ReelCraft 6800 Series User manual

Reelcraft Industries, Inc. • 2842 E Business Hwy 30, Columbia City, IN 46725
Ph: 800-444-3134 / 260-248-8188 • Fax: [phone]
Customer Service: 855-634-9109 • [email protected] • www.reelcraft.com
Form# 1309-719 Rev: 11/2019
Installation and
Operating Instructions
Pre-Conditioned Air (PCA) Hose Reel with Cart
Series 6800
IMPORTANT
READ MANUAL CAREFULLY
BEFORE INSTALLING, OPERATING,
OR SERVICING EQUIPMENT

Pre-Conditioned Air (PCA) Hose Reel with Cart
Page 2 www.reelcraft.com
Contents:
1. Safety Notes......................................................................................................
2. PCA Hose Reel with Cart Technical Data............................................................
2.1. Operating Temperature.......................................................................
2.2. Space Requirements...........................................................................
2.3. Lubricants...........................................................................................
2.4. Connections........................................................................................
2.5. Maximum Hose Length.......................................................................
3. PCA Hose Reel with Cart Unit Structure.............................................................
3.1. Reel Nomenclature.............................................................................
3.2. General Assembly of PCA Hose Reel with Cart....................................
3.3. Parts Breakdown of PCA Hose Reel with Cart.....................................
3.4. Name Plate, Designations...................................................................
4. Installation and Set-up.......................................................................................
4.1. Required Tools / Aids..........................................................................
4.2. Prerequisites for Assembly.................................................................
4.3. Installing the PCA Hose Reel...............................................................
4.4. Checks Before the First Commissioning..............................................
5. Standard Operation............................................................................................
5.1. Operating Method...............................................................................
5.2. Operating Safety Device......................................................................
6. Maintenance......................................................................................................
6.1. Inspecting the Bearings.......................................................................
6.2. Inspect the Chain.................................................................................
6.3. Inspect the Sealed Surfaces................................................................
6.4. Inspect the Handwind Assembly..........................................................
6.5. Maintenance Intervals.........................................................................
7. Troubleshooting.................................................................................................
7.1. Reel Will Not Function.........................................................................
8. Repair.................................................................................................................
8.1. Replacement of Chain.........................................................................
8.2. Converting Reel from Crank to Wheel..................................................
3
4
4
4
4
4
4
4
4
5
6
8
8
8
8
8
11
11
11
12
12
12
12
12
13
13
13
13
14
14
14

Pre-Conditioned Air (PCA) Hose Reel with Cart
www.reelcraft.com Page 3
1. Safety
Personal injury and/or equipment damage may result if proper safety precautions are not observed.
• Be aware of ground support equipment and personnel in work area.
• Treat and respect the hose reel as any other piece of ground support equipment, observing all common
safety practices.
• Ensure that reel is properly installed before connecting input and output hoses.
• If a leak occurs in the reel, remove system pressure immediately.
• Pull hose from reel by grasping the hose itself, not the PCA adapter.
• Engage spring loaded pin lock when reel is not in use.
• If reel ceases to unwind or rewind, remove system pressure immediately. Do not pull or jerk on
hose!
Designated
Use
Transportation
PCA hose reel systems are intended for outside use to transfer pre-conditioned hot and
cold air that supplies stationed aircraft. They correspond to the applicable standards and
regulations.
Technical data and information about the permitted conditions can be found on the
nameplate and in the documentation.
It is essential that you follow all the instructions!
Inspect the shipment for any damage that may have occurred in transit as soon as you
receive the delivery. Inform the shipping company immediately of any damage.
Safety features designed into the reel system are:
• Guards covering chain drives
• Tether retaining hand crank handle
• Spring loaded pin lock
• Safety yellow powder coat paint
Safety features

Page 4 www.reelcraft.com
Pre-Conditioned Air (PCA) Hose Reel with Cart
2. PCA Hose Reel with Cart Technical Data
2.1 Operating Temperature
Minimum: -22 °F (-30 °C) Maximum: 122 °F (50 °C)
2.2 Space Requirements
Minimum Space Requirement - See page 5 for additional dimensional information.
2.3 Lubricants
• Apply grease to bearings by utilizing a grease gun with the grease fitting (see page 13).
• Chain must be greased.
2.4 Connections
Inlet Connection: 14 inch (outer dimension)
Outlet Connection: 14 inch (outer dimension)
2.5 Maximum Hose Length
Reel will accommodate up to 100’ of lay flat 14” I.D. PCA ducting (up to 80’ with scuff strips).
Ducting is not included with reel.
3. PCA Hose Reel with Cart Unit Structure
3.1 Reel Nomenclature
Drive Type
HC - Hand crank
HW - Hand wheel
Material Type
50 - Aluminum frame and spool
Series
68 - Series 6800
Configuration
L- Cart mount, left side inlet, hand crank on
right side
R- Cart mount, right side inlet, hand crank on
left side
Options
CA - With 8” casters
SB - Swivel bracket, pin, bumpers, and
8” casters
- - - -
HC 68 50 39 24 14 L CA
Ducting
14 - 14 in. I.D. PCA ducting
Drum Length
24 - 24 in.
Flange Diameter
39 - 39 in.
Dimensions - Hand Wheel
41.66”
24.75”
20.125”
40.69”
9.5”
33.375”
38.44”
36.44”
40.44”
42.93”
Dimensions - Hand Crank
40.75”
Ø 15.65”
36.44”
38.44”
40.44”
9.5”
40.69”
24.75”
44.58”
20.125
33.375”

Pre-Conditioned Air (PCA) Hose Reel with Cart
www.reelcraft.com Page 5
3.2 General Assembly of PCA Hose Reel with Cart System
Reel Dimensions

Page 6 www.reelcraft.com
Pre-Conditioned Air (PCA) Hose Reel with Cart
3.3 Parts Breakdown of PCA Hose Reel with Cart
1
2
3
4
5
67
8
9
15
16
17
19
20 22
23
10b
11
12
37
38
10
21
18
39
40
13
14
41 42
43
44
45
46
47
48
50
10a
36
24
25
27
28
29
30
26
49
31
32
33
34
35
31a
31b
Components can be ordered individually or the following kits are available:
#19 Hitch Bracket Assembly - Part number S396687-35
#21 Handwind Assembly - Part number S396694-HC-35
#23 Chain Guard Assembly - Part number S396684
#24 Handwheel Assembly - Part number S396729-35
#31 Hand Crank Assembly - Part number S396728-35
#36 Caster Assembly - Part number S396688-P11

Pre-Conditioned Air (PCA) Hose Reel with Cart
www.reelcraft.com Page 7
ITEM DESCRIPTION QTY HC6850-39-
24-14X
HC6850-39-
24-14X-CA
HC6850-39-
24-14X-SB
HW6850-39-24-
14X
HW6850-39-24-
14X-CA
HW6850-39-24-
14X-SB
1Spool, Disc 1 390139-42 390139-42 390139-42 390139-42 390139-42 390139-42
2Spool, Disc 1 390140-42 390140-42 390140-42 390140-42 390140-42 390140-42
3Spool, Drum 1 390164-42 390164-42 390164-42 390164-42 390164-42 390164-42
4Axle, Support Assembly 1 366292Z 366292Z 366292Z 366292Z 366292Z 366292Z
5Spool, Stud Assembly 5 326468-24.375 326468-24.375 326468-24.375 326468-24.375 326468-24.375 326468-24.375
6Flat Sprocket 1 390162-35 390162-35 390162-35 390162-35 390162-35 390162-35
7Pillow Block Bearing 1 310020 310020 310020 310020 310020 310020
8Spool, Bracket 1 390177-42 390177-42 390177-42 390177-42 390177-42 390177-42
9Fitting, Adapter 1 323163-35 323163-35 323163-35 323163-35 323163-35 323163-35
10 Bearing, Housing 1 323160-35 323160-35 323160-35 323160-35 323160-35 323160-35
10a MDS Filled Nylon Rod 2 390200-42.875 390200-42.875 390200-42.875 390200-42.875 390200-42.875 390200-42.875
10b Zerk, Grease Fitting 1 316259 316259 316259 316259 316259 316259
11 Fitting, Adapter 1 396683-35 396683-35 396683-35 396683-35 396683-35 396683-35
12 Fitting, Adapter 1 396683M-35 396683M-35 396683M-35 396683M-35 396683M-35 396683M-35
13 Threaded Rod 2 390295 390295 390295 390295 390295 390295
14 Spacer 2 323588-7.875-35 323588-7.875-35 323588-7.875-35 323588-7.875-35 323588-7.875-35 323588-7.875-35
15 Side Frame 1 396688-D-42 396688-D-42 396688-D-42 396688-D-42 396688-D-42 396688-D-42
16 Side Frame 1 396688-S-42 396688-S-42 396688-S-42 396688-S-42 396688-S-42 396688-S-42
17 End Frame 2 396688-P8-42 396688-P8-42 396688-P8-42 396688-P8-42 396688-P8-42 396688-P8-42
18 Bumper Frame 2 NONE NONE S396688-P10 NONE NONE S396688-P10
19 Hitch Bracket Assembly 1 NONE NONE S396687-35 NONE NONE S396687-35
20 Clevis Pin 1 NONE NONE S396687-P1 NONE NONE S396687-P1
21 Handwind Assembly 1 396694-HC-35 396694-HC-35 396694-HC-35 396694-HW-35 396694-HW-35 396694-HW-35
22 Latch Pin Assembly 1 S396695-35 S396695-35 S396695-35 S396695-35 S396695-35 S396695-35
23 Chain Guard Assembly 1 S396684 S396684 S396684 S396684 S396684 S396684
24 Handwheel Assembly 1 NONE NONE NONE S396729-35 S396729-35 S396729-35
25 Crank Handle 1 NONE NONE NONE 261514 261514 261514
26 Crank, Handle Post 1 NONE NONE NONE 261515 261515 261515
27 Hex Nut 2 NONE NONE NONE S77-108 S77-108 S77-108
28 Split Lock Washer 1 NONE NONE NONE S115-816 S115-816 S115-816
29 Socket Head Screw 1 NONE NONE NONE 396697 396697 396697
30 Nyloc Nut 1 NONE NONE NONE S96-13 S96-13 S96-13
31 Hand Crank Assembly 1 S396728-35 S396728-35 S396728-35 NONE NONE NONE
31a Coat Wire Roap Tether 1 390495-12 390495-12 390495-12 NONE NONE NONE
31b Compression Sleeve 2 390497 390497 390497 NONE NONE NONE
32 Crank Handle 1 310005 310005 310005 NONE NONE NONE
33 Hex Screw 1 S347-616 S347-616 S347-616 NONE NONE NONE
34 Hex Nut 2 S338-6 S338-6 S338-6 NONE NONE NONE
35 Lock Washer 1 S339-616 S339-616 S339-616 NONE NONE NONE
36 Caster Assembly 4 NONE S396688-P11 S396688-P11 NONE S396688-P11 S396688-P11
37 Frame, Plate 2 396688-P9-42 396688-P9-42 396688-P9-42 396688-P9-42 396688-P9-42 396688-P9-42
38 Label, Reelcraft Plate 1 396688-P12-35 396688-P12-35 396688-P12-35 396688-P12-35 396688-P12-35 396688-P12-35
39 Flat Washer 33* S110-6 S110-6 (Qty 49) S110-6 (Qty 57) S110-6 S110-6 (Qty 49) S110-6 (Qty 57)
40 Hex Screw 12 S2-52 S2-52 S2-52 S2-52 S2-52 S2-52
41 Hex Screw 2 S2-55 S2-55 S2-55 S2-55 S2-55 S2-55
42 Carriage Bolt 12 S344-162 S344-162 S344-162 S344-162 S344-162 S344-162
43 Flat Washer 14 S350-4 S350-4 S350-4 S350-4 S350-4 S350-4
44 Screw, Flange Head Cap 11 S44-12 S44-12 S44-12 S44-12 S44-12 S44-12
45 Screw, Flange Head Cap 6 S44-2 S44-2 S44-2 S44-2 S44-2 S44-2
46 Screw, Flange Head Cap 12* S44-3 S44-3 S44-3 (Qty 16) S44-3 S44-3 S44-3 (Qty 16)
47 Screw, Flange Head Cap 18* S44-5 S44-5 (Qty 34) S44-5 (Qty 34) S44-5 S44-5 (Qty 34) S44-5 (Qty 34)
48 Screw, Flange Head Cap 4 S44-6 S44-6 S44-6 S44-6 S44-6 S44-6
49 Screw, Flange Head Cap 10 S44-9 S44-9 S44-9 S44-9 S44-9 S44-9
50 Nyloc Nut 14 S85-7 S85-7 S85-7 S85-7 S85-7 S85-7
51 Nyloc Nut 59* S85-8 S85-8 (Qty 75) S85-8 (Qty 83) S85-8 S85-8 (Qty 75) S85-8 (Qty 83)
-- Chain - ANSI 35 1 S366405P-72 S366405P-72 S366405P-72 S366405P-72 S366405P-72 S366405P-72
*Base Model Quantity
X variable used in place of Left or Right in model number

Pre-Conditioned Air (PCA) Hose Reel with Cart
Page 8 www.reelcraft.com
3.4 Name Plate, Designations
Sample name plate:
Model No: The designation number by Reelcraft Industries, Inc.
Serial No: Traceability number designating when the reel was made, unique for every reel.
4. Installation and Set-up
4.1 Required Tools / Aids
• Set of wrenches and screwdrivers required to install hose and to affix reel to installation
position.
• Lubricant, temperature range -50° to 175 °C (e.g. Mobilgrease®28)
• Bolt adhesive (e.g. Loctite® 248)
4.2 Prerequisites for Assembly
Check for the following:
• The data on the name plate of the PCA hose reel matches documentation.
• The reel system has not been damaged during transportation or storage.
4.3 Installing the PCA Hose Reel
The PCA reel can be mounted in a variety of ways. It is recommended that the reel is permanently
mounted based upon the configuration of the reel.
Swivel bracket and caster models:
• A swivel bracket has been provided to attach directly to the passenger loading bridge,
hose basket, or another slowly moving structure. Additional fabrication of mating parts
may be required.
• The swivel bracket provides (4) 0.438” diameter x 1.25” long slots for mounting to
user’s equipment (see Diagram A on page 9).
• Use 3/8” diameter fasteners with bolt adhesive to secure reel.

www.reelcraft.com Page 9
Pre-Conditioned Air (PCA) Hose Reel with Cart
Diagram A
Caster only models:
• Mounting holes have been provided on the rear tie plate to attach directly to passenger
loading bridge, hose basket, or another slowly moving structure. Additional fabrication
of mating parts may be required.
• The tie plate comes with (8) 0.438” diameter holes that can be utilized to mount to the
user’s equipment (see Diagram B).
• Use 3/8” diameter fasteners with bolt adhesive to secure reel.
Diagram B

Page 10 www.reelcraft.com
Pre-Conditioned Air (PCA) Hose Reel with Cart
Models without casters:
• Mounting holes have been provided on the bottom of the frame to attach directly to a
cart or the ground. Additional fabrication of mating parts may be required.
• The frame comes with (16) 0.438” diameter holes that can be utilized to mount to the
user’s equipment (see Diagram C - underside of reel).
• Use 3/8” diameter fasteners with bolt adhesive to secure reel.
Diagram C
4.4 Checks Before the First Commissioning
ATTENTION
Damage to the reel or system is possible
Confirm PCA hose has been installed properly and shows no sign of wear. Confirm if there is sufficient
space to unwind the ducting. Verify that the total system flow and pressure corresponds to the intended
purpose and the documentation. Should you identify any non-conformance, make sure to remedy them
before the first commissioning.
Check the following before the first use:
• Loose or missing parts (bolts, fasteners)
• Damages, deformations, or cracks
• Staining, soiling, or corrosion
• Untypical accumulation of moisture
• Lubricants leaking from bearing
• Guard covering chain

www.reelcraft.com Page 11
Pre-Conditioned Air (PCA) Hose Reel with Cart
5. Standard Operation
5.1 Operating Method
The PCA hose retrieval system is intended to be operated by one or two people.
Hose deployment -
Unreeling the PCA ducting is achieved by pulling the entire length of hose out by hand per-
pendicular to the reel.
• Confirm the reel is secured prior to deployment.
• Confirm latch pin is not engaged.
• Ensure the pathway of the PCA ducting is free from obstructions.
• For safety purposes, it is recommended to disconnect the hand crank handle from the
handwind assembly before hose deployment (hand crank models only).
• Completely deploy hose prior to pre-conditioned air operation.
Hose retrieval -
The operator can manipulate the reel by manually rotating the hand crank or hand wheel
to retrieve the hose.
• Ensure that the adapter is disconnected from the aircraft.
• The operator can rotate the handle with one hand and adjust hose with the other (as
needed) to prevent twisting.
• Engage latch pin.
5.2 Operating Safety Device
Latch Pin -
• Spring loaded latch pin to be engaged with reel flange to prevent unspooling when reel
is not in use.
• There are (4) latch pin holes located in the reel flange. Engage latch pin, rotate reel and
pin will engage flange.
Latch Pin Engaged Latch Pin Disengaged

Page 12 www.reelcraft.com
Pre-Conditioned Air (PCA) Hose Reel with Cart
6. Maintenance
The reel must be maintained at regular intervals. See page 13 for recommendations. The following
components, if necessary, should be inspected, lubricated, repaired, or replaced.
6.1 Inspecting the Bearings
• Remove chain guard
• Check the bearings located on each end of the
spool
• Grease by means of a grease gun until cavity is
filled completely - DO NOT OVERFILL!
• Grease nipples easily accessible
• Carry out a visual inspection of the bearing
• Rotate spool
• Re-attach chain guard
6.2 Inspect the Chain
The chain will stretch with time and usage. They must be inspected for wear and tightened when
needed (remove excessive chain links if necessary).
The drive chain runs from the handwind assembly to the large sprocket that drives the reel. This
chain is an ANSI 35 construction.
Tensioning of the drive chain -
• Remove chain guard.
• Loosen the screws that hold the handwind assembly to the frame.
• Move handwind assembly into the direction which tightens the chain.
• Fasten the handwind assembly again securely.
• Rotate the spool.
6.3 Inspect the Sealed Surfaces
• Bearings
• Chain
• Sealed surfaces
• Handwind assembly
• With the PCA ducting deployed out, visually
inspect the connection points between parts on
the drum.
• Inspect for loose silicone caulk.
• Reapply silicone caulk, as needed. Smooth into
corners / creases and remove access.
• Allow time for caulk to dry properly (follow rec-
ommendation of caulk manufacturer).
Drive Side Bearing Handwheel Bearing Support Side Bearing Caster Bearing

www.reelcraft.com Page 13
Pre-Conditioned Air (PCA) Hose Reel with Cart
6.4 Inspect the Handwind Assembly
Hand crank assembly -
• Inspect tethered connections.
Hand wheel assembly -
• Inspect for loose hardware.
6.5 Maintenance Intervals
Every 2 months -
• Visually check lubricated components and grease if necessary.
• Check the pressurized air duct visually for leakage.
• Ensure chain is taught.
• Check for loose hardware, including hand crank tether.
Every 6 months -
• Visually check lubricated components.
• Inspect fluid path on PCA reel to ensure all parts are secured properly and if any foreign
part is obstructing the air flow through the reel.
• Ensure that mounting fasteners are present and secure.
• Inspect reel for any corrosion.
7. Troubleshooting
7.1 Reel Will Not Function
Reel does not turn
Possible Cause Recognizable By Remedy
Mechanical fault Foreign parts obstructing drive
components.
Check whether foreign parts are in the chain
guard or hose is obstructing drive elements.
Hand assembly turns, but reel does not rotate
Possible Cause Recognizable By Remedy
Loose gear pin Gear connection is slipping through. Fix gear to drive shaft of handwind assembly.
Chain broken Visual inspection and/or removing of chain
guard. Fix or replace chain.
Broken tether Hand crank no longer attached to reel. Fix or replace tether.

Page 14 www.reelcraft.com
Pre-Conditioned Air (PCA) Hose Reel with Cart
8. Repair
8.1 Replacement of Chain
WARNING
When removing the covers and chain guard make sure to avoid unintended turning of the reel,
engaging latch pin. Be careful not to get your hand caught between the chain and sprockets.
Before reassembly, thoroughly clean all parts and check them with regard to possible damages.
Replacing the 3/8 inch drive chain-
• Remove chain guard
• Loosen the screws that hold the handwind assembly
• Move the handwind assembly into the direction of the large sprocket
• Take the chain off
• Install the new chain
• Move handwind assembly into the direction which tightens the chain and secure in place
• Ensure sprockets are aligned prior to tightening chain
• Allow up to 1/8” of play in chain to avoid tight spots
• Check lubrication of the chain
• Fasten chain guard again securely
8.2 Converting Reel from Crank to Wheel
1. Remove crank handle and tether.
2. Remove spring pin - tap out with a mallet or other means in either direction.
3. Remove washer.
4. Slide hand wheel over shaft.
5. Slide 1/4” bolt (supplied) through hole in hand wheel and shaft.
6. Tighten nut to bolt.