COXREELS 100W Series Manual

INSTALLATION AND MAINTENANCE MANUAL FORM #PM-129 REV - 12/10

Page 1 of 4

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

HAND CRANK HOSE/CABLE REELS:

SERIES: 100W

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 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 non-conforming 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 desi

ns, specifications, and dimensional data contained in this publication are sub

ect to chan

e without notice.

INSTALLATION AND MAINTENANCE MANUAL FORM #PM-129 REV - 12/10

Page 2 of 4

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

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:

oSEVERITY 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

oThe 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.

oThe 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

INSTALLATION AND MAINTENANCE MANUAL FORM #PM-129 REV - 12/10

Page 3 of 4

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

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.

WARNING: Prevent static sparking. When working around flammables,

ensure that the hose reel, hose, and equipment are properly grounded.

INSTALLATION

MOUNT REEL / FASTEN CRANK HANDLE

•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. NOTE: If you choose to permanently

mount series CM, you will need four ¼” screws or nails.

•Fit mounting hardware to ceiling/wall/floor so reel can be fastened

into position. Fit reel and tighten all hardware securely.

•Reels are supplied with plastic crank handle uninstalled. Remove

handle and hardware from plastic bag and install onto crank arm.

Models 1275 and 600-900 will include detachable crank for bevel

gear design.

•The series DM portable reels will include a U-shaped handle. Position

handle over swaged posts and fasten using hardware provided.

INSTALLATION OF INLET HOSES

•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.

•Flush some product through the system before connecting inlet hose to

the source.

•Connect end to supply source.

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).

Challenger series 112, 117, CM, DM and SM, outlet will be inside drum

area. Note: Outlet riser is removable on 1195 series.

•Using a wrench, firmly hold on to riser fitting while tightening hose

connector.

•The Series 100 reel includes a hose clamp. Fasten hose securely to

reel with hose clamp provided.

NOTE: The hose clamp restrains the hose when fully extended,

preventing strain on the fitting.

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

OPERATIONAL CHECKS

OPERATIONAL CHECK

CAUTION: ENSURE THAT ALL OPERATION CHECKS HAVE BEEN

COMPLETED BEFORE RELEASING FOR USE

•Adjust drag brake. Turn clockwise to add tension and counter-

clockwise to decrease tension. See figures 3.0-6.0.

•Check for correct operation by pulling out some of the hose/cable. A

slight friction or drag should be noticed. This drag is to prevent

backlash when pulling out hose/cable.

•Fit hose to swivel then fit swivel to reel.

SWIVEL SEAL REPLACEMENT

•Remove inlet hose from swivel.

•Remove swivel from reel by unscrewing swivel from reel axle.

Disconnect hose from swivel.

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

•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 repairs or

adjustments to reel.

INSTALLATION AND MAINTENANCE MANUAL FORM #PM-129 REV - 12/10

Page 4 of 4

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

TROUBLE SHOOTING GUIDE

TROUBLE CAUSE REMEDY

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 to wrap evenly as it is wound

on to the reel.

REEL KEEPS TURNING WHEN OPERATOR

STOPS PULLING OUT HOSE/CABLE. Tension drag brake is too loose causing

hose/cable backlash. Adjust tension drag brake by turning fastener clockwise.

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!

COXREELS

SERIES 100W

EXP-40W

REVISION:

ECO NO.:

BY:

DATE:

2606

JKUCERA

7/13/11

EXP-40W COMMON PARTS TO 100W WELDING HOSE CHALLENGER REELS

DETAIL

ITEM NO. PART NO. DESCRIPTION

8554 ASSEMBLY: DRUM, OXY-ACETYLENE, 12" DIA. X 8" - - 1 1 - -

8554-4 ASSEMBLY: DRUM, OXY-ACETYLENE, 12" DIA. X 4-1/2" 1 1 ----

8899-8 ASSEMBLY: DRUM, 117W, 17" ----11

26329-1-1 BEARING: MOLDED, CRANK SIDE 111111

38552 BEARING: 1-5/8" COMPOSITE 111111

415711-1 PLATE: BEARING KEEPER 222222

57105 RIVET: 3/16" DIA. X .25" GRIP 444444

615719 KNOB: BLACK PHOENOLIC, 1/4-20 111111

77272-1 ASSEMBLY: CRANK 111111

8245 SCREW: #10-32 X 3/8" PHILLIPS HEAD 111111

9 130 NUT: #10-32 KEPS 111111

10 7146 BOLT: 1/4-20 X 2-1/4" HEX 111111

11 688 WASHER: 1/4" FLAT 111111

12 10925-5 LABEL: STANDARD 111111

8553-8 FRAME: 'U', 8" - - 1 1 - -

8553-4 FRAME: 'U', 4-1/2" 1 1 ----

8898-8 FRAME: "U" 117W SERIES, 8" ----11

14 8550 ASSEMBLY: SWIVEL, OXY-ACETYLENE 111111

15 382 CLAMP: HOSE #14 111111

16 7145 SPACER: CHALLENGER REEL 111111

17 8562 ADAPTER: ACETYLENE WELDING HOSE 111111

18 8561 ADAPTER: OXYGEN WELDING HOSE 111111

19 8573 RETAINER: WELDING SWIVEL 111111

5423-1 ASSEMBLY: 1/4" X 12" 'R' GRADE DUAL WELDING HOSE 1 - 1 - 1 -

5424-1 ASSEMBLY: 1/4" X 12" 'T' GRADE DUAL WELDING HOSE - 1 - 1 - 1

5423-50 ASSEMBLY: 1/4" X 50' 'R' GRADE DUAL WELDING HOSE 1 -----

5423-100 ASSEMBLY: 1/4" X 100' 'R' GRADE DUAL WELDING HOSE - - 1 - - -

5423-200 ASSEMBLY: 1/4" X 200' 'R' GRADE DUAL WELDING HOSE ----1-

5424-50 ASSEMBLY: 1/4" X 50' 'T' GRADE DUAL WELDING HOSE - 1 ----

5424-100 ASSEMBLY: 1/4" X 100' 'T' GRADE DUAL WELDING HOSE - - - 1 - -

5424-200 ASSEMBLY: 1/4" X 200' 'T' GRADE DUAL WELDING HOSE -----1

REVISION: C ECO: 2903 DATE: 7/13/2011

21*

117W-1-200

117WT-1-200

NAME: JKUCERA

*FOR LESS HOSE MODELS, EXCLUDE ITEM 21.

112WT-1-50

112W-1-50

112W-1-100

112WT-1-100

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