I

NSTALLATION INSTRUCTIONS
SERVICE AND TROUBLESHOOTING

Single Line Hose Reels

Serial Numbers 679532 through 679545

Manual Number 680110-R1

cascade
corporation

Cascade is a Registered Trademark of Cascade Corporation

ONTENTS

INTRODUCTION
INSTALLATION
SERVICE
Disconnecting The Reel
Inboard Spring Reel Service
Outboard Spring Reel Service
Hose Replacement
TROUBLESHOOTING GUIDE
HOSE LENGTH CALCULATIONS

Page
i
1
3
3
4
5
6
7
8

NTRODUCTION

This manual contains Installation, Service and

Troubleshooting information for the Single Line Hose Reels.
For additional questions, refer to the back cover for the
nearest Cascade Service Department.

Junction Block Selection Guide

Refer to the chart for the appropriate type of junction block

for Cascade attachments. See Technical Bulletin 291 for
junction block selection and part numbers.

Attachment

To order replacement parts, contact the Cascade Central

Parts Depot:
Cascade Corporation
P.O. Box 360
Springfield, Ohio 45505
Tel.: (513) 322-1199
Telex: 279563
Fax: (513) 325-9270

Junction Block

Sideshifter

Fork Positioner

Integral Carriage

Push Pull

Without
Checks

Paper Roll Clamp

X

Carton Clamp

Rotators

Multiple Load Handlers

Clamps - D Series

With
Checks

X
X

680110-R1

NSTALLATION

1 Install one of the mounting kits listed below to the hose

reel shaft.

B The inner reel flange should not be no more then 1/4 in.
from the side of the mast and should be placed behind
the mast channel rather than along the side of it.

MODEL
MOUNTING KIT
Inboard Spring Reel
629330
Outboard Spring Reel
615492

C The reel should not extend beyond the widest part

of the truck to prevent possible damage to the reel
during truck operation.

Inboard Spring Reel

Mounting Kit 629330

Inner reel flange

placement.

Inner Reel
Flange

INBOARD SPRING
HOSE REEL SHOWN

Outer Reel
Flange

Mounting
Pad

4-7/8 in.
min.

Mounting
Pad

Outboard Spring Reel

Mounting Kit 615492

Mast Channel

HR0019.eps

MAST FRONT

1/
4
1/4

in.

HR0020.eps

2 Determine a location to weld the mounting pad on the

mast upright or truck cowling. Consider the following:

A Locate the mounting pad on the mast channel or truck
cowling. The reel flanges must not interfere with:
The truck overhead guard when the mast is tilted
all the way back (if the reel is mounted on the
mast).
The truck carriage as it moves past the reel (if the
reel is mounted on the mast).
The mast carriage members when the mast is
tilted all the way back (if the reel is mounted on
the truck cowling).

Locate mounting pad on mast

channel or truck cowling.

3 Remove the mounting kit from the hose reel shaft.

4 Weld the mounting pad in place using 3/16 in. fillet

welds (use E 60XX rod with no preheat or postheat)

along the vertical sides of the mounting pad only. Cover
the mast hoist chains to shield from weld splatter.

5 Attach the hose reel to the mounting pad.

caspcrews to a torque of 52-57 ft.-lbs.

WARNING:
Weld on vertical
seams only.
Fillet Weld

Tighten the

Mounting Pad

Check clearances at
these locations when
locating the Reel.
HR0021.eps

HR0012.eps

680110-R1

Lockwasher
Mounting capscrew
Torque to 52-57 ft.-lbs.

NSTALLATION

6 Raise the carriage to a position approximately even

with the top of the hose reel. Position the junction block
where the shaft fittings are centered between the reel
flanges. Using the junction block as a guide, mark the
location of the junction block mounting holes on the
back side of the carriage. Make sure the junction block
is positioned vertically.

11

Hoses

532
679

7 Lower the truck carriage to the floor.

8 Drill and tap the holes at the location marked on the

Hub Fittings

carriage. The thread depth should be drilled a minimum

of 1/2 in. Hole diameter and drilling information are
shown.

HR0024.eps

Junction Block
Shaft Fittings.
Center fittings
between Reel
Flanges.

12

HOSE REEL IDENTIFICATION

Viewed from the flange side of the reel

RIGHT HAND
REEL

.316 Drill
Tap .375-16 UNC
3 Holes - .5 in. min.
thread depth.

capscrews and lockwashers. Tighten the capscrews to

a torque of 52-57 ft.-lbs.

532

9 Install the junction block to the carriage using 3/8 in.

679

HR0022.eps

RIGHT HAND REEL SHOWN

Reel Flanges

Carriage

10

LEFT HAND
REEL

Install Fitting Kits

235
97

HR0023.eps

10 Install one of the fitting kits listed below to the hose reel
INBOARD SPRING HOSE REELS
FITTING KIT
HOSE SIZE

646063
No. 5

646062
No. 6

646061
No. 8
INBOARD SPRING HOSE REELS
FITTING KIT
HOSE SIZE

646308
No. 5

646307
No. 6

646306
No. 8

HR0025.eps

shaft and hub ports.

11 Install the outer hoses to the hose reel rub fittings.

12 Wind the outer hose completely onto the reel in the
direction indicated (viewed from the flange side):
Right Hand Reel: Wind hose clockwise.
Left Hand Reel: Wind hose counterclockwise.
A Right or Left hand reel is determined as viewed from
the flange side of the reel, as shown.

680110-R1

NSTALLATION

13 Prewind the reel spring by grasping the end of the outer

hose and turning the reel a minimum of 3 turns in the
direction indicated (viewed from the flange side):
Right Hand Reel: Wind reel clockwise.
Left Hand Reel: Wind reel counterclockwise.
CAUTION: Rotation in the wrong direction will damage
the inner spring.
If more tension is required, the reel can be prewound
additional turns. The maximum turn capacity is 16 total
turns.
CAUTION: Exceeding the turn capacity of the reel will
damage the inner reel spring.
WARNING: Do not let the reel unwind when
connecting the hose to the junction block.

14

Connect
Attachment
Hoses

14 With the reel prewound, pull the hose ends down and
install to the junction block shaft fittings.

15 Connect the attachment hoses to the junction block.

Be sure the hoses and their functions do not become

interchanged.

16 Operate the carriage up and down a few times to make

sure the hoses track smoothly and no interference exists.

15
Function B

Function A

From Hose
Reel

Carriage

Junction
Block Shaft
HR0027.eps

Function A
Function B

HR0026.eps

ERVICE

DISCONNECTING THE REEL

1 Disconnect the hoses from the junction block shaft

fittings. Fasten the loose hose ends to the reel flanges

with wire or strapping tape.

Hose Reel

680110-R1

pad. Remove the reel from the mast. For reassembly,

tighten the capscrews to a torque of 52-57 in.-lbs.

235
97

2 Disconnect the hoses from the hose reel shaft fittings.

3 Remove the capscrews fastening the reel to the mounting

WARNING: Hold hose firmly while

disconnecting the hoses from the junction
block. Allow the reel spring to unwind slowly
while maintaining tension on the hose end.

HR0066.eps

ERVICE

INBOARD SPRING REEL SERVICE

1 Disconnect the hoses from the reel hub fittings.

2 Remove the outer snap ring from the end of the hose reel
shaft.

3 Remove the four nuts fastening the spring assembly to

the reel flanges. For reassembly, tighten the capscrews

to a torque of 70-75 in.-lbs.

32
6795

4 Pull the reel flanges (with hoses) and hub off of the shaft.
5 Remove the three capscrews and nuts fastening the

HR0137.eps

reel flanges to the hub. For reassembly, tighten the

capscrews to a torque of 70-75 in.-lbs.

6 Disengage the spring end of the spring assembly from

8,9

the spring retainer on the shaft.

7 If the spring retainer has been damaged, remove the

spring retainer snap ring and install a new spring retainer.

Inspect
Shaft
Sealing
Surfaces

Hub
Grooves

8 Remove the seals from the hub.

Avoid scratching the

grooves. Clean the hub and shaft with solvent.
The sealing surface on the shaft is nickel plated. If
minor surface imperfections are noted, use emery
cloth (320 Grit) to lightly smooth up. If sharp edges or
grooves are found, shaft replacement is necessary.
Hub grooves must be free of sharp nicks or
projections to prevent cutting of the outside diameter
of the o-rings during installation.

O-Rings

9 For reassembly, reverse the above procedures except

Back-Up
Rings

as follows:

Lubricate the shaft, seal and bore of the hub with

hydraulic oil.
Install the back-up rings into the hub grooves. Place
a portion of the ring in the groove, then bend as
required to install. Install the o-ring seals.

HR0067.eps

Install the reel to the mast as described in the

Installation Instructions.

Reel Flanges

4
5

RIGHT HAND REEL SHOWN

Hub

Spring Assembly

Hub Seals

Shaft

Spring Retainer
Snap Ring
Felt Seal

Outer Snap Ring

Hose Guide

3
HR0070.eps

Mounting
Blocks

680110-R1

ERVICE

OUTBOARD SPRING REEL SERVICE

1 Remove the four nuts fastening the spring assembly to

the reel flanges. For reassembly, tighten the capscrews

to a torque of 70-75 in.-lbs.

2 Disengage the spring end of the spring assembly from

6795

32

the spring retainer on the shaft. Remove the spring

assembly.

3 Disconnect the hoses from the reel hub fittings.

4 Remove the spring retainer snap ring, spring retainer and

HR0138.eps

sleeve from the shaft.

5 Pull the reel flanges (with hoses) and hub off of the shaft.
6 Remove the three capscrews and nuts fastening the
reel flanges to the hub. For reassembly, tighten the
capscrews to a torque of 70-75 in.-lbs.

7 If the spring retainer has been damaged, it should be

replaced at this time.

8 Remove the seals from the hub.

Avoid scratching the

grooves. Clean the hub and shaft with solvent.

8,9

Inspect
Shaft
Sealing
Surfaces

Hub
Grooves

The sealing surface on the shaft is nickel plated. If

minor surface imperfections are noted, use emery
cloth (320 Grit) to lightly smooth up. If sharp edges or
grooves are found, shaft replacement is necessary.
Hub grooves must be free of sharp nicks or
projections to prevent cutting of the outside diameter
of the o-rings during installation.

O-Rings

Back-Up
Rings

9 For reassembly, reverse the above procedures except

as follows:

Lubricate the shaft, seal and bore of the hub with

hydraulic oil.
Install the back-up rings into the hub groove. Place
a portion of the ring in the groove, then bend as
required to install. Install the o-ring seals.

HR0067.eps

Install the reel to the mast as described in the

Installation Instructions.

1
2

Reel Flanges

Snap Ring

Spring
Assembly

RIGHT HAND REEL SHOWN

Sleeve

Hub

Hub Seals
Spring Retainer
Shaft

Hose Guide

680110-R1

HR0071.eps

ERVICE

HOSE REPLACEMENT

1 Disconnect the hoses from the junction block shaft

fittings.

WARNING: Hold hose firmly while

disconnecting the hoses from the junction
block. Allow the reel spring to unwind slowly
while maintaining tension on the hose end.

2 Disconnect the hoses from the reel hub fittings.

direction indicated (viewed from flange side):

Right Hand Reel: Wind hose clockwise.

Left Hand Reel: Wind hose counterclockwise.
A Right or Left hand reel is determined as viewed from
the flange side of the reel.

5 Prewind the reel spring by grasping the end of the outer

hose and turning the reel a minimum of 3 turns in the
direction indicated (viewed from the flange side):
Right Hand Reel: Wind reel clockwise.
Left Hand Reel: Wind reel counterclockwise.

Hub Fittings

Hoses

CAUTION: Rotation in the wrong direction will damage

the inner spring.
If more tension is required, the reel can be prewound
additional turns. The maximum turn capacity is 16 total
turns.
CAUTION: Exceeding the turn capacity of the reel will
damage the inner reel spring.

532

3 Install the new outer hoses to the hose reel hub fittings.
4 Wind the outer hose completely onto the reel in the

679

6 With the reel prewound, pull the hose ends down and
install to the junction block shaft fittings.

WARNING: Do not let the reel unwind when

connecting the hose to the junction block
fittings.

HR0024.eps

RIGHT HAND REEL SHOWN

HOSE REEL IDENTIFICATION

Viewed from the flange side of the reel

RIGHT HAND
REEL

From Hose
Reel

Carriage

532
679

Junction
Block Shaft

HR0068.eps

7 Operate the carriage up and down a few times to make

LEFT HAND
REEL

sure the hoses track smoothly and no interference exists.

976

235

c
HR0025.eps

680110-R1

ROUBLESHOOTING
PROBLEM

Excessive wear on the hose.

Hose jumps off the reel during

operation.

Hose binds during operation.

Hose reel leaks at the hub.

680110-R1

PROBLEM CAUSE

SOLUTION

Hose reel and junction block are not

in proper alignment.

Align the junction block and hose reel

properly. They must be on the same
centerline and mounted squarely to
each other. See page 2, step 6.

Hose reel flanges are damaged.

Repair or replace damaged parts.

Incorrect prewind of spring.

Prewind spring. Refer to page 2, step

13 through 16.

Hose reel and junction block are not

in proper alignment.

Align the junction block and hose reel

properly. They must be in the same
centerline and mounted squarely to
each other. See page 2, step 6.

Hose reel spring is broken.

Replace spring.

Seals in hub working between shaft

and hub.

Replace hub seals.

Scored seal areas.

Replace the damaged hub and/or

shaft.

Damaged seals in the hub.

Replace the hub seals.

Loose or damaged fittings.

Tighten or replace damaged fittings.

Scored seal areas.

Replace the damaged hub and/or

shaft.

OSE LENGTH CALCULATIONS

H = Total lift height

D = Distance from centerline of reel to junction block.

1 When H is equal to, or greater than 2 X D, the correct

hose length is H D + 38 in.

2 When H is less than 2 X D, the correct hose length is

D + 38 in.

Example:
H = 286 in.
D = 96 in.
2 X 96 = 192 (H is greater then 2 X D)
286 96 = 190 + 38 = 228 in.
Correct hose length

Junction
Block

HR0069.eps

WORKSHEET
1

H = (Enter mast lift height here)

D = (Enter distance between

junction block and center of reel
with truck carriage completely
lowered)

Multiply D by 2

If line 1 is less than line 3, the hose

length should be:
D (line 2)
+ 38 in.

38 in.

Hose Length =

If line 1 is equal to or larger than

line 3, the hose length should be:
H (line )
D (line 2)
+ 38 in.

38 in.

Hose Length =

680110-R1

This page intentionally left blank

Do you have questions you need

answered right now? Call your
nearest Cascade Service Department.
Visit us online at www.cascorp.com

AMERICAS
Cascade Corporation
U.S. Headquarters
2201 NE 201st
Fairview, OR 97024-9718
Tel: 800-CASCADE (227-2233)
Fax: 888-329-8207

Cascade Canada Inc.

5570 Timberlea Blvd.
Mississauga, Ontario
Canada L4W-4M6
Tel: 905-629-7777
Fax: 905-629-7785

Cascade do Brasil
Rua Joo Guerra, 134
Macuco, Santos - SP
Brasil 11015-130
Tel: 55-13-2105-8800
Fax: 55-13-2105-8899

EUROPE-AFRICA
Cascade Italia S.R.L.
European Headquarters
Via DellArtigianato 1
37030 Vago di Lavagno (VR)
Italy
Tel: 39-045-8989111
Fax: 39-045-8989160

Cascade (Africa) Pty. Ltd.

PO Box 625, Isando 1600
60A Steel Road
Sparton, Kempton Park
South Africa
Tel: 27-11-975-9240
Fax: 27-11-394-1147

ASIA-PACIFIC
Cascade Japan Ltd.
2-23, 2-Chome,
Kukuchi Nishimachi
Amagasaki, Hyogo
Japan, 661-0978
Tel: 81-6-6420-9771
Fax: 81-6-6420-9777

Cascade Korea
121B 9L Namdong Ind.
Complex, 691-8 Gojan-Dong
Namdong-Ku
Inchon, Korea
Tel: +82-32-821-2051
Fax: +82-32-821-2055

Cascade-Xiamen
No. 668 Yangguang Rd.
Xinyang Industrial Zone
Haicang, Xiamen City
Fujian Province
P.R. China 361026
Tel: 86-592-651-2500
Fax: 86-592-651-2571

Cascade Australia Pty. Ltd.

1445 Ipswich Road
Rocklea, QLD 4107
Australia
Tel: 1-800-227-223
Fax: +61 7 3373-7333

Cascade New Zealand

15 Ra Ora Drive
East Tamaki, Auckland
New Zealand
Tel: +64-9-273-9136
Fax: +64-9-273-9137

Sunstream Industries
Pte. Ltd.
18 Tuas South Street 5
Singapore 637796
Tel: +65-6795-7555
Fax: +65-6863-1368

Cascade India Material

Handling Private Limited
No 34, Global Trade Centre
1/1 Rambaugh Colony
Lal Bahadur Shastri Road,
Navi Peth, Pune 411 030
(Maharashtra) India
Phone: +91 020 2432 5490
Fax: +91 020 2433 0881

c
 Cascade Corporation 2007

4-2007

Part Number 680110-R1