Klutch 49549 User manual

Thank you very much for choosing a Klutch product. For future reference, please complete the

owner’s record below:

Serial Number/Lot Date Code: _______________ Purchase Date: _______________

Save the receipt, warranty and these instructions. It is important that you read the entire manual

to become familiar with this product before you begin using it.

These industrial hose reels, with item numbers 49549 and 49584, are each designed for certain

applications only. Northern Tool and Equipment cannot be responsible for issues arising from

modification or use of these reels in applications for which they were not designed. We strongly

recommend that each of these reels not be modified and/or used for any application other than

that for which it was designed.

For technical questions please call 1-800-222-5381.

Table of Contents

Intended Use.......................................................................................................................................1

Technical Specifications....................................................................................................................1

Important Safety Information.............................................................................................................2

Specific Operation Warnings..............................................................................................................3

Assembly.............................................................................................................................................3

Before Each Use.................................................................................................................................5

Operating Instructions........................................................................................................................5

Spring Tension Adjustment.............................................................................................................5

After Each Use....................................................................................................................................6

Maintenance.....................................................................................................................................6

Hose Replacement...........................................................................................................................6

Swivel Service..................................................................................................................................6

Parts List ............................................................................................................................................7

Parts Diagram.....................................................................................................................................8

Troubleshooting..................................................................................................................................9

Replacement Parts.............................................................................................................................9

Limited Warranty.................................................................................................................................9

Intended Use

These reels incorporate metal forms to ensure strength and function equally well in both mobile and

permanent-mount situations that are suitable for a variety of heavy- duty applications in the mining,

construction, service, and marine industries. The industrial-grade reels include: hose with a

maximum 300 PSI working pressure, automatic rewind, and easy installation on a wall, floor, or

ceiling. The reels feature an adjustable guide arm that allows for a variety of mounting orientations.

Technical Specifications

50ft. Industrial Air Hose Reels

OWNER’S MANUAL

50ft. Industrial Air Hose Reels

OWNER’S MANUAL

Item#s 49549, 49584

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WARNING:

Read carefully and understand all ASSEMBLY AND OPERATION

INSTRUCTIONS before operating. Failure to follow the safety rules and

other basic safety precautions may result in serious personal injury.

Property \ Item

Ship Weight (lbs.)

Hose Fitting Size (in. NPT)

Hose Diameter (in.)

Hose Length (ft.)

Max. PSI

Hose Material

Dimensions L x W x H (in.)

Hose Application

Temp Range (°F)

49549

58.6

3/8

300

NBR Rubber

20.3 x 10.4 x 20.3

Air

210 Max

49584

60.8

1/2

300

NBR Rubber

20.3 x 10.4 x 20.3

Air

210 Max

50ft. Industrial Air Hose Reels

OWNER’S MANUAL

50ft. Industrial Air Hose Reels

OWNER’S MANUAL

Important Safety Considerations

WARNING:

• Read and understand all instructions. Failure to follow all instructions may result in serious

injury.

• The warnings, cautions, and instructions in this manual cannot cover all possible conditions

or situations that could occur. Exercise common sense and caution when using the reel.

Always be aware of the environment and ensure that the reel is used in a safe and

responsible manner.

• DO NOT allow persons to operate or assemble the reel until they have read this manual and

have developed a thorough understanding of how it works.

• DO NOT modify the reel in any way. Unauthorized modification may impair the function

and/or safety and could affect the life of the reel.

• Use the right tool for the job. DO NOT attempt to force a small equipment to do the work of

larger industrial equipment. There are certain applications for which this equipment was

designed. It will do the job better and more safely at the capacity for which it was intended.

DO NOT use this equipment for a purpose for which it was not intended.

• Industrial or commercial applications must follow OSHA requirements.

WARNING:

WORK AREA SAFETY

• Inspect the work area before each use. Keep the work area clean, dry, free of clutter, and well

lit. Cluttered, wet, or dark work areas can result in injury. Using the reel in a confined work

area may put you dangerously close to other cutting tools and rotating parts.

• Do not use the reel when there is a risk of causing a fire or an explosion; e.g., in the presence

of flammable liquids, gases, or dust. The reel can create sparks, which may ignite the dust or

fumes.

• Keep children and bystanders away from the work area while operating the reel. Do not allow

children to operate the reel.

• Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in

your work area. Some of these hazards may be below the work surface hidden from your

view and may cause personal harm or property damage if unintentionally contacted.

PERSONAL SAFETY

• Stay alert, watch what you are doing, and use common sense when operating the reel. Do not

use the reel while you are tired or under the influence of drugs, alcohol, or medication. A

moment of inattention may result in serious personal injury.

• Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair,

clothing and gloves away from moving parts. Loose clothes, jewelry, or long hair can be

caught in moving parts.

• Use ANSI compliant safety goggles or safety glasses with side shields, or when needed, a

face shield. Use a dust mask in dusty work conditions. Also use non-skid safety shoes,

hardhat, gloves, dust collection systems, and hearing protection when appropriate.

• Do not overreach. Keep proper footing and balance at all times.

• Secure the work with clamps or a vise instead of your hand when practical. This safety

precaution allows for proper tool operation using both hands.

CAUTION:

REEL USE AND CARE

• Check for damaged parts before each use. Carefully check that the reel will operate properly

and perform its intended function. Replace damaged or worn parts immediately. Never

operate the reel with a damaged part.

• Disconnect the air or fluid supply from the reel before making any adjustments, changing

accessories, or storing the tool. Such preventive safety measures reduce the risk of starting

the tool accidentally.

• Use only accessories that are recommended by the manufacturer for use with the reel.

Accessories that may be suitable for one reel may create a risk of injury when used with

another reel. Never use an accessory that has a higher operating pressure than the reel itself.

• Inspect the reel, hose, and accessories for damage or excessive wear before each use. If you

find damage do not use the reel.

Specific Operation Warnings

WARNING:

• Wear ANSI Z87.1 compliant safety goggles or safety glasses with side shields when

assembling and using the hose reel.

• Assemble the hose reel on a clean workbench.

• Keep children away from the work area. If not in use, store out of the reach of children.

• Ensure that reel is properly installed before connecting input and output hoses.

• Make sure incoming pressure does not exceed the rated pressure (300 PSI) for reel.

• Before connecting a pressure source, ensure that supply pressure does not exceed

maximum working pressure rating of reel.

• Never attach any tool or accessory to the hose unless it is capable of safely operating at a

pressure greater than the supply pressure.

• If a leak occurs in the hose or reel, remove system pressure immediately.

• If reel ceases to unwind or rewind, remove system pressure immediately.

• Do not kink the hose. Do not step on the hose or drive or drag objects over the hose. Do not

place any objects on the hose or hose reel.

• Pull the hose from the reel by grasping the hose itself, not the valve.

• Bleed fluid/gas pressure from reel before servicing it.

• Use soap and water when checking for air leaks. Exposure of skin directly to pressurized air

or fluids could result in severe bodily injury.

• Remember, even low pressure is very dangerous and can cause personal injury or death.

WARNING:

This product may contain chemicals known to the State of California to cause cancer, birth

defects or other reproductive harm.

Assembly

WARNING:

To avoid a dangerous sudden release of pressure that can cause severe injury, ensure that the

pressure source for the reel is turned off and the supply hose is not pressurized.

Note: Before beginning assembly/installation, purchase appropriate hardware for mounting the

reel. The mounting base has four 1/2” (12.7mm) holes for mounting on a suitable flat surface.

1. Prior to mounting the hose reel, ensure that the supply hose pressure does not exceed the

maximum working pressure of the hose reel. Also check that the pressure source is turned

off and the supply hose for the reel is not pressurized.

2. Unpack the reel then check that all parts are present and inspect for damage. Check reel

function for smooth rotation.

3. Fasten the mounting base (24) in the desired location. Reel dimensions and the pattern of

the mounting holes in the base are shown below. Tighten all hardware securely.

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50ft. Industrial Air Hose Reels

OWNER’S MANUAL

50ft. Industrial Air Hose Reels

OWNER’S MANUAL

Units Conversions (for base hole spacing): 105mm = 4-1/8 inches 200mm = 7-7/8 inches

The bracket arms (5 & 41) that guide the hose on and off the reel can be repositioned for better

function as shown in the pictures below. If desired, follow steps 4 through 8 to reposition the

arms. Otherwise continue with step 9.

4. Pull out the hose until the reel latches.

5. Maintaining a firm hold on spool, disengage the reel latch and allow the reel to turn in the

direction of the drive spring approximately two or three revolutions until tension is released.

6. Remove the nuts and washers holding the bracket arms to the base.

7. Turn the bracket arms (5 & 41) to any of the three positions shown below then replace and

tighten the nuts and washers.

8. Tighten the drive spring by turning the spool two or three revolutions then engage the latch.

Connect the hoses

9. Apply Teflon tape or pipe sealant to the supply hose threads then attach it to reel’s inlet hose

fitting and tighten. If not already connected, the unpressurized supply hose can now be

connected to the supply source.

If the reel was supplied with hose already wound on it, continue with step 15. If not, continue

with the next step.

10. Turn the reel drum by hand until the rewind spring is tight, and drum has latched. As an

extra precaution while installing the new hose, secure the drum in its latched position.

11. Insert the end of the delivery hose through guide plate (22) then to the outlet fitting of the

reel.

12. Use Teflon tape or pipe sealant on the hose fitting threads then screw the fitting into the

reel’s outlet fitting and tighten. Note: To avoid damage to the reel fitting, use a wrench to

support the fitting while tightening the hose.

13. Attach the hose stopper (46) to the other end of delivery hose.

14. Carefully release the drum latch, and slowly allow hose to wind onto the reel in a controlled

way making sure the hose winds in even, straight turns on the reel.

15. Apply Teflon tape or pipe sealant to the outlet fitting on the delivery hose then attach it to a

desired tool, or nozzle. Pressurize the reel and check all the connections for leakage. Also

check the hose reel for correct rotation/latching and that system pressure is adequate to

perform the intended function (see the Operating Instructions).

16. If a final adjustment to the hose stopper (46) is required, pull the hose from the reel and

allow it to latch at a desired length. Loosen the stopper bolts, and slide the stopper to a

position close to the guide plate (22). Retighten the stopper bolts.

Before Each Use

• Ensure that the hose reel is in proper working order before use.

• Inspect the hose reel fittings, alignment, hoses and components periodically before use.

Have damaged or worn components repaired or replaced by an authorized technician.

Operating Instructions

• Check the reel for correct operation by slowly pulling out the hose. A “clicking” noise will be

heard every half revolution of the drum.

• To latch the reel, pull out the hose then allow it to retract after hearing the first, second, or

third “ click”.

• To unlatch the reel, slowly pull out the hose until the “clicking” noise stops then, holding on

to the hose, let it retract in a controlled way until the stop/block rests against the hose

guide/rollers.

• Keep the hose and air-tools or nozzles dry, clean, and free from oil and grease.

• Periodically clean the hose with a cloth dipped in warm water to remove dirt or deposits and

ensure correct winding on the reel. Do not use detergents or solvents which could prove

incompatible with cable-winder materials.

• Also periodically check the hose condition for wear or damage, and check the swivel fitting

for leakage. See the maintenance section for tips to replace any worn, damaged, or leaking

parts.

Spring Tension Adjustment

WARNING:

Avoid accidentally releasing the reel’s latching mechanism. The reel is under tension and

accidental release can cause a wildly spinning reel and personal injury.

If necessary, adjust spring tension on reel by adding or removing wraps of hose from spool, one

wrap at a time, until desired tension is obtained.

1. Pull out approximately 6 or 8 feet of hose and allow the drum to latch.

2. Remove hose stop/block from the hose and pull the hose back through guide/rollers.

CAUTION:

When adding wraps of hose to the reel, be careful not to exceed the winding mechanism’s

spring capacity. Add just enough wraps of hose to achieve the desired tension. Damage to the

winding mechanism will result if spring is over-tensioned.

3. To increase spring tension, wrap the loose hose one extra turn around the drum or, to

decrease tension, un-wrap the hose one turn from drum.

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50ft. Industrial Air Hose Reels

OWNER’S MANUAL

4. Re-insert the hose through guide/rollers and install the stop/block at the desired distance

from the hose end.

5. Unlatch the drum and check the tension. Readjust the tension by repeating these steps.

After Each Use

• Inspect the hose reel fittings, alignment, hoses and components periodically after use so that

worn or damaged components can be ordered and replaced before the next use. Have

damaged or worn components repaired or replaced by an authorized technician.

Maintenance

Maintain your reel. It is recommended that the general condition of any tool be examined before

it is used. Keep your reel in good repair by adopting a program of conscientious repair and

maintenance in accordance with the recommended procedures found in this manual.

WARNING:

If the rewind spring fails, for safety reasons, it is strongly recommended the replacement of the

spring canister be performed by an authorized service technician. The spring can be under

high tension and accidental release can cause severe personal injury.

User servicing of the reel is limited to replacing input/output hoses and swivel maintenance

only. Refer all other repairs to an authorized service technician. Failure to do so can result in

person injury and/or equipment damage and may void the warranty.

• Use soap and water when checking for air leaks.

Hose Replacement

WARNING:

To avoid a dangerous sudden release of pressure that can cause severe injury, ensure that the

pressure source for the reel is turned off and the supply hose is not pressurized before

performing any maintenance or adjustment on the reel.

1. Turn off the pressure supply to reel and release pressure from the system in a controlled way.

CAUTION:

Make sure reel drum is securely locked in the next step and cannot accidentally spin.

2. Pull out all the old hose and lock the reel in position.

3. Take note of the hose connection, any hose clamps, and the position of the stop/block on the

hose.

4. Remove any hose clamps from the hose.

5. Carefully disconnect the hose from its connection and remove it.

6. Route a new equivalent type and size hose through guide/rollers to the old hose connection point.

7. Use Teflon tape or pipe sealant on the hose fitting threads then screw it into the connection

fitting on the reel. Note: To avoid damage to a swivel connection, use a wrench to support

the swivel while tightening the hose.

8. Re-install any hose clamps and the hose stop/block as noted in step 2.

9. Carefully release the drum latch, and slowly allow the hose to wind onto the reel.

10. Apply Teflon tape or pipe sealant to the outlet fitting on the new hose then attach it to a

desired tool, or nozzle. Pressurize the reel and check all the connections for leakage.

11. If needed, adjust the spring tension. See Spring Tension Adjustment in the Operation

section.

Swivel Service

WARNING:

To avoid a dangerous sudden release of pressure that can cause severe injury, ensure that the

pressure source for the reel is turned off and the supply hose is not pressurized before

performing any maintenance or adjustment of the reel.

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50ft. Industrial Air Hose Reels

OWNER’S MANUAL

• If the swivel leaks, replace the O-ring or seal (#31) and washer (#30) by removing the lock

washer (#40) and the part of the swivel shaft (35).

• If the ball bearings (#37) wear-out, replace them by removing the lock washer (#40).

• Replace part of the swivel shaft (35) by removing the lock washer (#40).

After making the repairs, use Teflon tape or thread sealant to reconnect the fittings then

pressurize the system and check for leaks.

Parts List

Part No.

Description

Nut

Spring washer

Washer

Bolt

Bracket arm

Washer

Ratchet

Washer

Lock washer

Click pulley

Nut

Lock washer

Washer

Shaft

Key

Guide sub-plate

Drum

Roller axle

Roller

Roller axle

Guide plate

Bolt

Base

Q’ty

Part No.

Description

Double bolt

Spring core

Spring

Drum

Swivel shaft

Washer

O-ring or seal

Washer

Swivel shaft

Bearing cover

Ball bearing

Bearing washer

Washer

Lock washer

Bracket arm

Double bolt

Hose assembly

Clamp

Stopper assembly

Ratchet spring

Q’ty

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Troubleshooting

Replacement Parts

• For replacement parts and technical questions, please call Customer Service at

1-800-222-5381.

• Not all components are available for replacement. The illustrations provided are a convenient

reference to the location and position of parts.

• The following are required when ordering parts: model number, serial number/lot date code,

and description.

• The distributor reserves the rights to make design changes and/or improvements to product

lines and manuals without notice.

Limited Warranty

Northern Tool and Equipment Company, Inc. ("We'' or '"Us'') warrants to the original purchaser

only ("You'' or “Your”) that the Ironton Air Tool product purchased will be free from material

defects in both materials and workmanship, normal wear and tear excepted, for a period of one

year from date of purchase. The foregoing warranty is valid only if the installation and use of the

product is strictly in accordance with product instructions. There are no other warranties,

express or implied, including the warranty of merchantability or fitness for a particular purpose.

If the product does not comply with this limited warranty, Your sole and exclusive remedy is

that We will, at our sole option and within a commercially reasonable time, either replace the

product without charge to You or refund the purchase price (less shipping). This limited

warranty is not transferable.

Limitations on the Warranty

This limited warranty does not cover: (a) normal wear and tear; (b) accessories both

consumable and durable; (c) damage through abuse, neglect, misuse, or as a result of any

accident or in any other manner; (d) damage from misapplication, overloading, or improper

installation; (e) improper maintenance and repair; and (f) product alteration in any manner by

anyone other than Us, with the sole exception of alterations made pursuant to product

instructions and in a workmanlike manner.

Obligations of Purchaser

You must retain Your product purchase receipt to verify date of purchase and that You are the

original purchaser. To make a warranty claim, contact Us at 1-800-222-5381, identify the

product by make and model number, and follow the claim instructions that will be provided. The

product and the purchase receipt must be provided to Us in order to process Your warranty

claim. Any returned product that is replaced or refunded by Us becomes our property. You will

be responsible for return shipping costs or costs related to Your return visit to a retail store.