Page 1
Operating Instructions
Series LS 5000 Stainless Steel Cord Reels
Model Numbers:
LS 5445 123 3 LS 5425 123 3M LS 5445 123 9G
LS 5445 123 3A LS 5445 123 7 LS 5400
LS 5425 123 3M-WC LS 5445 123 7A LS 5425 123 X
LS 5445 123 3M-WC LS 5445 123 7B LS 5445 123 X
LS 5415 123 3M LS 5445 123 9
Dimensions
A 14 3/8”
B 14 1/4”
C 9 3/4”
D 2 1/2”
E 10 1/2”
F 2 1/8”
SAFETY
Personal injury and/or equipment damage may result if proper safety
precautions are not observed.
• Ensure that only a qualified electrician installs/services this
equipment.
•
• Ensure that power supply voltage does not exceed maximum
voltage rating of reel.
•
• Ensure that all electrical power is removed from reel before
servicing.
•
• A high-tension spring assembly is contained within the reel.
Exercise extreme caution.
•
• Check for frayed and/or broken wires before each use. Pull
electrical cord from reel by grasping the electrical cord itself,
not the work device.
•
• If an electrical malfunction should occur, remove power from
reel immediately.
Electrical Information
Voltage AMPS Frequency
125 15 60 HZ Single Phase
125 20 60 HZ Single Phase
IMPORTANT
Read this manual carefully before installing, operating or
servicing this equipment.
• Ensure that reel, electrical cord, and equipment being serviced
are properly grounded. Use an ohmmeter to check ground
continuity.
•
• If reel ceases to unwind or rewind, remove power immediately.
Do not pull or jerk on electrical cord!
•
• Treat and respect the reel as any other piece of machinery,
observing all common safety practices.
•
• All cord reels with flying leads must be hard wired into the
electrical circuit to ensure proper function.
•
WARNING: Even low voltage can cause irreparable damage or
death! Exercise extreme caution while operating or servicing this
equipment.
Reelcraft Industries, Inc. • 2842 E Business Hwy 30, Columbia City, IN 46725
Ph: 800-444-3134 / 260-248-8188 • Fax: 800-444-4587 / 260-248-2605
Customer Service: 855-634-9109 • reelcraft@reelcraft.com • www.reelcraft.com
Form# 1306-418 Rev: 5/2018
Page 2
Series LS 5000 Stainless Steel Cord Reels
Installation Instructions
Mounting
2
1
3
CAUTION:
Unless reel was specified differently when
ordering, maximum installation height is 16
feet. Do not exceed this distance. Ensure
that only a qualified electrician installs/
services this equipment. Observe applicable
NEC, OSHA, and local codes when installing this equipment. Installation of GFCI cord
reels should be performed by a qualified and
licensed professional in accordance with local
building codes and applicable NEC standards.
1. Unpack and inspect the reel for damage.
Turn by hand to check for smooth operation. Check for completeness.
2. Configure reel for top, side or bottomwind (bottom-wind for constant tension
reels only) electrical cable dispensing by
removing bolts (1) securing guide arm
bracket (2).
3. Determine new guide arm bracket location and remove corresponding bolts.
Position guide arm bracket to reel and
replace bolts.
4. Position reel on floor, wall or ceiling.
Secure into place using four (customer
supplied) screws or bolts (3).
Adjusting the Spring Tension
If necessary, adjust spring tension on reel by
adding or removing wraps of electrical cord
from spool, one wrap at a time, until desired
tension is obtained. Add wraps to increase
tension. Remove wraps to decrease tension.
WARNING:
When adding wraps of electrical cord, be careful not to exceed the winding mechanism’s
spring capacity. Add just enough wraps of
cord to achieve the desired tension. Damage
to the winding mechanism will result if spring
is over-tightened. Always be aware of spring
tension on reel. Exercise extreme caution.
Troubleshooting Instructions:
20 AMP Models
Troubleshooting of the reel consists of
isolating a problem to a defective electrical
cord/work device, brush holder/brushes, or
collector assembly. Refer any other
discrepancies only to an authorized service
person or directly to Reelcraft.
WARNING:
The following procedure directs the technician
to take voltage measurements. Remember,
even low voltage is dangerous and can cause
personal injury or death. Exercise extreme
caution! Ensure that only a qualified electrican
installs or services this equipment.
3
13
12
10
14
1
11
7
15
6
1. If work device is either an incandescent
or fluorescent light, replace bulb with a
known good bulb. If this does not correct
the problem, proceed to step 2. If work
device is an electrical receptable, ensure
that tool or fixture connected to it is in
good working order. If it is, proceed to
step 2.
2. Remove power from reel.
3. Remove access cover (1).
4. Reapply power to reel.
5. Check for correct voltage (120 vac) at a
terminal strip (2). If voltage reading is
correct, replace output electrical device
(refer to Service Instructions). If voltage
reading is incorrect, proceed to step 6.
6. Remove power from reel.
5
8
2
9
4
7. Using ohmmeter, check continuity of
input electrical cord. If cord checks
good, proceed to step 8. If cord is faulty,
replace it (refer to Service Instructions).
Remove brush holder/brushes from
reel and inspect (refer to Service
Instructions). Replace defective components then proceed to step 9.
8. Reapply power to reel.
9. Check for correct voltage (120 vac) at
terminal strip (2).
10. If voltage reading is still incorrect,
replace defective collector assembly
(refer to Service Instructions).
11. Replace access cover (1).
Service Instructions:
20 AMP Models
Maintain reel by following the service
instructions given below. Refer all other
repairs, other than those listed, only to an
authorized service person or directly to
Reelcraft. Failure to do so can result in
personal injury and/or equipment damage and
may void the warranty.
Installing the Input Electrical Cable:
20 AMP Models
WARNING:
Use only 12/3 cable for input wiring. Ensure
that application does not exceed electrical rating of reel (see page 1 of this manual).
1
4
3
2
5
1. Feed input cable (1) through elbow (2)
and main shaft.
2. Screw elbow (2) onto reel.
3. Connect input wires (3) and collector
ring wires (4) together using wire nuts (5).
4. Take the provided zip tie (not pictured)
and zip tie the input cable wires together
closest to the slip ring.
5. Assemble cover (6) to reel.
6
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Page 3
Series LS 5000 Stainless Steel Cord Reels
Installing the Output Electrical
Cable: 20 AMP Models
WARNING:
Select output cable in accordance with power
requirement of apparatus to be supplied.
Ensure that application does not exceed
electrical rating of reel (see page 1 of this
manual). Use extreme caution, reel under
tension. Avoid releasing latch mechanism.
10
6
7
1
8
4
3
9
5
2
1. Manually turn sheave (1) until spring is
tight, back off 2 turns and latch.
2. Remove access cover (2).
3. Remove 6” of output cable outer jacket
(3) and add fork terminals (4) to ends.
4. Route cable through strain relief (6), then
through cut out in spool (7).
5. Pull enough cable through hole for
roughly a 1/2 an inner wrap shown.
6. Connect output wires to terminal block
(8) as shown.
7. Connect ground wire to grounding stud
(9) as shown.
8. Using an ohmmeter check for ground
faults.
9. Take the provided cable clamp (not pictured) and attach it to the wire. Then take
the cable clamp and screw it down to the
right-most screw on the brush assembly
(with the brush assembly facing upward).
10. Replace cover (2).
11. Replace latch and wind cable onto reel.
12. Install bumper stop (10).
Replacing the Output Electrical
Cord/Work Device
WARNING:
Remove power from reel before performing
any of the following procedures. Use extreme
caution, reel under tension. Avoid releasing
latch mechanism.
3
13
12
10
14
1
11
7
15
6
5
8
2
9
4
1. Pull output electrical cord from reel until
fully extended, then latch.
2. Remove output bumper stop (3).
3. Remove access cover (1).
4. Disconnect output electrical cord/work
device (4) at terminal strip (2).
5. Remove cable clamp.
6. Remove strain relief (5). Remove output
electrical cord/work device.
7. Install replacement electrical cord/work
device by reversing steps 2 through 5.
8. Release latch and rewind electrical cord
on reel.
9. Replace access cover (1) and bumper
stop (3).
Replacing the Input Electrical Cord
WARNING: All cord reels with GFCI recep-
tacles must be hard wired into the electrical
circuits. Use of 2 or 3 prong plugs may cause
a potential malfunction of the GFCI receptacle.
3
13
12
10
14
1
11
7
15
6
1. Remove access cover (1).
2. Remove wire nuts (6) securing input
electrical cord to collector assembly (7).
3. Remove zip tie (not pictured), being careful to not damage wires.
4. Remove 90 degree elbow (8).
5. Remove input electrical cord.
6. Remove 11” of outer jacket from replacement input electrical cord (input electrical
cord wires must protrude a minimum of
5
8
9
4
6” from center of collector assembly).
7. Install replacement input electrical cord
by reversing steps 1 through 4.
8. Replace access cover (1).
Replacing the Brush Holder/Brushes
13
12
10
14
1
11
4
7
15
6
1. At terminal strip (2), remove wires
connecting brushes (9) to terminal strip.
2. Remove lock nuts (10) securing brush
holder (11) to reel. Relocate cable clamp
temporarily and remove brush holder.
3. Remove brushes (12) from holder (11).
4. Install replacement brush holder/brushes
by reversing steps 1 through 3. Upon
completion of installation, adjust brush-to ring alignment by loosening nuts (13) and
sliding finger assembly (14).
Replacing the Collector Assembly
1. Remove access cover (1).
2. Remove wire nuts (6) securing input
electrical cord to collector assembly.
3. Remove zip tie (not pictured), being careful to not damage wires.
4. At terminal strip (2), disconnect wires (9)
connecting brushes (12) to terminal strip.
5. Remove lock nuts (10) securing brush
2
holder (11) to reel. Relocate cable clamp
temporarily and remove brush holder.
6. Remove coupling nut (15).
7. Remove collector assembly.
8. Install replacement collector assembly
by reversing steps 1 through 5. Upon
completion of installation, adjust brushto-ring alignment by loosening nuts (13)
and sliding finger assembly (14).
9. Replace access cover (1).
3
5
8
2
9
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Page 4
Series LS 5000 Stainless Steel Cord Reels
Page 6
www.reelcraft.com
Page 5
Series LS 5000 Stainless Steel Cord Reels
Item
#
1 Inlet Cord Assembly 1 260630 602002 602793 602793 602237 602237 602237 260630
2 Connector, 90° Cord 1 261140-C 261140-C 261140-C 261140-C 261140-C 261140-C 261140-C 261140-C
3 Set Screw 3/8-19 x 1/2” Pin 1 S47-64 S47-64 S47-64 S47-64 S47-64 S47-64 S47-64 S47-64
4 Lock Nut 10-32 Hex 22 S348-15 S348-15 S348-15 S348-15 S348-15 S348-15 S348-15 S348-15
5 Snap Ring 2 S147-25 S147-25 S147-25 S147-25 S147-25 S147-25 S147-25 S147-25
6 Spring Case Stud 1 261361 261361 261361 261361 261361 261361 261361 261361
7 Screw, 10-32 x 1/2” 2 S46-107 S46-107 S46-107 S46-107 S46-107 S46-107 S46-107 S46-107
8 Guide Arm Assembly 1 600057 600057 600057 600057 600057 600057 600057 600057
9 Bumper Assembly 1 1-HS1004-A 1-HS1004-A 1-HS1004-A 1-HS1004-A 1-HS1004-A 1-HS1004-A 1-HS1004-A 1-HS1004-A
10 Spring Arbor 1 S400017 S400017 S400017 S400017 S400017 S400017 S400017 S400017
11 Latch Cam 1 260224 260224 260224 260224 260224 260224 260224 260224
12 Sheave Disc 1 260223 260223 260223 260223 260223 260223 260223 260223
13 Strain Relief 1 260633 260633 260633 260633 260633 260633 260633 260633
14 Plate Adapter 1 261577 261577 261577 261577 261577 261577 261577 261577
15 Hex Screw 1/4-20 x 5/8” 3 S324-102 S324-102 S324-102 S324-102 S324-102 S324-102 S324-102 S324-102
16 Collector Ring Assembly 1 602296 602296 602296 602296 602296 602296 602296 602296
17 Cover 1 261723 261723 261723-W 261723-W 261723 261723 261723 261723
18 Snap Ring 1 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13
19 Wire Nut 3 260774 260774 260774 260774 260774 260774 260774 260774
20 Grounding Cord Assembly 1 600283 600283 600283 600283 600283 600283 600283 600283
21 Lock Washer 1 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10
22 Connect Terminal 1 260609 260609 260609 260609 260609 260609 260609 260609
23 Terminal Block Assembly 1 600205 600205 600205 600205 600205 600205 600205 600205
24 Sheave Assembly 1 602790 602790 602790 602790 602790 602790 602790 602790
25 Screw 10-32 x 3/8” 5 S46-105 S46-105 S46-105 S46-105 S46-105 S46-105 S46-105 S46-105
26 Latch Plate Spring 1 S400018 S400018 S400018 S400018 S400018 S400018 S400018 S400018
27 Screw 10-24 x 3/8” 1 S332-117 S332-117 S332-117 S332-117 S332-117 S332-117 S332-117 S332-117
28 Screw 10-32 x 1” 1 300035 300035 300035 300035 300035 300035 300035 300035
29 Latch Bumper 1 S400021 S400021 S400021 S400021 S400021 S400021 S400021 S400021
30 Latch Plate Bumper 1 600062 600062 600062 600062 600062 600062 600062 600062
31 Latch Bushing 1 260225 260225 260225 260225 260225 260225 260225 260225
32 Base Assembly 1 600056 600056 600056 600056 600056 600056 600056 600056
33 Main Shaft Kit 1 263124 263124 263124 263124 263124 263124 263124 263124
34 Spacing Washer 1 260238 260238 260238 260238 260238 260238 260238 260238
35 Drive Spring Assembly 1 504240 504240 504240 504240 504240 504240 504240 504240
36 Spring Case Assembly 1 600061-1 600061-1 600061-1 600061-1 600061-1 600061-1 600061-1 600061-1
37 Nyloc Nut 10-32 x 3/8” 1 S95-22 S95-22 S95-22 S95-22 S95-22 S95-22 S95-22 S95-22
38 Single Outlet 1 600251 602003 602792-25 602792-45 602236-15 602236-25 602236-45 None
39 Duplex Box Cord Assembly 1 None None None None None None None 602332-45
40 Triple Tap Cord Assembly 1 None None None None None None None None
41 Flying Leads 1 None None None None None None None None
Description
#
Req.
LS 5445
123 3
LS 5445
123 3A
LS 5425
123 3M-WC
LS 5445
123 3M-WC
LS 5415
123 3M
LS 5425
123 3M
LS 5445
123 3M
LS 5445
123 7
www.reelcraft.com
Page 7
Page 6
Series LS 5000 Stainless Steel Cord Reels
Item
#
1 Inlet Cord Assembly 1 602002 602002 260630 260630 None 262307 262307
2 Connector, 90° Cord 1 261140-C 261140-C 261140-C 261140-C 261140-C 261140-C 261140-C
3 Set Screw 3/8-19 x 1/2” Pin 1 S47-64 S47-64 S47-64 S47-64 S47-64 S47-64 S47-64
4 Lock Nut 10-32 Hex 22 S348-15 S348-15 S348-15 S348-15 S348-15 S348-15 S348-15
5 Snap Ring 2 S147-25 S147-25 S147-25 S147-25 S147-25 S147-25 S147-25
6 Spring Case Stud 1 261361 261361 261361 261361 261361 261361 261361
7 Screw, 10-32 x 1/2” 2 S46-107 S46-107 S46-107 S46-107 S46-107 S46-107 S46-107
8 Guide Arm Assembly 1 600057 600057 600057 600057 600057 600057 600057
9 Bumper Assembly 1 1-HS1004-A 1-HS1004-A 1-HS1004-A 1-HS1004-A 1-HS1004-A 1-HS1004-A 1-HS1004-A
10 Spring Arbor 1 S400017 S400017 S400017 S400017 S400017 S400017 S400017
11 Latch Cam 1 260224 260224 260224 260224 260224 260224 260224
12 Sheave Disc 1 260223 260223 260223 260223 260223 260223 260223
13 Strain Relief 1 260633 260633 260633 260633 260633 260633 260633
14 Plate Adapter 1 261577 261577 261577 261577 261577 261577 261577
15 Hex Screw 1/4-20 x 5/8” 3 S324-102 S324-102 S324-102 S324-102 S324-102 S324-102 S324-102
16 Collector Ring Assembly 1 602296 602296 602296 602296 602296 602296 602296
17 Cover 1 261723 261723 261723 261723 261723 261723 261723
18 Snap Ring 1 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13 S140-13
19 Wire Nut 3 260774 260774 260774 260774 260774 260774 260774
20 Grounding Cord Assembly 1 600283 600283 600283 600283 600283 600283 600283
21 Lock Washer 1 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10 S115-10
22 Connect Terminal 1 260609 260609 260609 260609 260609 260609 260609
23 Terminal Block Assembly 1 600205 600205 600205 600205 600205 600205 600205
24 Sheave Assembly 1 602790 602790 602790 602790 602790 602790 602790
25 Screw 10-32 x 3/8” 5 S46-105 S46-105 S46-105 S46-105 S46-105 S46-105 S46-105
26 Latch Plate Spring 1 S400018 S400018 S400018 S400018 S400018 S400018 S400018
27 Screw 10-24 x 3/8” 1 S332-117 S332-117 S332-117 S332-117 S332-117 S332-117 S332-117
28 Screw 10-32 x 1” 1 300035 300035 300035 300035 300035 300035 300035
29 Latch Bumper 1 S400021 S400021 S400021 S400021 S400021 S400021 S400021
30 Latch Plate Bumper 1 600062 600062 600062 600062 600062 600062 600062
31 Latch Bushing 1 260225 260225 260225 260225 260225 260225 260225
32 Base Assembly 1 600056 600056 600056 600056 600056 600056 600056
33 Cable Path Axle 1 263124 263124 263124 263124 263124 263124 263124
34 Spacing Washer 1 260238 260238 260238 260238 260238 260238 260238
35 Drive Spring Assembly 1 504240 504240 504240 504240 504240 504240 504240
36 Spring Case Assembly 1 600061-1 600061-1 600061-1 600061-1 600061-1 600061-1 600061-1
37 Nyloc Nut 10-32 x 3/8” 1 S95-22 S95-22 S95-22 S95-22 S95-22 S95-22 S95-22
38 Single Outlet 1 None None None None None None None
39 Duplex Box Cord Assembly 1 602333-45 602255-45 None None None None None
40 Triple Tap Cord Assembly 1 None None 602498 602497 None None None
41 Flying Leads 1 None None None None None 602353-25 602353-45
Description
#
Req.
LS 5445
123 7A
LS 5445
123 7B
LS 5445
123 9
LS 5445
123 9G
LS 5400
LS 5425
123 X
LS 5445
123 X
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