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Endo HR-4000 Series Instruction Manual

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INSTRUCTION MANUAL
HOSE REEL
HR-4000 SERIES
HR-5000 SERIES
HR-6000 SERIES
HR-7000 SERIES
・ Read t his manual bef ore use.
・ Keep this manual available.
ENDO KOGYO CO., LTD
RM-10638a
Issued on Mar. 2020

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  • Page 1 Supply this manual to the user. INSTRUCTION MANUAL HOSE REEL HR-4000 SERIES HR-5000 SERIES HR-6000 SERIES HR-7000 SERIES ・ Read t his manual bef ore use. ・ Keep this manual available. ENDO KOGYO CO., LTD RM-10638a Issued on Mar. 2020...
  • Page 2 Copyright and liabilities The copyright for this manual belongs to Endo Kogyo Co., Ltd. The manual is provided for the limited purpose of supporting the safe and proper use of the product. It cannot be used for other purposes. The customer may not use or make copies of this manual, in whole or in part, outside of this purpose without receiving prior consent from Endo Kogyo Co., Ltd.
  • Page 3 SAFETY ALERT SYMBOL AND ALERT SIGNS Please read this manual carefully and follow its instructions. The SAFETY ALERT SYMBOL ( ), WARNING, CAUTION, and NOTE carry special messages. This SAFETY ALERT SYMBOL is used to call your attention to items or operations that could be dangerous to you or other persons using this equipment.
  • Page 4 Scope of warranty and liabilities for the equipment 1. We will repair or replace the product free of charge if a failure due to manufacturing defects occurs under proper usage during the warranty period. For details, contact us or your dealer. 2.

  • Page 5: Table Of Contents

    Contents Safety instruction ·························································· 2. Terminology definitions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4 3.

  • Page 6: Safety Instruction

    Safety instructions Regarding name plates, warning labels and labels: ・ Never remove or def ace any name plates, w arning labels or l abels w hich are attached to the body. The operator should alw ays observe them. Regarding installation (page 8): ・...
  • Page 7 Safety instructions on use (page 14): ・ Never approach the moving parts during operation. There is a danger of being caught up. ・ Bef ore supplying deff erent f luid into the hose, take maker ’s advise. If there is no specif ication request on t he t ype of f luid application, the product will be f or air, w ater (less than 80℃...
  • Page 8 Regarding with O-ring replacement (page 17): ・ High pressured f luid on hose reel is very dangerous. Shut of f the fluid supply and set 0 pressure in the hose. ・ Allow the hose to fully w ind onto the drum to give the minim um w inding tension bef ore carrying out replacement.

  • Page 9: Terminology Definitions

    2. Terminology Definitions The terminology used in this manual will be explained here. If there is any terminology which is unclear or not included in this section, please contact our company. Winding methods: Figure 1 Ｍ ｏ ｖ ｉ ｎ ｇ ｒ ｅ ｅ ｌ Ｆ...

  • Page 10: Product Description

    3. Product Description 3-1. Models and specifications (1) Models Please observe the name plate attached to the main body. Refer to Figure 5 (page 7) for the attached location. Figure 4 Ｍ ａ ｘ ． ｗ ｏ ｒ ｋ ｉ ｎ ｇ ｐ ｒ ｅ ｓ ｓ ｕ ｒ ｅ Ｍ...
  • Page 11 (2) Specifications Table 1 ※ Calculated Maximum Conection Reference maximum Total number Spring spring torque Model size Mass spring tension of spring turns structure N・m {kgf・m} {Rc} {kg} N{kgf} HR-4524 23.5 Rc 3/4 HR-4524-R {2.4} {17.0} HR-4524W 23.5 Rc 3/4 HR-4524W-R {2.4} {17.0}...

  • Page 12: Names Of Main Parts

    3-2. Names of main parts Ｓ ａ ｄ ｄ ｌ ｅ Ｄ ｒ ｕ ｍ Figure 5 Ｄ ｒ ｕ ｍ ｃ ｏ ｖ ｅ ｒ Ｄ ｒ ｕ ｍ ｃ ｏ ｖ ｅ ｒ Ｓ ｐ ｒ ｉ ｎ ｇ Ｊ...

  • Page 13: Installation

    4. Installation 4-1. Checks before i nstallation ・Please check whether the items ordered were received. (Check the name plate.) ・Check there is no damage to the product caused during transportation. 4-2. Installation Figure 6 ・ Take suf f icient care not to knock or drop the reel w hen handling.

  • Page 14: Hose Connection

    5. Hose Connection 5-1. Calculation of r equired hose length on winding side Figure 9 Ｍ ａ ｔ ｉ ｎ ｇ Ｗ ｉ ｎ ｄ ｉ ｎ ｇ ｌ ｅ ｎ ｇ ｔ ｈ ｅ ｑ ｕ ｉ ｐ ｍ ｅ ｎ ｔ Ｃ...
  • Page 15 Figure 11 Ｗ ｉ ｎ ｄ ｉ ｎ ｎ ｇ ｓ ｉ ｄ ｅ ｈ ｏ ｓ ｅ Ｏ ｂ ｌ ｏ ｎ ｇ ｈ ｏ ｌ ｅ Ｓ ａ ｄ ｌ ｅ Ｊ ｏ ｉ ｎ ｔ Ｓ ｐ ｉ ｎ ｄ ｌ ｅ Ｆ...

  • Page 16: Spring Tension Adjustment

    ■Fixed side hose (Refer to Figure 11 on page 10) (1) Attach the hose to spindle. NOTE: For hose without fitting, use and tie the sliding band. Remove nipple for hose with fitting. Then use seal tape around the screw part of hose fitting. (Refer to Figure 12 on page 10) 6.

  • Page 17: Standard Value Of Initial Spring Turns And Calculation For Upper Limit Of Initial Spring Turns

    6-2. Standard value of initial spring turns and calculation for upper limit of initial spring turns. (1) Check the total number of spring turns using Table 1 (page 6). (2) Rotate the drum by hand until the hose of the winding length is fully retracted, checking the number of drum turns.

  • Page 18: Measures Against Uneven Winding

    7. Measure against Uneven Winding Uneven means the hose is wound on mainly one side of the drum width. winding The uneven winding will cause the hose to drop from the drum or recovery problems, resulting in damage to the hose. 7-1.

  • Page 19: Safety Instructions On Use

    8. Safety Instructions on Use ・ Never approach t he moving parts during operation. There is a danger of being caught up. ・ Bef ore supplying diff erent f luid into the hose, take maker's advise. If there is no specif ication request on the type of f luid application, the product will be f or air, w ater (less than 80ºC), lubricating oil (Mineral type), grease (lithium type).
  • Page 20 ・ Never employ a sw ivel base or a standard turn table f or side attachment or inverse attachment. (1) Turn table Figure 18 This can swivel the reel up to 300゜(Refer to Figure 18). When turned, take care the fixed side hose is not put under excessive force or contacts the reel or surrounding objects.

  • Page 21: Periodic Inspections

    10. Periodic Inspections ・ Periodically inspect the reel and replace any w orn or damaged parts. Caref ully check the hose has no damage. ・ If a malf unction is f ound during a periodic inspection, never reuse the reel but repair immediately.

  • Page 22: Troubleshooting

    11. Troubleshooting Malfunction Main causes Solution Direction of initial spring turn is Rotate in the hose paying out incorrect. direction. Unable to set the initial tension. The spring is broken. Replace with a new spring. The initial tension is insufficient. Increase the initial spring turns.
  • Page 23 ■Refer to Figure 20 (page 17) (1) Remove fixed side hose from spindle. If it is impossible to remove the joint from spindle, remove the bushing too. (The bush referred to here is a reducing bush between the spindle and the nipple.) (2) Remove winding side hose from joint.

  • Page 24: Spring Replacement

    13. Spring Replacement ・ High pressured f luid on hose reel is very dangerous. Shut of f the fluid supply, and set 0 pressure in the hose. ・ If the w inding side hose is disconnected f rom mating equipment, the drum may suddenly rotate.

  • Page 25: Disassembly And Reassembly According To Spring Structure

    (7) Remove the drum cover from the drum (Refer to Figure 21 on page 19). ・ Move the drum cover upw ard about 15mm and check the i nternal spring does not pop out, t hen remove the drum cover. (8) Follow the disassemble and reassembly procedures depending on the spring structure.
  • Page 26 (5) Attach the bush to the spring. The machined end of the bush should face upward. (6) Place the notch key and notch springs into the slit of the spindle. Take care as the assembling direction of the notch key depends on the winding direction of the reel. Refer to Figure 24.
  • Page 27 (11) Lubricate the spring with grease (KYODO, ONELUBER MP No.2 or equivalents) with the specified volume shown in Table 3. Spread grease all over the spring. Spring type Table 3 Grease volume {cm (mL)} (12) Follow the procedure given in Section 13-3. "Common reassembly method" (page 25). ■...
  • Page 28 (7) Press the attached notch key in the slit with a soft or slippery rope. Refer to Figure 25 (page 21). Also use a rope with soft and slippery strong. [Example: a nylon string for civil engineering, wire rope less than φ2mm, plastic band (3mm width), wire (less than φ1mm), etc.] ・...
  • Page 29 ■ For spring structure N (2 or more springs, double-stroke) ・ The spring have a w eight of approximat ely 5 kg to 36 kg. Take care w hen handling the spring. For spring types 130 (ref er to Section 3-1. "Model and specif ications" on page 5), lif ting w ork requires more than tw o people.

  • Page 30: Common Reassembly Method

    (9) Place the notch key and notch springs into the slit of the spindle. Take care as the assembling direction of the notch key depends on the winding direction of the reel. Refer to Figure 24 (page 21). (10) Press the attached notch key in the slit with a soft and a slippery rope. Refer to Figure 25 (page 21).

  • Page 31: Parts List

    14. Parts list ■ When ordering part: ・State the MODEL, SER. NO. and DATE indicated on the name plate. ・State the part number and description. ・Parts without a part number cannot be supplied individually. Please purchase a set or complete unit. ■...
  • Page 32 ■ＨＲ－４５２４～４６２４Ｔ Ｓ ａ ｄ ｌ ｅ Ｈ ｏ ｓ ｅ ｃ ｏ ｎ ｎ ｅ ｃ ｔ ｉ ｏ ｎ Quantity Part number Description 4524 4524W 4524T 4624W 4624T － LRP003847 Bracket assembly － － Bracket assembly － LRP003848 － －...
  • Page 33 ■ＨＲ－４５２４～４６２４Ｔ Quantity Part number Description 4524 4524W 4524T 4624W 4624T P1R200553 Drum cover － － Drum cover P1R200297 － － － － LRP003830 Spring assembly － －Spring assembly － －Spring case Bush P1R300465 10 P1R300479 Bush － － LRP003836 Notch key assembly 11 －...
  • Page 34 ■ＨＲ－５７３６～５７３６Ｔ Ｓ ａｄｌｅ Ｈｏ ｓｅ ｃ ｏｎｎｅ ｃｔｉ ｏ ｎ Quantity Part number Description 5736 5736W 5736T Bracket assembly － LRP003849 LRP001170 －Bracket P1R304412a －Base plate 20 P1R404217 －Hex. Bolt －Spring 29 P1R404506 P1R300300 Spindle － LRP003810 Drum assembly － －Drum 30 KA42410512 －Spring pin...
  • Page 35 ■ＨＲ－５７３６～５７３６Ｔ Quantity Part number Description 5736 5736W 5736T － LRP003837 Notch key assembly 11 － －Notch key 12 P1R400025 －Notch spring － LRP003872 Joint assembly 13 － －Joint －Ｏ-ring 19 KA50300450 － LRP003854 Actuation plate assembly － － － LRP003856 Actuation plate assembly －...
  • Page 36 ■ＨＲ－６８５５～６９７５Ｔ Ｓ ａ ｄ ｌ ｅ Ｈ ｏ ｓ ｅ ｃ ｏ ｎ ｎ ｅ ｃ ｔ ｉ ｏ ｎ Quantity Part number Description 6855 6855W 6855T 6975W 6975T Bracket assembly － LRP003850 － － － LRP003851 Bracket assembly － －...
  • Page 37 ■ＨＲ－６８５５～６９７５Ｔ Quantity Part number Description 6855 6855W 6855T 6975W 6975T Drum cover assembly － LRP003825 － － － LRP003826 Drum cover assembly － － － － LRP002027 －Drum cover set － － － LRP002028 －Drum cover set － － － －...
  • Page 38 ■ＨＲ－６８５５～６９７５Ｔ Quantity Part number Description 6855 6855W 6855T 6975W 6975T Drive screw 38 KA14549804 39 P1R305037 Label 40 P1R401833 Label 41 P1R305035 Warning label 42 P1R304994 Warning label ■ＨＲ－６８５５－Ｒ～６９７５Ｔ－Ｒ (Reverse winding type reel) Quantity Part number Description 6855-R 6855W-R 6855T-R 6975W-R 6975T-R －...

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