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1 Instructions -Parts List- Service Manual NS Series Hydraulic Driven Hose Reel New Product NS Series c/w Hydraulic Motor (OMP 80) August 2012 Suitable for dispensing, transfer and evacuation of lubricants, fuels, air and other automotive & industrial products. To be used in general industry, mining & heavy earth moving applications. Special Features include: Long hose length capacity High strength / ridged frame and drum Compact width & height The Reel People JSG Industrial Systems PTY LTD Unit 1, 21 Amour St Revesby 2212 Australia T: +61 2 9914 8720 F: +61 2 9914 8798 T: [email protected] W: www.jsgindustrial.com

NS Series Hydraulic Driven Hose Reel - JSG Industrial Systems Pty Ltd

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1

Instructions -Parts List- Service Manual

NS Series Hydraulic Driven Hose Reel New Product

NS Series c/w Hydraulic Motor (OMP 80) August 2012

Suitable for dispensing, transfer and evacuation of lubricants, fuels, air and other

automotive & industrial products. To be used in general industry, mining & heavy earth

moving applications.

Special Features include:

Long hose length capacity

High strength / ridged frame and drum

Compact width & height

The Reel People

JSG Industrial Systems PTY LTDUnit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 T: [email protected]: www.jsgindustrial.com

2

INDEX

Legal Notices Pg 3

List of NS models Pg 4

Warning Pg 5

Roller bracket Positioning Pg 6

Hose & swivel installation Pg 7

Motor installation Pg 8

NS hose reel Exploded View Pg 9

Parts List NS600-HMG-25/06 Pg 10

Parts List NS600-HM-30/08 Pg 10

Parts List NS 1000-HM-25/16 Pg 11

Parts List NS1800-HM-25/16 Pg 11

Dimensions drawing Pg 12

Dimensions of hose reel Pg 13

Service and Maintenance Pg 14

Trouble Shooting Guide Pg 15

The Reel People

JSG Industrial Systems PTY LTDUnit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected]: www.jsgindustrial.com

3

Legal Notices and Indemnity Copy right All the information contained in this booklet which includes but not limited to the Drawings, pictures, diagram’s technical information & technical knowhow process remains the intellectual property of COBRA REELING (PROPRIETY) LIMITED and no part of it may be reproduced, published or copied in any form electronic or any other, without the express written permission of COBRA REELING and/or any duly appointed agent, supplier or OEM manufacturer within the Republic of South Africa or any continent, country or territory whatsoever. The court of Jurisdiction is the Magistrates Court jurisdiction Johannesburg South Africa. Cobra Reeling and/or any affiliated agents, suppliers, distributors or OEM manufactures may at its sole prerogative or in the ordinary practice of law apply to any court in any country, continent or territory to found jurisdiction. COBRA REELING reserves the right to institute any legal proceedings civil or criminal in any court jurisdiction worldwide relating to copying of this material or any Cobra Reeling OEM products or agents products. All local, National, municipal or bylaws must be followed at all times when operating and installing any Cobra Reeling equipment and Cobra Reeling denies any liability whatsoever for non-compliance to National, Local or Municipal laws by any operator, distributor or customer in the Republic of South Africa or any continent, country or territory what so ever. Waiver of Liability The OEM (original Equipment manufacturer) of this Equipment COBRA REELING (propriety) limited its Shareholders, directors, staff, duly appointed distributors or any company this equipment forms part of any OEM product denies any responsibility for any incidents, injuries or death due to misprints or clerical errors, improper use or improper installation whatsoever. The same applies for any COBRA REELING products within the Republic of South Africa and/or any Continent, country or territory whatsoever, in any criminal or civil matter that may arise.

Good Faith COBRA REELING (PTY) LIMITED equipment is only for its intended purpose and industry & only supplies equipment in a BONA FIDA manner to customers, distributors and OEM manufactures and cannot be held responsible for any misrepresentation by customers, distributors or OEM manufactures who supply equipment incorrectly either intentionally or in error to any person(s) natural or juristic and any government, terrorist or criminal organisation in the Republic of South Africa, Australia, Indonesia, Philippines, European Union or in any continent, country or territory worldwide.

The Reel People

JSG Industrial Systems PTY LTDUnit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected] W: www.jsgindustrial.com

4

List of NS Hydraulic Driven Models

Model Typical Application

Working Pressure Bare Hose Reel

Hose Length & Diameter

NS600-HMG-25/06

General Industry Mining & Heavy Construction, Truck and bus servicing & Mariner service applications

400 BAR MAX FOR GREASE Inlet 1/2" NPT F Outlet 9/16" JIC M

R2 3/8” X 25 MET R 2 ½” X 25MET

NS600-HML-30/08

General Industry Mining & Heavy Construction, Truck and bus servicing & Mariner service applications

220 BAR MAX FOR LUBE OILSInlet 3/4" BSP FOutlet 1 1/16" JIC F

R1 3/8” 30 MET R1 ½” X 30 MET

NS1000-HML-26/16

General Industry Mining & Heavy Construction, Truck and bus servicing & Mariner service applications

220 BAR MAX FOR LUBE OILSInlet 1" BSP FOutlet 1 5/16" JIC M

R1 ¾” 25 MET R1 1” X 25MET

NS1800-HML-15/24 Co

General Industry Mining & Heavy

nstruction, Truck and bus servicing & Mariner service applications

220 BAR MAX FOR LUBE OILSInlet 1 1/2" BSP FOutlet 1 7/8" JIC M

R1 1 ½” X 15 MET

Note: 1. All hose reel lengths stated include “hose hang down’ 2. All hose reel capabilities are based on using the hose specified

The Reel People

JSG Industrial Systems PTY LTD Unit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected] W: www.jsgindustrial.com

5

WARNING

Read all instructions before operating equipment.

Use equipment within specific working range – pressure & hose lengths.

Use only products compatible with flow path components.

If hose is fitted to equipment follow the instructions as detailed in this document.

Ensure all pressure is released from the hose reel before working in the reel or hose.

Check that hose reel is suitable mounted before commencing with hose pay out.

Only qualified personnel to handle this equipment.

The Reel People

JSG Industrial Systems PTY LTD Unit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected] W: www.jsgindustrial.com

6

WARNING

Never allow the hose reel drum to spin freely. Tension should be applied on the brake through rotation of the wing nut on the brake assembly Roller bracket positioning The NS Series of hose reels referred to in the booklet are able to be mounted in Various positions to suit the working applications. The hose guides can to be repositioned to suit the different mountings.

Position A: Floor / Upright Mounting

Position B: Rear Pay-out / Mid-Level Mounting

The Reel People

JSG Industrial Systems PTY LTDUnit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected] W: www.jsgindustrial.com

7

Instructions to fit or reposition roller bracket:

Ensure that the hose reel is always mounted securely before working with it.

If the hose reel is not fitted with hose ensure the hose reel drum is not under tension from the air/ hydraulic motor.

If the hose reel is fitted with hose use the tension on the brake to keep drum from freely rotating and set up brake by rotation of wing nut if required. Remove the hose stop from the hose. Carefully hold the hose on the drum.

Remove the hose guide from the hose reel by loosening the four hex securing bolts.

Attach the hose guide to the hose reel in the required position.

Reroute the hose through the hose guide as shown in the illustration.

Replace hose stop.

Motor Installation:

Hose reel is factory fitted with an ”OMP 80” hydraulic motor.

Secured to reel with two M12 bolts on a two hole S.A.E Flange.

The Reel People

JSG Industrial Systems PTY LTDUnit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected]: www.jsgindustrial.com

8

WARNING To avoid injury ensure that you always wear non slip heavy duty gloves when installing hose on a hose reel.

Hose and swivel installation Note: Ensure that the correct length and type of hose is installed to avoid over winding, hose skipping the drum or rubbing on the roller brackets

Ensure the hose reel is secured to a firm level surface.

Fit swivel ensuring dowty washer is in place and liquid thread sealant is used.

Attach the hose to be fitted in the centre of the hose reel drum

Place the hose to be fitted in a straight line in front of the hose reel

After the hose has been coiled on the drum the hose stop should be fitted in the appropriate place on the hose. The length of the hose left outside of the hose reel should be suitable for the mounting application and the operator should be able to reach the dispensing valve with ease and safety

The Reel People

JSG Industrial Systems PTY LTDUnit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected] W: www.jsgindustrial.com

9

NS Hydraulic Drive hose reel exploded view

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10

NS600-HMG-25/06

PARTS LIST REFER TO EXPLODED VIEW PAGE 9

DRW NO Part Number Description Qty per Reel

1 09-OMP80 Hydraulic Motor 1

2 09-NS600-SPD-30-0B Side Plate drive side 2

3 09-NSC-DB-1B Drum boss 2

4 09-NS600-SFTD-0P-1/2G 19mm Drive shaft NS 600 1

5 09-NSC-B-40 C6008-2RS bearing on shaft 2

6 09-NS600-CBS/H-0b NS 600 Centre band steel 1

7 09-NSC00-BB-1B NS Bearing Boss 2

8 09-NS678-FKZ-ZP Drum spacer part of kit 6

9 09-NS678-RBKC-0B NS Series Roller bracket assembly c/w rollers

1

10 09-8-8-CTX 90 ®Adaptor 1

11 NOT APPLICABLE

12 09-9SS8MP50XFP50 Super Grease swivel HP ½” NPT 1

13 09-NS1510-BSC-0b NS1510 Bearing stop cover 1

14 09-NS600-BB-278-0B Ns 600 Base bracket 275 MM 2

15 09-NSC00-CBC-140-0b Centre Band clamp 140mm 2

16 09-PLC36mm P Clamp 36mm 1

17 09-BSC-BB-1B Refer to item 7 2

18 09-NS600-SP-30-0B Side plate plain side 1

NS600-HML-30/08 PARTS LIST REFER TO EXPLODED VIEW PAGE 9

DRW NO Part Number Description Qty per Reel

1 09-OMP80 Hydraulic Motor 1

2 09-NS600-SP-30-0B Side Plate 2

3 09-NS-600-DS-0B NS 600 Drum Side 2

4 09-NS600-SFTD—0P-1/2” 19mm Drive shaft NS 600 1

5 09-NSC-B-40 C6008-2RS bearing on shaft 2

6 09-NS600-CBS/H-0b NS 600 Centre band steel 1

7 09-NSC00-BB-1B NS Bearing Boss 2

8 09

9 09-NS678-RBKC-0B NS Series Roller bracket assembly c/w rollers

1

10 09-8-8-CTX 90®Adaptor 1

11 NOT APPLICALBE

12 09-111-2062 Grease swivel HP ½” NPT 1

13 09-NS1510-BSC-0b NS1510 Bearing stop cover 1

14 09-NS600-BB-278-0b Ns 600 Base bracket 275 MM 2

15 09-NSC00-CBC-140-0b Centre Band clamp 140mm 2

16 09-PLC36mm P Clamp 36mm 1

17 09-BB-1B Refer to item 7 2

18 09-NS600-SP-30-0B Side plate plain side 1

11

NS1000-HML-25/16 PARTS LIST REFER TO EXPLODED VIEW PAGE 9

DRW NO Part Number Description Qty per Reel

1 09-CMP80 c/w Flange Hydraulic Motor 1

2 09-NS1500-SPh--0B Side Plate hyd and air 1

3 09-NSC00-DB-1B NS Drum boss 2

4 09-NS1000-SFTDH—0P Hydraulic drive shaft 1

5 09-NSC-B-40 C6008-2RS bearing on shaft 2

6 09-NS1500-CBS-0B NS 1500 Centre band steel 1

7 09-NSC00-BB-1B NS Bearing Boss 2

8 09-NS1000-FK-ZP Drum spacer part of fastener kit

9 09-NS1510-RBKC-0B Roller bracket assembly c/w rollers

1

10 09-NS16-GN-REV1 Goose neck 1

11 NOT APPLICABLE 1

12 09-111-2064 1” oil swivel 1

13 09-NS1510-BSC-0b NS1510 Bearing stop cover 1

14 09-NS600-BB-375-0B Base bracket 375 MM 2

15 09-NSC00-CBC-235 Centre Band clamp 235mm 2

16 09-PLC36mm P Clamp 36mm 1

17 09-NSC00-BB-1B Refer to item 7 2

18 09-NS1500-SP-0B NS1500 side plate 1

NS1800-HML-25/16 PARTS LIST REFER TO EXPLODED VIEW PAGE 9

DRW NO Part Number Description Qty per Reel

1 09-CMP80 Hydraulic Motor c/w flange 1

2 09-NS1800-SPH--0B NS 1800 side plate hyd and air 1

3 09-NS-1500-DB-0P NS 1500 drum boss plated 2

4 09-N1800-SFTDH-0P NS 1800 drive shaft 1

5 09-NSC-B-40 C6008-2RS bearing on shaft 2

6 09-NS1800-CBS-0B NS 1800 Centre band steel 1

7 09-NSC00-BB-1B NS Bearing Boss 2

8 09-NSP-237P Drum spacer 5

9 09-NS1800-RBKC-0B NS Series Roller bracket assembly c/w rollers

1

10 NS24-GN-REV1 Goose Neck for 1 ½” hose reel 1

11 NOT APPLICABLE 1

12 09-111-2066 1 ½” oil swivel 1

13 09-NS1510-BSC-0b NS1510 Bearing stop cover 1

14 09-NSC-BB-0B-375 Base bracket 375 2

15 09-NSC00-CBC-235-0B Centre Band clamp 235mm 2

16 09-PLC36mm P Clamp 36mm 1

17 Refer to item seven Refer to item 7

18 NS1800-SP-0b Ns 1800 Side plate 1

12

DIMENSIONS DRAWING

The Reel People

JSG Industrial Systems PTY LTDUnit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected] W: www.jsgindustrial.com

13

DIMENSIONS OF REELS Refer to page 12

NS600-HMG-25/06 NS600-HML-30/08

A 250 mm A 250 mm B 276 mm B 276 mm

C 344 mm C 344 mm D 305 mm D 305 mm

E 443 mm E 443 mm

F 580 mm F 580 mm G 287 mm G 287 mm

NS1000-HML-25/16 NS1800-HML-15/24 A 370 mm A 370 mm

B 370 mm B 375 mm C 462 mm C 466 mm

D 405 mm D 405 mm

E 580 mm E 582 mm F 664 mm F 750 mm

G 337 mm G 423 mm

The Reel People

JSG Industrial Systems PTY LTDUnit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected] W: www.jsgindustrial.com

14

SERVICE AND MAINTENANCE

Swivel:

Warning– relieve all pressure from the hose reel before working on the equipment

All models in this range have removable swivels

If the swivel needs replacing or repair – i.e. leaking or seized up, the following procedure must be followed:-

o Unscrew the swivel from the hose reel shaft by using a wrench on the two flats located on the rear of the swivel spindle.

o With non-slip gloves hold the drum of the hose reel & loosen & unscrew the swivel.

o Replace the Swivel with a new swivel as there are no serviceable parts & screw back by holding the drum of the hose reel.

The Reel People

JSG Industrial Systems PTY LTDUnit 1, 21 Amour St Revesby 2212 AustraliaT: +61 2 9914 8720 F: +61 2 9914 8798 E: [email protected] W: www.jsgindustrial.com

15

TROUBLE SHOOTING GUIDE

WARNING - RELIEVE ALL PRESSURE FROM THE HOSE REEL BEFORE WORKING ON THE EQUIPMENT

Diagnosis Likely Cause Solution Hose does not retract at all

Product supply piped to the swivel connected is not a flexible hose

When the flexible connection hose to the swivel is not used excessive pressure is exerted on the shaft and bearing causing the reel to bind. This will invalidate the warranty

Malfunctioning hydraulic motor

Make sure the hydraulic motor is functioning correctly i.e. sufficient pressure to the motor, sufficient hydraulic oil.

Hose reel turning the wrong way

The hose connections to the hydraulic motor are connected in the wrong ports

Swop the hoses to the hydraulic motor around

Swivel Leak Damaged backing ring and/or O-ring

Fit a new swivel.

Hose does not retract fully

Insufficient motor pressure

Check and clean air or hydraulic reticulation. Set pressure correctly