Reelcraft Welding Reels Condensed Version - Manual

Safety
1. Ensure that the reel is properly installed before
connecting input/output hoses or to power supply.
2. Bleed fluid/gas pressure from system and
disconnect all power before servicing the reel.
3. Before connecting reel to supply line, ensure that
pressure/voltage/amperage does not exceed maximum
working pressure/voltage/amperage rating of the reel.
4. Ensure that the reel, hose/cord and equipment being
serviced are properly grounded. Use an ohmmeter to
check ground continuity.
5. Pull hose/cord from reel by grasping the hose/cord
itself, not the work device.
6. A high tension spring assembly is contained
within the reel.
Exercise extreme caution.
7. If reel ceases to unwind or rewind, remove
system pressure/power immediately. Do not pull or jerk
excessively on hose/cord!
8. Treat and respect the reel as any other piece of
machinery, observing all common safety practices.
9. If a leak/electrical malfunction occurs in the hose or
reel, remove system pressure/power immediately.
10. Remember, even low pressure/low voltage is very
dangerous and can cause personal injury or death.
Exercise extreme caution.
12. Check for faulty supply wires or hoses before
operating.
13.
CAUTION: Do not shut off the fuel gas at the
regulator or supply source first, as a flashback may
result, and thereby damage the hose. Shut off the gas
at the torch first, and then at the regulator or supply
source, to limit permeation of gas through the hose wall.
This should be done when the torch will not be used for
periods in excess of 30 minutes.
14. After the flame has been extinguished and the gas
turned off at the supply source, it is recommended that
any remaining gas be bled to minimize degradation of
the rubber during long shutdowns.
15. To prevent an accumulation or concentration of gas
that could be explosive or otherwise harmful to person-
nel, adequate ventilation must be provided at all times,
particularly in confined areas where fuel gas is being
used.
Installation
For cable reels, ensure that only a qualified electrician
installs/services equipment. Observe applicable NEC,
OSHA, and local electrical codes when installing this
equipment. Unless reel was specified differently when
ordering, maximum installation height is 16 feet. Do not
exceed this distance.
Mounting & Guide Arm Adjustment
The reel is equipped for universal mounting so that it
can be mounted on a structurally sound floor, wall or
ceiling; whichever provides maximum performance. The
guide arm on spring driven reels must be rotated to a
position that allows the hose/cord to feed through the
roller brackets with minimal bending. Replace the
fasteners. Where applicable, the U-Bolt, which fastens
hose to spool, must be placed in the proper location
when rotating the guide arm, otherwise the reel might
“latch out” during use. Refer to online manual for proper
U-Bolt locations. Position reel to mounting surface and
secure into place, using four secure fasteners (not
included).
Install the Output Cord (Series WC)
1. Remove the three outer nuts on the collector ring
cover and remove the cover.
2. Strip 1 1/8” of insulation from the output cord and
insert cord around the reel spool (not through the guide
arm opening).
3. Add protective tubing around opening in spool.
4. (Series WC7000) Route the cord through the
opening in the spool, through the opening in the
collector ring base casting, then through the strain relief
until cord is between 2 clamp plates. Tighten clamp
plate fasteners until the cord is securely captured
between the plates; tighten strain relief. (Series
WC80000) Route cord through the opening in the spool,
through the strain relief, through the main shaft and then
capture cord at end of collector ring with set-screw.
Fasten strain relief to the main shaft and tighten cord
with strain relief.
5. Replace the collector ring with 3 outer nuts.
6. Fasten cord to spool by capturing with U-Bolt .
Fasten to spool with nuts/washers supplied.
7. Wrap all of the cord around the spool.
8. Once cord is on the spool, add additional turns to
add tension (2-3 should be sufficient).
9. Add cord bumper stop at desired location.
10. Use an ohmmeter, check for ground faults.
Install/Replace the Hose (Series TW)
CAUTION: Use extreme caution; reel under tension.
Avoid releasing the latch mechanism. Apply Teflon tape
to inlet/outlet connections. Refer to page 4 for inlet hose
connection instructional drawings.
1. Manually turn spool assembly until spring is tight,
back off three turns then latch.
2. Route output hoses through guide bracket.
3. Using a wrench, firmly hold onto output fittings
on swivel (Series 5000, 7000 & 8000) or fittings
on shaft (Series 30000 & 80000) while tightening the
hose connector.
Replace the Swivel
CAUTION: Remove supply line pressure before
performing the following procedure.
1. Remove supply line from swivel.
2. Remove swivel assembly from inlet shaft.
3. Apply thread sealant to threaded connection and
re-install swivel assembly to inlet shaft by reversing
steps 1 and 2.
Adjust the Reel
CAUTION: Use extreme caution; reel under tension.
Avoid releasing latch mechanism.
1. If necessary, adjust spring tension of reel by adding/
removing wraps of hose/cord from spool, one at a time,
until desired tension is obtained.
2. Add wraps to increase tension. Remove wraps to
decrease tension.
CAUTION: When adding wraps of
hose/cord, be careful not to exceed the winding
mechanisms spring capacity. Add just enough wraps of
hose/cord to achieve the desired tension. Damage to the
winding mechanism will result if spring is
over-tensioned.
Repairs
User servicing of the reel is limited to replacing the
hoses/cords or swivel only. Refer all other repairs
directly to the manufacturer. Failure to do so can result
in personal injury and/or equipment damage and may
void the warranty.
Operating Instructions
Condensed Version (Welding)
R
Reelcraft Industries, Inc.
2842 East Business Hwy 30, Columbia City, IN 46725 USA
Toll-free: 1-800-444-3134 or 260-248-8188
Toll-free fax: 1-800-444-4587 or 260-248-2605
[email protected] www.reelcraft.com
Read these instructions carefully before attempting to install, operate or maintain this
product. Only qualified persons should install this product. Failure to comply with
nstructions may result in personal injury and/or property damage. Every attempt is made
to ensure the accuracy and completion of these instructions; however, manufacturer is not
responsible for ommissions. To obtain the complete version of Reelcraft’s service manu-
als, please visit www.reelcraft.com or call Customer Service during business hours. For
Technical Bulletins and support, please visit www.reelcraft.com.
Welding Reels
Series TW Series WC Series BA
Refer to page 4 for dimensional drawings.
Series TW
TW5425 OLP
Rely on Reelcraft
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s Better by Design
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Page 1
Series TW
TW7450 OLP
Series TW
TW84100 OLPT
Series BA
BA36106 L
Series WC
WC7000
Series WC
WC80001
Form #400-908 REVISED: 1/11