CAR-MON TSR-P User manual

PRODUCTS, INC.
1225 Davis Road Elgin, IL 60123
Phone (847) 695-9000 Fax (847) 695-9078
INSTALLATION AND
OPERATIONS MANUAL
POWER
OPERATED
TUBING STORAGE
REEL
MODEL TSR-P
18" DIAMETER OVERSIZE DRUM

INSTALLATION - OPERATION - MAINTENANCE
CAR-MON PRODUCTS, INC.
1225 Davis Road Elgin, IL 60123 Phone (847) 695-9000 Fax (847) 695-9078
INSTALLATION - OPERATION - MAINTENANCE
CAR-MON PRODUCTS, INC.
1225 Davis Road Elgin, IL 60123 Phone (847) 695-9000 Fax (847) 695-9078
INSPECTION AND PREPARATION
1. Check each unit to see that it is complete. The components of the system include:
A. Tubing Storage Reel. Reel also may have an attached CMW fan.
B. Hose assembly consisting of hose with flange one end, exhaust adapter other end, hardware and gasket to
attach hose to reel.
C. Up/down control, either wall mounted or a hanging pendant and any optional components.
2. Check for any damage that may have been caused by shipping. If concealed damage is found, report it to the
carrier immediately. Car-Mon cannot be responsible for any damage not reported to the carrier in a timely
manner.
3. Review the instruction sheets before proceeding with the installation.
REEL INSTALLATION
1. Tubing storage reels may be wall or ceiling mounted. Make sure the mounting surface is level and plumb and
able to support the weight of the reel which can weigh up to several hundred pounds when the hose is attached.
Use all four mounting holes with bolts that are capable of withstanding the weight and stress of the reels. After
the reel is mounted, verify the reel is level. Extra large reels may have additional mounting supports.
2. Connect the power supply . There are several different options that can be supplied with a power reel with
options for different up/down controllers and fan options. The wiring diagram in this manual is only for single
phase, 120v supply with the standard up/down wall mounted switch. If other options are supplied, a diagram will
be enclosed. If not, contact the factory immediately before proceeding with wiring. If there is any question as to
the correct diagram supplied, do not connect unit to power source. NOTE: Any damage caused to reel
electrical components caused by improper wiring will be the responsibility of installer and not covered
by the factory warranty.
3. After power is connected, push the "up" button on the up/down control. The drum should turn counterclockwise
when viewed from the motor end enclosure of the reel. If it does not turn in that direction, recheck the wiring
connections. If it is turning properly, use the up/down controls to run the reel from stop to stop position two or
three times to assure it is operating properly.
4. The hose assembly can now be attached. Push the down button
control till the reel stops. The hose must be installed when the reel is
in the fully down position. All reels have been tested and preset to the
length of hose supplied. If different lengths of hose were ordered,
make sure to match the hose length to the correct reel.
Attach the flanged end of the hose to the pocket of the reel using the
gasket supplied between the flange and the pocket. When attaching,
the reel pocket should be in the 11-12 o’clock position. If for any
reason the reel is not in this approximate position, it will have to be
adjusted using the up limit switch. (See page 3 for adjustment of limit
switches)
After the hose has been attached, push the "up" button until the hose stops. The reel should stop with about three
feet of hose, including the adapter, hanging down from the reel. (If hose appears not to stop and the adapter is
about to go onto the reel, release the up button immediately.) Please note that some reels are shipped with an
extra length of hose that is not designed to wind onto the reel. In this case, more than three feet may hang down.
5. Connect duct work to crimped discharge collar for models without a connected fan. Recheck all connections and
make sure all wiring is complete. Unit is now ready for final test.
6. Put hose assembly in the complete down position. Hose should always be in the complete down position when
operating the system. Leaving tubing on the reel will increase static pressure and cut air flow and possibly cause
damage to the hose and reel. Turn on the fan and make sure a good air flow is going through the tube. Let
system run for a few minutes. Fan should be off before retracting hose.
TUBING STORAGE REEL-POWER OPERATED
Page 1
DRUM
POCKET
DETAIL
NOTE: FOR REELS WITH ATTACHED CMW OR DXi FAN, SEE SEPARATE MANUAL
FOR FAN OPERATION

INSTALLATION - OPERATION - MAINTENANCE
CAR-MON PRODUCTS, INC.
1225 Davis Road Elgin, IL 60123 Phone (847) 695-9000 Fax (847) 695-9078
OPERATION
1. When the vehicle to be serviced is in position, push the down button and lower the tubing completely. There
should be no tubing wound on the reel when system is in operation. Vehicle should not be running. Attach the
exhaust adapter to the exhaust pipe.
2. IT IS VERY IMPORTANT THAT THE FAN IS RUNNING BEFORE THE VEHICLE IS STARTED. If fan is not
running and vehicle is started, damage can be done to the system and could create an unsafe condition for
the operator.
3. When service is finished, turn off vehicle and leave fan running. The adapter will be HOT! It is best to wait a
few minutes with the fan running before removing the exhaust adapter. Leaving the fan running will also clear
the system of any carbon dioxide in the tube and the reel.
4. After several miuntes, remove the adapter, turn off the fan and retract the tubing completely. If reel has
attached fan and internal control option, tubing must be fully rewound before fan will shut off.
MAINTENANCE
1. Periodically check and lubricate the discharge duct bearing with a lithium based grease.
2. The heavy duty cast steel flange bearing should be checked and greased periodically.
3. Check chain drive and sprockets to make sure the chain is fully tensioned.
4. Check hose assembly, flange connection, and adapter. Check carefully to insure there are no tears or cracks
in hose. Wipe off any excess dirt or grease. Make sure flange connection and adapter connection are sound.
3. Follow maintenance procedures for fan.
TROUBLESHOOTING
Up/Down switch does not work
Check all electrical connections and make sure the connection to the reel is correct. Review the connections
diagram. Make sure the chain drive is in place and connected to the sprocket drives at gear box and at reel.
Tubing does not extend or retract to proper length.
The reel should have been in the fully down position when the tubing was attached. Reels are fully adjusted
to the tubing before they leave the factory. If correct procedures were followed, and tubing is still not winding
properly, a limit switch adjustment may be necessary. (See page 3)
During continued use.
Tubing stops retracting or rewinding
Check electrical connections, making sure they are intact. Remove motor end cover of reel. Check to see that
the chain and gear assembly is functioning. If problem persists, contact factory-customer service.
Tubing gets very hot or scorched
Check to make sure tube is clear and that no foreign object is lodged in tube. Make sure exhaust conditions
have not changed. (Attaching to a larger engine different from the original specification or increased RPM
testing).
Page 2

CAR-MON PRODUCTS, INC.
1225 Davis Road Elgin, IL 60123 Phone (847) 695-9000 Fax (847) 695-9078
INSTALLATION - OPERATION - MAINTENANCE
REMOVABLE
ENCLOSURE
DOWN
LIMIT
UP
LIMIT
CONTROL
WIRING
CHAIN & SPROCKET DRIVE
OPTIONAL
POWER
INPUT
LIMIT SWITCH ACCESS IS GAINED BY REMOVING PLUGS ON REMOVABLE ENCLOSURE
FIELD WIRING AND ADJUSTMENTS FOR TUBING STORAGE REEL
POWER OPERATED
LIMIT CONTROL ADJUSTMENTS
UP POSITION
1. TO INCREASE LENGTH TURN SCREW CCW.
2. TO REDUCE LENGTH TURN SCREW CW.
DOWN POSITION
1. TO INCREASE LENGTH TURN SCREW CCW.
2. TO REDUCE LENGTH TURN SCREW CW.
FIELD WIRING OF TSR-P REEL
The only field wiring that is required is power wiring to the electrical junction box mounted on the assembly, and the wiring
between the "UP/DOWN" push button station. (Furnished by Car-Mon Products) Please see wiring diagram.
NOTE: If hanging pendant option is supplied, the black & red wires are for the up control. The green & white wires are for the
down control.
(See photo detail of parts on next page)
Page 3
LIMIT SWITCH ADJUSTMENTS
1. Run the reel to the end of travel for the side that needs to be adjusted (Run reel all the down, if you need to
change how far the tube hangs off the reel)
2. Estimate length of change desired.
3. Rotate the drum 2 full turns off the limit switch. This is crucial. If this is not done, it is possible to overdrive
the limit switch which can cause extreme damage to the drive assembly.
4. Each quarter turn of the adjustment screw will result in approximately one foot of travel. It is advisable to
make several smaller adjustments rather than one large one. Working on one adjustment at a time will help
eliminate confusion.
5. Once the desired change has been achieved, run the reel frm stop-to-stop several times to verify
repeatability.
6. Replace black plug covers.

PARTS DESCRIPTION FOR OVERSIZED
EXTENDED DRUM REEL
CONTROL
BOX
MOTOR
CAR-MON PRODUCTS, INC.
1225 Davis Road Elgin, IL 60123 Phone (847) 695-9000 Fax (847) 695-9078
INSTALLATION - OPERATION - MAINTENANCE
Page 4
CONTACTOR
LIMIT SWITCH ADJUSTMENT
BEHIND REMOVABLE PLUGS
GEAR BOX
ASSEMBLY
NOTE: THE CHAIN DRIVE IS FULL TENSIONED AT
THE FACTORY AND SHOULD NOT NEED
ANY FURTHER ADJUSTMENT UNLESS A
REPLACEMENT PART IS INSTALLED.
LIMIT
SWITCH
ASSEMBLY
DOWN
ADJUSTMENT
UP
ADJUSTMENT
NOTE: SOME REELS OF SPECIAL CONSTRUCTION
MAY DIFFER FROM PHOTO ABOVE.

Page 6
LIMITED WARRANTY
Car-Mon Products, Inc. shall replace or repair at its discretion any products or components sold or manufactured which prove to be defective
in workmanship or materials within 1 year from date of shipment.
The foregoing is in lieu of all warranties, expressed or implied, and all other obligations or liabilities on behalf of the company, regarding
products it may manufacture or sell. Except as otherwise provided herein, the purchaser accepts the product "as is".
No warranty is made regarding the suitability or compatibility of any Car-Mon product for a particular application or purpose unless
specifically stated. The Customer is responsible for the final selection and utilization of Car-Mon products for their use. The Customer
assumes all liability for the consequences of performance, application, use and/or misuse by employees of products purchased from Car-
Mon Products, Inc.
In no event shall Car-Mon Products, Inc. be liable for consequential or special damages; for transportation, labor, or other charges for
adjustment, replacement, installation, incorrect electrical connections, overloading of motor, performance at low voltage, or other alterations
which may be performed in connection with such products. The warranty specified herein is waived in the event that the Distributor,
Contractor, or Purchaser perform any unauthorized repairs or modifications to the product.
With regard to products or components which are furnished by Car-Mon, Inc. but not manufactured by Car-Mon, Inc., the warranty obligation
of Car-Mon shall be limited to and be the same as that of its supplier.
CAR-MON PRODUCTS, INC.
1225 Davis Road Elgin, IL 60123 Phone (847) 695-9000 Fax (847) 695-9078
INSTALLATION - OPERATION - MAINTENANCE
DRIVE CHAIN DETAIL
REEL DRUM
SPROCKET
CHAIN DRIVE
GEAR BOX SPROCKET
(ADJUSTABLE FROM
GEAR BOX SIDE)
GEAR BOX
ASSEMBLY
ADJUSTMENT SLOTS
FOR TENSIONING
CHAIN DRIVE
(4 BOLTS)
CHAIN AND SPROCKET DRIVE
There is a small sprocket drive on the gear box assembly
and a larger one on the storage reel, and a chain
connecting the two. If the chain ever needs re-tensioning it
can be done by loosening the four bolts in the adjustable
slots behind the gear box (see above) and re-applying the
tension. There should be enough tension on the chain to
keep it from jumping the sprocket.
1"
The chain is properly tensioned
when there is about a 1" deflection
at mid-point on the chain.
MARCH 2012
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