COXREELS 100W Series Manual

INSTALLATION AND MAINTENANCE MANUAL FORM #PM-129 REV - 12/10
Page 1 of 4
For assembly drawings, parts lists, or specific repair instructions, refer to web site at www.coxreels.com or consult factory.
Coxreels, Inc., 5865 S. Ash Ave., Tempe, Arizona, USA, 85283 Tel: [phone]
HAND CRANK HOSE/CABLE REELS:
SERIES: 100W
COXREELS
The technical data and images which appear in this manual are for informational purposes only. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE CREATED BY THE DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN
THIS MANUAL. COXREELS makes no warranty (and assumes no liability) as to function of equipment or operation of systems built according to customer design or of the
ability of any of its products to interface, operate or function with any portions of customer systems not provided by COXREELS.
COXREELS agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and material discovered and reported COXREELS
within two years after shipment of such goods to Buyer.
Except where the nature of the defect is such that it is appropriate, in COXREELS’ judgment, to effect repairs on site, COXREELS’ obligation hereunder to remedy defects
shall be limited to repairing or replacing (at COXREELS’ option) FOB point of original shipment, any part returned to COXREELS at the risk and cost of Buyer. Defective parts
replaced shall become the property of COXREELS.
COXREELS shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service recommended. COXREELS is not responsible
for defects which arise from improper installation, neglect, improper use of or from normal wear and tear.
COXREELS obligation shall be limited by the manufacturer’s warranty (and is not further warranted by COXREELS) for all parts procured from others according to published
data, specifications or performance information not designed by COXREELS.
COXREELS further agrees to replace or at COXREELS’ option to provide a refund of the sales price of any goods that do not conform to applicable specifications or which
differ from that agreed to be supplied which non-conformity is discovered and forthwith reported to COXREELS within 30 days after shipment to the Buyer. COXREELS’
obligation to replace or refund the purchase price for non-conforming goods shall arise once Buyer returns such goods FOB point of original shipment by COXREELS at the
risk and cost of Buyer. Goods replaced by COXREELS shall become property of COXREELS.
COXREELS liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage arising out of, connected with, or resulting from the
manufacture, sale, delivery, resale, repair, replacement or use of any products or services shall in no case exceed the price paid for the product or services or any part thereof
which give rise to the claim. In no event shall COXREELS be liable for consequential, special, incidental or other damages, nor shall COXREELS be liable in respect of
personal injury or damage to property not the subject matter hereof unless attributable to gross misconduct of COXREELS, which shall mean an act or omission by
COXREELS demonstrating reckless disregard of the foreseeable consequences thereof.
COXREELS is not responsible for incorrect choice of models or where products are used in excess of their rated and recommended capacities and design functions or under
abnormal conditions. COXREELS assumes no liability for loss of time, damage or injuries to property or persons resulting from the use of COXREELS products. Buyer shall
hold COXREELS harmless from all liability, claims, suits and expenses in connection with loss or damage resulting from operation of products or utilization of services,
respectively, of COXREELS and shall defend any suit or action which might arise there from in Buyer’s name – provided that COXREELS shall have the right to elect to
defend any such suit or action for the account of Buyer. The foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer.
NOTE: All desi
g
ns, specifications, and dimensional data contained in this publication are sub
j
ect to chan
g
e without notice.

INSTALLATION AND MAINTENANCE MANUAL FORM #PM-129 REV - 12/10
Page 2 of 4
For assembly drawings, parts lists, or specific repair instructions, refer to web site at www.coxreels.com or consult factory.
Coxreels, Inc., 5865 S. Ash Ave., Tempe, Arizona, USA, 85283 Tel: [phone]
WARNING – APPLICATION
THE PRODUCTS IN THIS INSTALLATION AND MAINTENANCE MANUAL HAVE BEEN TESTED UNDER CONTROLLED LABORAROTY CONDITIONS TO MEET SPECIFIC TEST
CRITERIA. THESE TESTS ARE NOT INTENDED TO REFLECT THE PERFORMANCE OF THE PRODUCTS OR ANY OTHER MATERIAL IN ANY SPECIFIC APPLICATION, BUT ARE
INTENDED TO PROVIDE THE USER WITHY APPLICATION GUIDELINES. THE PRODUCTS ARE INTENDED FOR USE BY KNOWLEDGEABLE PERSONS HAVING THE TECHNICAL
SKILL NECESSARY TO EVALUATE THEIR SUITABILITY FOR SPECIFIC APPLICATIONS.
WARNING – USER RESPONSIBILITY
THE USER, THROUGH ITS OWN ANALYSIS AND TESTING, IS SOLELY RESPONSIBLE FOR MAKING THE FINAL SELECTION OF THE SYSTEM AND COMPONENTS AND
ASSURING THAT ALL PERFORMANCE, ENDURANCE, MAINTENANCE, SAFETY AND WARNING REQUIREMENTS OF THE APPLICATION ARE MET.
TO THE EXTENT THAT COXREELS PROVIDE COMPONENT OR SYSTEM OPTIONS BASED UPON DATA OR SPECIFICATIONS PROVIDED BY THE USER, THE USER IS
RESPONSIBLE FOR DETERMINING THAT SUCH DATA AND SPECIFICATIONS ARE SUITABLE AND SUFFICIENT FOR ALL APPLICATIONS AND REASONABLY FORESEEABLE
USES OF THE COMPONENTS OR SYSTEM.
WARNING – SAFETY
READ ALL SAFETY INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE, OR MAINTAIN THIS PRODUCT. ONLY QUALIFIED PERSONNEL SHOULD
UNDERTAKE THE INSTALLATION AND COMMISSIONING OF THIS PRODUCT. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR
PROPERTY DAMAGE.
FAILURE TO FOLLOW RECOMMENDED APPLICATION INFORMATION AND RECOMMENDED PROCEDURES FOR SELECTION, INSTALLATION, CARE, MAINTENANCE AND
STORAGE OF REEL ASSEMBLY, SWIVEL, HOSE, COUPLINGS OR HOSE ASSEMBLIES MAY RESULT IN FAILURE TO PERFORM PROPERLY AND MAY RESULT IN DAMAGE TO
PROPERTY AND SERIOUS BODILY INJURY.
FOLLOW GOOD MAINTENANCE PRACTICES – ESTABLISH A PROGRAM OF INSPECTION, TESTING AND REPLACEMENT OF REEL COMPONENTS FROM FACTORS INCLUDING:
oSEVERITY OF APPLICATION, FREQUENCY OF EQUIPMENT USE, AND PAST PERFORMANCE OF REEL COMPONENTS
ONLY PROPERLY TRAINED PERSONS SHOULD INSPECT, TEST OR SERVICE REEL AND HOSE/CABLE ASSEMBLIES. PERIODIC UPDATING OF TRAINING IS RECOMMENDED.
DOCUMENT MAINTENANCE, INSPECTIONS AND TESTING.
PROP 65 WARNING: Handling of brass material on this product exposes you to lead, a chemical known to the State of California to cause birth defects or other reproductive harm. “WASH
HANDS AFTER USE”

SAFETY
PRESSURE WARNINGS
•This equipment should be properly installed before use in accordance
with local codes and ordinances.
•The pressure from the hose reel should be disconnected from the
hose reel before any service functions are performed.
•This hose reel must not be used for pressure greater that the rating
listed in the COXREELS catalog / website www.coxreels.com.
OPERATIONAL WARNINGS
•Exercise care when handling the hose reel during normal operation.
•Do not use hose different from that for which the reel is intended.
Changes in diameter, weight per foot, length of hose or flexibility
(Minimum Bend Radius) will affect the operation of the reel.
•Mounting hardware and fasteners should be installed to maintain
tightness under vibration and checked periodically to ensure
tightness.
•Overhead installation mountings should be such that the reel is not
supported by bolts in tension. A safety chain, cable, enclosure or
netting is strongly recommended to minimize damage and/or possible
injury in the event of a mounting failure.
MAINTENANCE WARNINGS
•Modification of the equipment may cause excessive wear and will
void the warranty. Contact COXREELS regarding changes or
modifications of equipment which could affect reliability or safety.
SPECIFICATIONS & LISTINGS
•The identified Series of Hose Reel products within this manual are
not certified or listed by any independent certifying or regulatory body.
•This series of hose reels is intended for industrial use and are
provided with permanent mounting means.
PRESSURE & TEMPERATURE RATING
•All reels covered in this manual with or without hose have specific
P.S.I. ratings. (Please refer to the COXREELS catalog, website or
contact Customer Service for Reel specific data). Reels should not
be used at pressures greater that the rating of the hose.
•Multipurpose hose is installed with tube compounded for maximum oil
resistance. Hose can be used for air, water, oil and many other
chemical applications.
•Operational temperature ranges vary across the wide range of hose
options. (Please refer to the COXREELS catalog, website or contact
Customer Service for hose specific data). Hose reels should not be
used at temperatures below or above the rating of the hose.
•The operational rating of a reel not equipped with hose is determined
by the capacity of the installed hose. The pressure rating of the reel
without hose must not be greater than the than the operational
capacity of a reel. (Please refer to the COXREELS catalog, website
or contact Customer Service for reel/hose specific data). Variations
in the OD of higher rated hose will affect the operational capacity of
the reel.
LABELS & MARKINGS
Hose Reels with and without hose
•The marking of the hose reel provide with or without hose includes
the following
oThe label on the frame includes the COXREELS name and
Logo, the product catalog number, the individual product serial
number, PSI rating and what type and length of hose intended
for use on the reel.
oThe maximum pressure rating for every hose reel supplied
without house is marked on the COXREELS Identification
Label. In absence of this information, refer to website, catalog,
or customer service. Actual rating is determined by the installed
hose and is not to exceed the indicated maximum operational
rating. The pressure rating of the hose installed on reels
provided without hose must be marked on the label upon
installation

INSTALLATION AND MAINTENANCE MANUAL FORM #PM-129 REV - 12/10
Page 3 of 4
For assembly drawings, parts lists, or specific repair instructions, refer to web site at www.coxreels.com or consult factory.
Coxreels, Inc., 5865 S. Ash Ave., Tempe, Arizona, USA, 85283 Tel: [phone]
PERSONAL SAFETY
•Ensure reel has been properly installed before connecting supply line.
•Before connecting to reel, be certain supply line does not exceed
rated pressure of the hose reel or amperage rating on cable reel.
•Thoroughly review the “Hose Installation” instructions to properly
install hose.
•Perform “Operational Check” per instructions to ensure reel is
operating properly.
•If a leak should occur after applying pressure to the reel, immediately
discontinue supply line pressure.
WARNING: Prevent static sparking. When working around flammables,
ensure that the hose reel, hose, and equipment are properly grounded.
INSTALLATION
MOUNT REEL / FASTEN CRANK HANDLE
•To mount reel to a solid structure use 7/16” or M12 bolts, washers,
and nuts. Masonry bolts may be used depending on mounting
application. Mounting hardware is NOT provided. Mounting patterns
will vary depending on model. NOTE: If you choose to permanently
mount series CM, you will need four ¼” screws or nails.
•Fit mounting hardware to ceiling/wall/floor so reel can be fastened
into position. Fit reel and tighten all hardware securely.
•Reels are supplied with plastic crank handle uninstalled. Remove
handle and hardware from plastic bag and install onto crank arm.
Models 1275 and 600-900 will include detachable crank for bevel
gear design.
•The series DM portable reels will include a U-shaped handle. Position
handle over swaged posts and fasten using hardware provided.
INSTALLATION OF INLET HOSES
•Apply thread sealant to inlet hose and connect to the swivel joint on
reel.
CAUTION: IT IS IMPORTANT TO USE A “FLEXIBLE” INLET HOSE.
DO NOT USE SOLID PIPING OR RESTRAIN INLET HOSE AS TO
CAUSE ANY SIDE FORCE ON SWIVEL JOINT. THE WARRANTY
IS VOID IF NOT PROPERLY INSTALLED.
•Flush some product through the system before connecting inlet hose to
the source.
•Connect end to supply source.
INSTALLATION OF OUTLET HOSE
NOTE: Before proceeding, ensure that you are installing the proper
size, length and type of hose that the reel is rated for. Consult factory if
unsure of rating.
•Securely install hose reel prior to installing outlet hose.
•Apply thread sealant to male hose fitting and insert into the drum
opening. Note: It is recommended that a swivel type connector be
used to ease installation of outlet hose.
•Thread male hose fitting into outlet riser(s) (Refer to FIGURE 1.0).
Challenger series 112, 117, CM, DM and SM, outlet will be inside drum
area. Note: Outlet riser is removable on 1195 series.
•Using a wrench, firmly hold on to riser fitting while tightening hose
connector.
•The Series 100 reel includes a hose clamp. Fasten hose securely to
reel with hose clamp provided.
NOTE: The hose clamp restrains the hose when fully extended,
preventing strain on the fitting.
CAUTION: FULLY EXTEND AND CHARGE HOSE BEFORE
INITIALLY WINDING ON TO REEL. THIS PREVENTS FLATTENING
OF HOSE AND EXCESSIVE PRESSURE ON DRUM WHEN HOSE IS
FULLY CHARGED DURING OPERATION
OPERATIONAL CHECKS
OPERATIONAL CHECK
CAUTION: ENSURE THAT ALL OPERATION CHECKS HAVE BEEN
COMPLETED BEFORE RELEASING FOR USE
•Adjust drag brake. Turn clockwise to add tension and counter-
clockwise to decrease tension. See figures 3.0-6.0.
•Check for correct operation by pulling out some of the hose/cable. A
slight friction or drag should be noticed. This drag is to prevent
backlash when pulling out hose/cable.
•Fit hose to swivel then fit swivel to reel.
SWIVEL SEAL REPLACEMENT
•Remove inlet hose from swivel.
•Remove swivel from reel by unscrewing swivel from reel axle.
Disconnect hose from swivel.
•Remove retaining ring on swivel; pull out spool from body.
•Fit hose to swivel then fit swivel to reel.
DO NOT OVER TIGHTEN!
•Reconnect inlet hose and test for leakage.
NOTE: Swivels designs vary depending on the reel model. Refer to repair
procedure shipped with individual seal replacement kits or consult factory.
CAUTION: Release line pressure prior to making repairs or
adjustments to reel.

INSTALLATION AND MAINTENANCE MANUAL FORM #PM-129 REV - 12/10
Page 4 of 4
For assembly drawings, parts lists, or specific repair instructions, refer to web site at www.coxreels.com or consult factory.
Coxreels, Inc., 5865 S. Ash Ave., Tempe, Arizona, USA, 85283 Tel: [phone]
TROUBLE SHOOTING GUIDE
TROUBLE CAUSE REMEDY
HOSE/CABLE WILL NOT FULLY FIT ON TO
DRUM OF REEL
a) Hose/cable is longer than specified.
b) Outside diameter of hose is larger than
specification.
c) Hose/cable was not hand guided onto reel and
wound up evenly on drum.
a) Cut down hose/cable to meet reels specified capacity.
b) Replace hose with a hose that meets the specified maximum
outside diameter requirements.
c) Hand guide hose/cable on to drum to wrap evenly as it is wound
on to the reel.
REEL KEEPS TURNING WHEN OPERATOR
STOPS PULLING OUT HOSE/CABLE. Tension drag brake is too loose causing hose/cable backlash. Adjust tension drag brake by turning fastener clockwise.
NO ELECTRICAL CURRENT AT OUTPUT
END OF CABLE.
(1125WC SERIES ONLY)
a) Cable is severed.
b) Slip ring brushes are worn.
a) Replace cable.
b) Replace slip ring brushes.
Note: Ensure current does not exceed rated amperage.
DRUM OF REEL IS CRUSHED OR
DAMAGED. Hose was not charged when initially installed on to reel. Replace damaged drum. Contact factory. Install hose per instructions.
FLUID PATH (PLUMBING AND/OR SWIVEL)
IS LEAKING OR DAMAGED.
a) Maximum pressure rating for reel has been
exceeded.
b) Application is not compatible with plumbing
and/or swivel seal materials.
a) Replace or repair damaged components. Consult factory. Check
maximum pressure rating of reel.
b) Contact factory to determine chemical compatibility or
environmental issues (i.e. temperature rating).
FLUID LEAKS FROM SWIVEL Swivel seals are damaged or worn. Replace swivel seals. See "Swivel Seal Replacement".
Caution: Be sure leak is not at Hose Fitting!

COXREELS
SERIES 100W
EXP-40W
REVISION:
ECO NO.:
BY:
DATE:
C
2606
JKUCERA
7/13/11
21
1
20
14
19
43
5
13
16
9
15
8
11
7
4
2
10
17
12
18
6

EXP-40W COMMON PARTS TO 100W WELDING HOSE CHALLENGER REELS
DETAIL
ITEM NO. PART NO. DESCRIPTION
8554 ASSEMBLY: DRUM, OXY-ACETYLENE, 12" DIA. X 8" - - 1 1 - -
8554-4 ASSEMBLY: DRUM, OXY-ACETYLENE, 12" DIA. X 4-1/2" 1 1 ----
8899-8 ASSEMBLY: DRUM, 117W, 17" ----11
26329-1-1 BEARING: MOLDED, CRANK SIDE 111111
38552 BEARING: 1-5/8" COMPOSITE 111111
415711-1 PLATE: BEARING KEEPER 222222
57105 RIVET: 3/16" DIA. X .25" GRIP 444444
615719 KNOB: BLACK PHOENOLIC, 1/4-20 111111
77272-1 ASSEMBLY: CRANK 111111
8245 SCREW: #10-32 X 3/8" PHILLIPS HEAD 111111
9 130 NUT: #10-32 KEPS 111111
10 7146 BOLT: 1/4-20 X 2-1/4" HEX 111111
11 688 WASHER: 1/4" FLAT 111111
12 10925-5 LABEL: STANDARD 111111
8553-8 FRAME: 'U', 8" - - 1 1 - -
8553-4 FRAME: 'U', 4-1/2" 1 1 ----
8898-8 FRAME: "U" 117W SERIES, 8" ----11
14 8550 ASSEMBLY: SWIVEL, OXY-ACETYLENE 111111
15 382 CLAMP: HOSE #14 111111
16 7145 SPACER: CHALLENGER REEL 111111
17 8562 ADAPTER: ACETYLENE WELDING HOSE 111111
18 8561 ADAPTER: OXYGEN WELDING HOSE 111111
19 8573 RETAINER: WELDING SWIVEL 111111
5423-1 ASSEMBLY: 1/4" X 12" 'R' GRADE DUAL WELDING HOSE 1 - 1 - 1 -
5424-1 ASSEMBLY: 1/4" X 12" 'T' GRADE DUAL WELDING HOSE - 1 - 1 - 1
5423-50 ASSEMBLY: 1/4" X 50' 'R' GRADE DUAL WELDING HOSE 1 -----
5423-100 ASSEMBLY: 1/4" X 100' 'R' GRADE DUAL WELDING HOSE - - 1 - - -
5423-200 ASSEMBLY: 1/4" X 200' 'R' GRADE DUAL WELDING HOSE ----1-
5424-50 ASSEMBLY: 1/4" X 50' 'T' GRADE DUAL WELDING HOSE - 1 ----
5424-100 ASSEMBLY: 1/4" X 100' 'T' GRADE DUAL WELDING HOSE - - - 1 - -
5424-200 ASSEMBLY: 1/4" X 200' 'T' GRADE DUAL WELDING HOSE -----1
REVISION: C ECO: 2903 DATE: 7/13/2011
21*
117W-1-200
117WT-1-200
NAME: JKUCERA
*FOR LESS HOSE MODELS, EXCLUDE ITEM 21.
112WT-1-50
112W-1-50
13
1
20
112W-1-100
112WT-1-100