or o-ring see appendix 4 and 5) 4.4.4 Replacing the gooseneck or seal in 1½ and 2 swingjoints Equipment: 17mm A/F spanner, suitable tools for removing and re-fitting the delivery hose, thread sealant and 1 new seal (check type is correct for your model of hosereel). 4.4.4.1 Drain the delivery hose and fully unwind it from the drum. Remove the two bolts and shakeproof washers which secure the gooseneck (still attached to the delivery hose), noting the orientation of the gooseneck for future use. 4.4.4.2 If replacing the gooseneck remove it from the delivery hose taking care not to damage/crush the gooseneck when removing the hose. Connect the delivery hose to the new gooseneck using suitable tools and thread sealant as required. Take care not to damage/crush the gooseneck when fitting the hose. 4.4.4.3 Remove the seal from inside the groove, taking care not to scratch the bottom of the o-ring groove. 4.4.4.4 Wipe all parts clean, fit new seal into groove and refit gooseneck holding down with the two bolts removed at 4.4.4.1 and check for any leaks from the fluid path. SDM09E-Hosereel Page 18
4.4.5 Replacing the inlet or seal of 1½ and 2 swingjoints 4.4.5.1 Drain the delivery hose and remove the inlet hose from the hosereel inlet. 4.4.5.2 Remove the 3 bolts and shakeproof washers securing the inlet and pull off the inlet to expose the seal. Wipe all parts clean and if required fit a new seal into the inlet. 4.4.5.3 Apply a little grease to the mating parts of the seal and carefully push the inlet back into position, locate with the 3 bolts previously removed, taking care not to damage the seal. 4.4.5.4 Refit 3 bolts and tighten firmly, reconnect the hose to the inlet and check for leaks. 4.4.6 Replacing the bearing housing of 1½ and 2 swingjoints Equipment 2 x 13mm A/F spanners. 17mm A/F spanner. Flat bladed screwdriver. Suitable equipment to lift/support the hosereel drum. Suitable tools for removing and refitting the inlet hose. Thread sealant. 4.4.6.1 Drain the delivery hose and, if the hosereel has a rewind motor, isolate the power supply. 4.4.6.2 To reduce the weight of the drum to be supported during bearing replacement, unwind the delivery hose fully from the drum. 4.4.6.3 If the hosereel has power rewind, remove the chain guard. 4.4.6.4 Slacken the chain fully by loosening the 4 bolts on the drive unit mounting flange and moving the drive unit towards the centre of the frame. 4.4.6.5 Support the drum, using appropriate equipment and remove the 3 bolts and shakeproof washers securing the inlet to the bearing housing, and remove the inlet. 4.4.6.6 Remove the 2 bolts and shakeproof washers which connect the two halves of the bearing housing and lift off the top of the bearing housing. 4.4.6.7 At the opposite end of the drum, remove the bolts securing the bearing to the top of the hosereel frame, lift the hosereel drum away from the frame assembly and set aside carefully to avoid damage to the end disks. 4.4.6.8 Remove the nuts and shakeproof washers, which secure the bottom half of the bearing housing to the top of the hosereel frame. Remove the old part and replace with the new component. Refit the nuts and shakeproof washers and tighten. 4.4.6.9 Lower the drum into place, at the opposite end of the drum, refit the bolts securing the bearing to the top of the hosereel frame, and tighten. Fit the new bearing housing top, refitting and tightening the two bolts and shakeproof washers. 4.4.6.10 Refer to section 4.4.3 regarding replacement of the inlet seal (and the two types of seal that may be fitted). 4.4.6.11 Apply a little grease to the mating parts of the seal and put the inlet in position, locating with the 3 bolts and shakeproof washers. If the spindle has the o-ring type seal, take care not to damage the o-ring when positioning the inlet. 4.4.6.12 Tighten the 3 bolts evenly until secure and reconnect the inlet hose to the inlet using thread sealant as required. 4.5.6.13 If the hosereel has a chain drive, re-tension the chain by moving the motor mounting plate until there is 12mm (+/-6mm) total side movement of the chain at the mid-point in its tightened position. Check the tension of the chain over one complete revolution of the drum. Once this has been achieved, tighten the 4 drive unit fixing bolts. SDM09E-Hosereel Page 19
4.4.6.14 Refit the chain guard. 4.4.6.15 Check the reel turns freely when the hose is pulled out. If necessary adjust the brake as described in section 2.4. 4.4.6.16 Fit the rewind handle (or re-connect the rewind power supply) and check that the rewind operation works correctly, ensuring the gears are correctly meshed and running smoothly and check for any leaks in the fluid path. 4.5 Problem Solving Table 2 - Problem solving Problem Possible fault Corrective action The handwind brake is engaged. Release handwind friction brake, section 2.4 a. Drum does not rotate easily. The drum bearings are not lubricated. Apply grease to grease nipples. The drive chains are too tight. The frame was twisted when mounted. Rewind gears are not meshed correctly. b. Rewind is weak Supply cable connections loose. Cable size insufficient for load. Motor voltage is less than stated. The clutch does not engage. Loosen the tension so that there is 13mm total side movement at the midway position. Check that the sprockets are correctly aligned. Loosen mounting bolts, place packing piece under one corner of the frame and retighten bolts, see section 2.0 Contact Collins Youldon for advice. Make sure connections are tight. Check size against details in Technical Data, see section 2.0 Measure voltage at motor terminals, when motor is running full load. If voltage is less than 90% of nominal the motor speed will be reduced. Check for moisture in the electrical system. Check that motor speed is 700 rpm or higher, less than 650 rpm the clutch will not engage. Make sure that the clutch shoes are not contaminated with oil, clean as instructed in section 4.3.2 Drum friction slows motor speed, check causes as for (a). SDM09E-Hosereel Page 20
M10 NYLOC NUT DRUM HUB GREASE NIPPLE 1 1/16" PLASTIC BEARING ROLLER CORNER BLOCK ROLLER INSERT SHORT ROLLER TUBE SHORT ROLLER SPINDLE NARROW ROLLER BRACKET LONG ROLLER SPINDLE LONG ROLLER TUBE WIDE ROLLER BRACKET DRUM DISK DRUM TIE ROD CENTRESHAFT FRAME DRUM DISK SPACER 120T SPROCKET MOTOR STUD PLATE SPROCKET SPACER/NUT SPROCKET/C.WHEEL SPACER CROWNWHEEL PLASTIC GUARD LUBRICATOR KIT 42mm ALUMINIUM BEARING MOTOR SPACER ELECTRIC MOTOR SWINGJOINT SLEEVE 'O'RING SWINGJOINT STEM CIRCLIP WASHER IDLER GUARD IDLER STUD PLATE SHAFT GUARD HANDWIND COLLAR SINGLE STUD PLATE IDLER GUARD EXTENSION IDLER SPINDLE IDLER BRACKET HANDWIND BRACKET YOKE CIRCLIP WASHER PINION & SHAFT HANDWIND SPRING HANDWHEEL SECONDARY CHAIN SPACER PRIMARY CHAIN CLUTCH Layout drawing typical hosereel with electric rewind motor Appendix 1 SDM09E-Hosereel Page 21
Appendix 2 ¾ and 1 Fluid Path Layouts X XX XX FSB.310 HEX.HD.SCREW ST/STL. M10 x 20mm LONG FPB.320 HEX.HD.SCREW M.STEEL M10 x 20mm LONG FPW340 SHAKEPROOF WASHER M.STEEL Ø10mm FSW338 SHAKEPROOF WASHER ST.STL. Ø10mm 7605.05.P PLASTIC DRUM HUB (FOR 1 1/16"DIA.) Ø82.6mm [3 1/4"] Ø27.0mm [1 1/16"] 7605.02.A 7605.02.S SHORT SPACER PLASTIC DRUM HEAD HUBS AS USED ON POWER REWIND REELS FPD.214 M.STEEL SPRING DOWEL 1/4" x 1 1/2" LONG FSD.215 ST/STL. SPRING DOWEL 1/4" x 1 3/4" LONG AS USED ON POWER REWIND REELS DRUM WITH STEEL DRIVE PLATE FPN.320 FULL HEX.NUT M10 - M.STEEL FSN.347 FULL HEX.NUT M10 - ST.STL FPW340 SHAKEPROOF WASHER M.STEEL Ø10mm FSW338 SHAKEPROOF WASHER ST.STL. Ø10mm FIT BONDING STRAP 7603.01.B ON LPG REELS X XXXXXXXX XXXXXXXX FPW340 SHAKEPROOF WASHER M.STEEL Ø10mm FSW338 SHAKEPROOF WASHER ST.STL. Ø10mm FPB.323/FSB.308 HEX.HD.SCREW M10 x 60mm LONG 7605.06.P PLASTIC DRUM HUB (FOR 1 5/16"DIA.) 7605.05.P PLASTIC DRUM HUB (FOR 1 1/16"DIA.) SHORT SPACER POWER REWIND 7605.02.A / 7605.02.S 7606.02.A / 7606.02.S FPB.323/FSB.308 HEX.HD.SCREW M10 x 60mm LONG LONG SPACER POWER REWIND 7607.01.A / 7607.01.S 7609.00.A XXXXXXXX XXXXXXXX PLASTIC DRUM HEAD HUBS AS USED ON MANUAL REWIND REELS FPB.322/FSB.322 HEX.HD.SCREW M10 x 35mm LONG 7605.06.P PLASTIC DRUM HUB (FOR 1 5/16"DIA.) 7605.05.P PLASTIC DRUM HUB (FOR 1 1/16"DIA.) REWIND REELS AS USED ON MANUAL STEEL DRIVE PLATE FPB.321/FSB.309 HEX.HD.SCREW M10 x 25mm LONG SHORT SPACER MANUAL REWIND 7605.01.A / 7605.01.S 7606.01.A / 7606.01.S X XX X X XX XXX SDM09E-Hosereel Page 22
Appendix 3 ¾, 1 and 1¼ Swingjoint Assemblies For Air Water - Oil ¾ & 1 Suitable for Working Pressures up to 93 bar [1350 psi] All Liquid & Gas Groups 1¼ Suitable for Working Pressures up to 60 bar [870 psi] Liquid Groups 1 & 2 only and up to 93 bar [1350 psi] Liquid Group 2 only 2 5 1 3 4 'B' 'C' 'D' ¾ BSP 1 BSP 1¼ BSP mm Inches mm Inches mm Inches Dimension A 76.2mm [3 ] 88.9mm [3.1/2 ] 110.9mm [4.3/8 ] Dimension B 80.9mm [3.3/16 ] 95.2mm [3.3/4 ] 104.8mm [4.1/8 ] Dimension C 50.8mm [2 ] 60.3mm [2.3/8 ] 63.5mm [2.1/2 ] Dimension D 47.9mm [1.7/8 ] 57.2mm [2.1/4 ] 69.9mm [2.3/4 ] Swingjoint Assembly fitted with nitrile seals Gunmetal and brass (part no 7510.00.B) Gunmetal and brass (part no 7515.00.B) Gunmetal only (part no 7515.00.GM) 'A' Gunmetal and brass (part no 7516.00.B) Item 1 Sleeve 7510.01.B 7515.01.B 7516.01.B Item 2 Stem 7510.02.BR 7515.02.B / 7515.02.BR 7516.02.BR Item 3 Washer 7510.03.B 7515.03.S / 7515.03.B 7516.03.B Item 4 Circlip FPC.109 FSC.111 / FPC.111 FPC.114 Item 5 Nitrile Seal 0216.00.T 0220.00.T 0326.00.T For High Pressure or LPG type swingjoints please contact our sales office for further details. For Working Pressure refer to the Pressure Equipment Directive 97/23/EC SDM09E-Hosereel Page 23
Appendix 4 1½ Swingjoint / Fluid Path Assemblies 5a OLD STYLE WITH 'O'RING DIAMOND MARK 2c 2a 2b 5b NEW STYLE WITH CHEVRON SEAL 4c 4b 4a 3 'A' 1 'B' 6 1a b c d e f g h 2a b c d e f g h i j k 3a b 4a b c d e f Description Aluminium Gun Metal Old Spindle Early models 7525.10.A 7525.10.B Standard o-ring 7525.21.A 7525.21.B Extended Drive o-ring 7525.25.A 7525.25.B Extended Manual o-ring 7525.23.A 7525.23.B New Spindles Gooseneck (taper thread) Gooseneck (parallel thread) Housing Inlet Standard Drive Chevron seal Extended Drive Chevron seal Standard Manual Chevron seal Extended Manual Chevron seal 1½ BSPT(M) (10 or 11¼ dia. drum) 1¼ BSPT(M) (10 or 11¼ dia. drum) 1½ BSPT(M) (15 ½ dia. drum) 1½ NPT(M) (10 or 11 ¼ dia. drum) 1¼ NSPT(M) (10 or 11 ¼ dia. drum) 1½ NSPT(M) (15 ½ dia. drum) 1¼ BSPP (10 dia. drum Storz coupling) 1½ BSPP (10 dia. drum Storz coupling) 1½ BSPP (11¼ dia.drum Storz coupling) 1½ BSPP (15½ dia.drum Storz coupling) 2 BSPP (10 dia. drum Storz coupling) Early models tapped 5/16 UNC Standard current tapped M8X1,25-6H Straight 1¼ BSPP(F) 90 O 1½ BSPP(F)-12 holes std; 6 holes- A6 90 O 1½ BSPP(M) Hosetail Straight 1½ BSPP(F)*use with 7525.11.PW Straight 1½ NPT(F) Flange 3-8.2mm dia. holes on 79.4mm [3 1/8 ] PCD. With 35mm inside dia. Nitrile o-ring (early models) 5a Seal b Chevron seal kit 6 Seal Nitrile o-ring (all models) Viton o-ring (all models) 7525.82.A 7525.80.A 7525.83.A 7525.81.A 7594.00.A 7594.01.A 7594.07.A - - - 7594.04.A 7954.09.A 7594.10.A 7594.13.A 7594.02.A - - - 7525.02.A6 - *7525.11.A - - 7525.22.T 7525.03.V.KIT 7525.22.T 7525.22.V 7525.82.B 7525.80.B 7525.83.B 7525.81.B 7594.00.B 7594.01.B - 7594.05.B 7594.06.B 7594.14.B 7594.04.B - 7594.10.B - - 7525.07.B 7525.09.B 7525.12.B 7525.02.B 7525.08.B 7525.11.B 7525.28.B 7525.01.B 7525.22.T 7525.03.V.KIT 7525.22.T 7525.22.V SDM09E-Hosereel Page 24
2 Swingjoint / Fluid Path Assemblies Appendix 5 5a 2a OLD STYLE SEAL WITH 'O'RING 2c 2d NEW STYLE WITH CHEVRON SEAL 2b 5b 4b 4a 3 1 6 Description Aluminium Gun Metal 1 Spindle Standard 7526.19.A 7526.19.B 2a b Gooseneck 1 ½ BSPT (M) (11 ¼ dia. drum) 2 BST (M) (11 ¼ dia. drum) 7526.10.A 7526.09.A 7526.10.B 7526.09.B c d 2 BSPT (M) (15 ½ dia. drum) 2 BSPT (M) (19 ½ dia. drum) 7526.16.A 7526.07.A.X 3 Housing 7526.13.B 4a b Inlet Straight 2 BSPP (M) 90 degree 2 BSPT (M) 7526.04.A 7526.04.B 7526.11.B 5a b Seal Nitrile o-ring (early models) Viton o-ring (early models) Chevron seal Viton (current models) 6 Seal Nitrile o-ring (all models) Viton o-ring (all models) 7526.22.T 7526.22.V 7526.17.V.KIT 7526.22.T 7526.22.V 7526.22.T 7526.22.V 752617.V.KIT 7526.22.T 7526.22.V SDM09E-Hosereel Page 25