*
D-TM
-0 Service
Manual
THINLINE™
Hose Reel
l
Manual Number 673975 R-1
cascade@
Cascade IS a Registered Trademark of Cascade Corporation
Contents
Introduction, Section 1 . . . . . . . . . . . . . . . . . 1
Hose Length Calculation, Section 2 . . . . . . . . . . . . 2
Periodic Maintenance, Section 3 . . . . . . . . . . . 2
Troubleshooting Guide, Section 4 . . . . . . . . . . . . 3
Service, Section 5 . . . . . . . . . . . . . . . . . . . 4
Disconnecting the Reel . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reel Disassembly . . . . . . . . . . . . . . . . . . . 5
Hose Replacement. . . . . . . . . . . . . . . . . 7
Reversing the Reel Assembly. . . . . . . . . . . . . . . . 8
673975 Rev. 1
l..
Section
1 Introduction
This manual contains the troubleshooting procedures and
service information for the CascadeTHlNLlNE™ series of
hose reels. If you have questions, call the Cascade Service
Department at the location nearest you. See the back cover
for a list of the locations.
1.1 Truck System
Requirements
Pressure: 3000 psi (210 bar) maximum.
Volume--Recommended flows:
No. 4 - 2.5 gpm (10 L/min)
No. 6 - 6 gpm (25 L/min)
No. 8 - 10+ gpm (40 L/min)
NOTE: If you have questions concerning these ratings, call
your nearest Cascade Service Department. See back cover.
1.2 Special Instructions
Definitions
A WARNING
A statement preceded by AWARNING is information that
should be acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
CAUTION
A statement preceded by CAUTION is information that
should be acted upon to prevent machine damage.
IMPORTANT
A statement preceded by IMPORTANT is information that
posseses special significance.
NOTE
A statement preceded by NOTE is information that is handy
to know and may make your job easier.
673975 Rev. 1
Section
2.1 Twinline Hose
2 Hose Length Calculation
Length Calculations
H =Total lift height
D = Distance from centerline of reel to hose end with carriage
fully lowered.
K =CONSTANT = 18 inches (460mm) for No. 4
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”
286”-96”= 190”+28”=218”correct hose length.
In this case, use hose 673395.
Example mm
H = 7265mm
D = 2440mm
K = 710mm
7265-2440 = 4825+710 = 5535 correct hose length.
In this case, use hose 673395.
= 28 inches (710mm) for No. 6
= 34 inches (860mm) for No. 8
~ -
Section
3 Periodic Maintenance
500 Hour Maintenance
After each 500 hours of lift truck operation, perform the
following procedures.
Ž Retorque the mounting capscrews. Use the torque
specifications shown in Section 5.
Ž Retighten all hydraulic hose fittings.
Ž Check hoses for cracks, peeling or leaking. Replace as
required.
673975 Rev. 1
Section 4 Troubleshooting
.
a
4.1 Troubleshooting Guide
PROBLEM
Excessive wear on hose.
Hose jumps off reel
during operation.
Hose binds during operation.
Hose reel leaks at hub.
PROBLEM CAUSE SOLUTION
Hose reel and hose terminal are
not in proper alignment.
Hose reel flanges damaged.
Hose reel not aligned with hose
terminal.
Incorrect prewind of spring.
Hose reel spring is broken.
Flanges are bent.
Worn or cut seals in the rotating hub.
Loose or damaged fittings.
Scored seal areas.
Align the hose terminal and hose reel properly.
They must be on the same center line and
mounted squarely to each other.
Repair or replace damaged parts.
Align hose terminal with hose reel.
Prewind spring.
Replace the spring.
Straighten or replace flanges. See Section 5.2.
Replace all seals. 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. 672563.
Tighten or replace damaged fittings.
Replace the damaged shaft or use
an emery cloth (320 grit) to remove the
nicks from the shaft or hub.
X894-161 ‘5
673975 Rev. 1
3
Section
5 Service
5/1 Disconnecting the Reel
NOTE: It is not necessary to remove the reel assembly from
the truck. All service procedures may be done in place; but
for purposes of this manual, they will be done on the work
bench.
1 Remove the twinline hoses from the hose terminal.
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. For
reassembly, tighten the hose terminal
clamp capscrews to 15-20 ft.-lbs.
(20-27 N.m).
0
Righi Side Shown
2
Disconnect the truck valve hoses from the hose reel
mounting block. Tag the hoses to prevent switching of
hydraulic functions during reassembly.
Remove the capscrews and self-locking nuts fastening
3
the reel to the mounting bracket. Remove the reel from
the mast. For reassembly, tighten the capscrews to
30-35 ft.-lbs. (40-47 N.m).
Determine whether the reel is a right or left hand model
4
(viewed from the outer flange side of the reel). This
must be noted for future reference. If the reel is lefthanded, an ‘L” will show on the hub casting. If the reel is
right-handed, an “R” will show on the hub casting.
Right hand hose reel shown
4
Left Hand Reel
Right Hand Reel
673975 Rev. 1
Section
5 Service
5.2 Reel Disassembly
1 Clamp the reel mounting block in a vice.
2 Remove the twinline hose.
3 Remove the capscrews fastening the flanges and hub to
the spring/shaft assembly. For reassembly, tighten the
capscrews to 10-14 ft.-lbs. (13-19 N.m).
4 Remove the capscrew, end cap and O-ring from the
shaft end. For reassembly, tighten the capscrews to
10-14 ft.-lbs. (13-19 N.m).
5 Grasping both flanges and hub as an assembly, slowly
rotate as you pull them off the shaft.
6 Separate the hub from the flanges.
Spacer
Hose Guide
8 Rotate the spring assembly to disengage the declutch-
ing pin and slide the O-rings and spring assembly off
the shaft, being careful not to damage the shaft O.D.
673975 Rev. 1
CAUTION: Do not
damage shaft.
5
Section
5 Service
5.2 Reel Disassembly (Continued)
8 Remove the three O-rings and four back-up rings from
the hub bore. Remove O-rings first by prying them out
with a hook-type dental tool or a small flat screw driver.
(Use Cascade O-ring Tool Part No. 674424.) Use the
same tool to remove teflon rings next.
NOTE: Do not scratch or damage groove surfaces.
9 Clean the hub and shaft with a non-corrosive solvent.
Inspect the following areas:
l The sealing surface on the shaft is nickel plated. If
minor surface imperfections are noted, use emery
cloth (320 Grit) to lightly smooth up. Sand radially
around the shaft. If sharp edges or grooves are found,
shaft replacement is necessary.
l Hub grooves must be free of sharp nicks or projec-
tions to prevent cutting of the outside diameter of the
O-ring during installation.
If the O-ring seal nearest the spring assembly was
damaged and allowed hydraulic oil to leak into the
spring can, drain the spring can before reassembly. If
excessive oil is left in the spring assembly, it will seep
out after reassembly and appear as though there is a
serious oil leak.
10 Apply a liberal amount of petroleum jelly or hydraulic oil
(STP) to the shaft, seals and the interior of the hub before
reassembling.
11 Install the four back-up rings into their respective hub
grooves. Next, install three O-ring seals.
O-Ring
Torque to
lo-14ft.-lbs. (13-19 N.m)
12 Reverse Steps 1 through 7 for reassembly, being careful
to rotate the hub slowly as you push it onto the shaft. This
will prevent damage to the seals and make reassembly
easier. Also be sure O-ring dust seals (3) are in their
correct positions.
0.
BackuD
Backup Rings
/
O-Ring Dust Seal
6
673975 Rev. 1
.
.
e
Section
5 Service
5.3 Hose Replacement
1 Disconnect the twinline hoses from the hose terminal.
WARNING: Hold hoses firmly while
disconnecting them from the carriage.
Allow the reel spring to unwind slowly
while maintaining tension on the loose
al._-
2 Cover the number of prewinds while unwinding the hose
3 Disconnect the hoses from the reel hub. It is not neces-
sary to remove the outer flange.
4 Remove the hoses from the reel.
5 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.
6 Wind the new hose assembly completely onto the reel in
the direction indicated (viewed from the outer 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 identify the reel.
7 Remove the restraint from old hoses by twisting off.
Install new hoses by twisting into the restraint.
8 Prewind the reel spring by grasping the end of the hose
and turning the reel the specified number of complete
turns in the direction indicated (viewed from the outer
flange side).
Right Hand Reel: Wind reel clockwise.
Left Hand Reel: Wind reel counterclockwise.
Normal prewinds = No. 4-11 - 5 turns
If more tension is required, the reel can be prewound
additional turns. The maximum total turn capacity of the
reel is:
Total Turns = Prewind Turns + Working Turns
Caution: Exceeding the total turn capacity of the reel
will damage the reel spring.
9 Reconnect the hoses to the hose terminal. Tighten the
hose terminal capscrews to 15-20 ft.-lbs. (20-27 N.m).
10 Cycle mast carriage slowly to ensure adequate hose
length and alignment on reel.
No. 6-13 - 5 turns
No. 6-16 - 5 turns
No. 8-16 - 5 tums
No. 4-11 - 11 turns
No. 6-13 - 13 turns
No. 6-16 - 13 turns
No. 8-16 - 13 turns
Left Hand
0
Wind Counterclockwise
install clamp with
detent between first
and second segments.
@ Right Hand
Wind Clockwise
Hose Restraint
673975 Rev. 1
UC
? capscrew to
!O
ft:lbs. (20-27 Nm)
7
Section 5 Service
.
5.4
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:
1 Disconnect the reel assembly from the truck as de-
scribed in Section 5.1.
2 Disassemble the reel to gain access to the spring as-
sembly as described in Section 5.2, steps 1 through 7
3 Remove four nuts and bolts that retain the spring can
cover.
I
WARNING: Once the spring cover is
removed, the spring itself should never be
A
4 Turn the spring can assembly, making sure that can and
cover stay together.
5 Lift off the spring can, leaving the cover and spring on
the work bench. Flip over spring can.
A
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.
WARNING: Do not remove spring from
inner can.
I
6 To reverse the spring direction, use the spring cover and
slide the spring into the can. Align the can notch with the
spring washer, When complete, the spring winding will
be exposed for a right hand reel and covered for a left
hand application.
7 Reverse the spring retainer pin by removing the snap
ring and rotating the retainer pin 180°. Replace the snap
ring.
8 For reassembly, reverse the above procedures except
as follows:
*Tighten the spring can cover nuts to a torque of 30-40
in.-lbs. (3-4 N.m).
0 Install the hub and flanges on the shaft in the orienta-
tion shown in Section 5.1 Step 4.
Right Hand Reel
I
Left Hand Reel
Rotate
Left
Hand
Reel
Right
Hand
Reel
673975 Rev. 1
Do you have questions you need
answered right now? Call your
nearest Cascade Service Department.
Cascade Corporation
PO. Box 20187
2201 N.E. 2Olst Ave.
Troutdale, OR 97060
Tel.: 503/666-1518
800-227-2233 (Toll Free)
Telex: 590480
Cable: Cascade Ptl
FAX: l-503-665-0301
Cascade N.V.
European Headquarters
PO. Box 50086
1305 AB Almere-Haven
Achterwerf 240
1357 CB Almere-Haven
The Netherlands
Tel.: 03240-92911
Telex: 40838 case nl
FAX: 011-31-3240-92286
Cascade Scandinavia
Hydraulik A.B.
Muskdtaatan 17-(E.8-91
.z ’
252 55 Helsingborg
Sweden
Tel.: 042-151135
Telex: 72565 caschbg s
Cascade GmbH
Klosterhofweg 52
4050 Monchengladbach 3
B.R. Deutschland
Tel.: 02166-602091
Telex: 852812 cast d
Cascade Hydraulics Ltd.
7615 Kimbel Street
Mississauga, Ontario
Canada L&l A8
Tel.: 4161677-9695
Direct Parts Line:
4161677-9686
4161677-9684
TelAc: 06-968715
Cascade Materials Handling
llncoroorated in N.S.W.1
i21 Long Street ’
Smithfield, N.S.W. 2164
Australia
Tel.: 02-604-6222
TelAc: (790124302
Cabl&‘Cascaus
FAX: 011-61-2-609-2742
Cascade Materials Handling
44E Winterton Road
Clayton, Victoria 3168
Australia
Tel.: 03-543-4344
Cable: Casmel
Cascade Japan Ltd.
4-l, l-Chome,
Shin Senri Higashimachi
Toyonaka, Osaka 565
Japan
Tel.: 06-835-2900
Tel/AC: 781-5287115 Cascade J
Cable: Cascadecfe, Osaka
FAX: 011-816-835-2905
Cascade (UK) Ltd.
- (Aust.) Pty. Ltd.
15, Orgreave Crescent
Dore House Industrial Estate
Handsworth
;;;Mfi;; S13 9NQ
Cascade N.V.
Benelux Sales and Service
F!O. Box 170
1110 AD Diemen
Weesperstratt 110
1112 AP Diemen
The Netherlands
Tel.: 020-906411
Telex: 14495 cast nl
Cascade France S.A.R.L.
11, rue Jean Charcot
Zone lndustrielle Sud
BP 22
91421 Morangis Cedex
France
Tel.: 0742-697524/5/6/7
Telex: 547254 cascsh g
Cascade Hispania S.A.
- (Aust.) Pty. Ltd.
Avenida De La Fabregada, 7 PO. Box 625
Hospitalet De Llobregat
Barcelona
Spain
Tel.: 93-3355158
Telex: 54018 cast e
Tel.: (1)69091139
Telex: cascade 690016f
Cascade (Africa) Pty. Ltd.
15 Power Street
lsando 1600
South Africa
Tel.: Oil-974-5611/2/3/4/5
Telex: 4-29718 S.A.
@Cascade Corporation 1988
12-86
Part Number 673975 R-l
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