Balcrank PGE-55 Instruction Manual

Thoroughly read and understand this manual before
installing, operating or servicing this equipment.
OPERATION, INSTALLATION,
MAINTENANCE AND REPAIR GUIDE
SERVICE BULLETIN SB 3026
Rev. D 11/09
PGE-55 ELECTRONIC
CONTROL HANDLE
Model #3330-054
3330-055
3330-056
3330-057
3330-058
3330-059

2
GENERAL SAFETY REQUIREMENTS
NOTE: THOROUGHLY READ AND UNDERSTAND THIS MANUAL BEFORE INSTALL-
ING, OPERATING, OR SERVICING THIS EQUIPMENT.
• Please retain this instruction manual for future
reference.
• Your safety is important to us. Please read, and
follow all safety instructions listed below.
• Some of these instructions alert you to the potential
for personal injury. “Warnings” listed throughout
this manual advise of potential practices or
procedures which may cause damage to your
equipment.
• This control handle is not designed for in-line
installation. Do not install with a shut-off valve on
the outlet side of the meter. Such an installation
could result in damage to the meter housing.
• Ensure all operators have access to adequate
instructions about safe operating and maintenance
procedures.
• Do not exceed the maximum working pressure
of 1,500 psi.
• Do not strike the control handle if it fails to
operate. Refer to the “trouble shooting guide” or
return unit to your nearest Balcrank authorized
service center.
• Never allow any part of the human body to come
in contact with the control handle outlet.
• Never point the outlet nozzle at yourself or anyone
else.
• Never exceed the pressure rating of any compo-
nent installed in the System.
• Before each use check all hoses for signs of wear,
leaks or loose ttings. Tighten all uid connections
regularly and replace weak or damaged hoses.
Your personal safety and well-being are at stake.
• Before attempting any repairs or maintenance
of this product disconnect the air supply on the
pump, and release the line pressure by pressing
the lever on your control handle.
WARNING
!
DANGER: Not for use with
fluids that have a flash point
below 100°F (38°C). Examples:
gasoline, alcohol. Sparking could
result in an explosion which could result in
death.
IMPORTANT
!
Read these safety warnings and
instructions in this manual completely,
before installation and start-up of the
control handle. It is the responsibility of the purchaser
to retain this manual for reference. Failure to comply
with the recommendations stated in this manual will
damage the control handle and void factory warranty.
Before doing any maintenance on
the control handle, be certain all
pressure is completely vented from
the pump, suction, discharge, piping, and all other
openings and connections. Be certain the air supply is
locked out or made non-operational, so that it cannot
be started while work is being done on the control
handle. Be certain that approved eye protection
and protective clothing are worn at all times in the
vicinity of the control handle. Failure to follow these
recommendations may result in serious injury or
death.
WARNING
!
Airborne particles and loud
noise hazards.
Wear ear and eye
protection.
WARNING
!

3
GENERAL DESCRIPTION
This manual assists you in operating and maintaining your new PGE-55 Electronic Control
Handle. The information contained will help you ensure many years of dependable
performance and trouble free operation.
Please take a few moments to read through this manual before installing and operating
your new control handle. If you experience problems with this product, refer to the trouble
shooting sections of this manual. If you require further assistance please contact your local
Balcrank distributor or Balcrank authorized service center.
SPECIFICATIONS
Accuracy: + - 0.5% (of Reading)
Flow Range: 0.26 – 8 gal/min
Maximum Operating Pressure: 1,500 PSI
Weight: 2.55 lbs
Inlet: 1/2” NPT
Outlet: 3/8” NPT (prior to May 2003)
3/8” NPS (straight thread) (after May 2003)
Operating Temperature: 320– 1220F
Storage Temperature: 140 - 1220F
Battery: 2 x 1.5 volt alkaline AA
Wetted Parts: Aluminium, Acetal, Steel, Nitrile Rubber
Fluid Compatibility: Engine Oil, Diesel Oil, Automatic Transmission Fluid,
Anti-freeze
Pressure Loss: 14.4PSI at 3.2 US gal/min with calibration uid
(6 Centipoise viscosity) without extension.
Dimensions: 10 inch Long x 3.7 inch Wide, 4.33 inch High
(Dimensions without extension)
ASSEMBLY
Use Teon®tape (or suitable thread sealant)
when connecting the control handle to the hose
connection.
Outlet Extension
The outlet extension can be tted either inline
(forward) or on the outlet port “pistol style”
located under the meter.
Note: The threaded plug removed from the
outlet port on the underside of the meter, is
used to seal the outlet port not in use.
Threaded
Plug
Threaded
Plug
831335
Kit
(Not Included with
control handle)
831336
O-Ring
Manual tip cannot be used on
PGE-55 control handle. An auto
tip or semi-auto tip must be used.
Use of manual tip can result in overpressurization,
which can cause control handle to crack.
WARNING
!
(Included with
models prior
to 5/03)

4
METER INTRODUCTION
Operating mode description.
Sleep Mode: To minimize battery consumption
the meter will revert to sleep mode if left idle
for more than 2 minutes, and will automatically
“power up” when the reset button is pressed or
there is ow through the meter.
Operation of Buttons
The control buttons can be used in two ways
1) Press: Press & release the button.
2) Double click: Press & release the button
twice quickly.
Totalizers
There are three totalizers built in to your meter
1) Reset batch total: To reset batch total
press the reset button.
2) Non-reset accumulative total: This is
located below the batch total and displays
the total volume the meter has dispensed.
3) Reset accumulative total: Is hidden from
view and is used to track daily, weekly, or
monthly usage.
To View or Reset Total
A) Double click the reset button (the display
will enter the reset total mode)
B) To reset the resettable total, press and
hold the reset button (3 seconds) until the
total zeros.
C) The display will automatically return to
manual mode after 5 seconds.
Changing Units
1) Press and hold the reset button for five
seconds. (The units segment starts ash-
ing.)
2) Press the reset button to cycle through the
unit options.
3) Stop at the required setting.
Batch Total - Accumulative Total
Liter Liter
Pint Gallon
Quart Gallon
Gallon Gallon
4) To store the selected units, press and hold
down the Reset button for five seconds
until the batch and accumulative totals
appear. If the reset button is not held down
for 5 seconds, the original settings will be
stored.
Low Battery
The battery segment will ash when the battery
is low and needs replacing.
NOTE: When the battery segment starts ashing
replace the battery as soon as possible. Use
only Alkaline AA batteries.
Battery Replacement
1) Remove the protective rubber boot.
2) Remove the battery cover screw located
near the inline (forward) outlet port and
remove the battery cover.
3) Replace the two AA Alkaline batteries.
(Check + - are correct)
4) Inspect the battery cover seal for damage
and replace if necessary.
5) Replace battery cover and tighten screw,
while pressing cover in place.
Error Message
If an error is detected in meter operation,
the following error codes will appear on the
display.
Err1 – Sensor error
Err3 – Flow rate too high
Err4 – Calibration error
Err5 – Computer error
To reset the meter after an error message
press reset.

5
Maintenance
Inspect your control handle daily for any signs
of damage. Replace any damaged parts or
components as required.
Handle Disassembly
Use a clean work area to carry out
maintenance.
A) Remove the fluid hose from the control
handle inlet swivel (31).
B) Unscrew and remove swivel (31), washer
(29), and o-ring (30) from the control handle
inlet. Clean or replace the strainer and
o-ring.
CAUTION: The swivel is under spring
tension.
C) Slide of the handle sleeve (28).
D) Remove valve spring (27), seal/valve body
assembly (25, 26) and plunger (24).
Lever and Valve Removal
A) Using a 2.5mm allen wrench, remove the
two handle screws (32).
B) Remove lever (34).
C) Remove the washer (20) and o-ring (19),
then push the valve cam (16) from the
handle body (15), and remove o-ring (19).
Handle Reassembly
A) Clean and inspect all parts. Replace any
suspect, worn, or damaged components.
NOTE: Lightly lubricate the valve cam before
assembly.
B) Place o-ring (19) onto valve cam (16).
NOTE: The cutout section in the middle of
the valve cam (16) must face the inlet swivel
(31).
C) Replace the valve cam (16) into the body
(15). Note the orientation shown on the
assembly drawing. Fit the second o-ring
(19) and washer (20).
D) Slide lever assembly (34) into position and
replace the two allen screws (32). Use
Loctite or similar sealant.
E) Replace plunger (24).
NOTE: The end hole in the plunger must face
the meter.
F) Assemble the seal/valve body (25, 26) and
spring (27) and replace into the handle
body.
NOTE: Install the spring, small end rst.
G) Replace handle sleeve (28).
H) Replace washer (29), o-ring (25), and swivel
assembly (31) and screw rmly into place.
Use Loctite or similar sealant.
Meter Disassembly
A) Unscrew the swivel assembly (31) two
complete turns to allow easy disassembly
and reassembly of the meter and remove
boot (1).
B) Remove battery cover screw (5) and
batteries (9).
C) Remove the three screws (11) and the
calibration port screw (18) from the
underside of the meter.
D) Carefully remove the computer module (2)
from the module housing (10).
NOTE: The computer module is non repairable
and will need to be replaced if damaged.
E) Remove the four allen screws (17) from
the underside of the meter and remove the
module housing (10).
Before maintenance or repair, shut
off the compressed air line, bleed
the pressure, and disconnect the
air line from the pump. The discharge line may be
pressurized and must be bled of its pressure.
WARNING
!

6
Control Valve Service Kit
(Order 900013)
!
Meter Reassembly
A) Clean and inspect all parts. Replace any
suspect, worn, or damaged components.
B) Replace rotors (13).
NOTE: Ensure the rotor with the magnets is
assembled with the magnets facing up and
positioned on the correct side of the meter. Both
rotors must also be positioned at 90 degrees
to each other.
C) Replace the handle body o-ring (14).
D) Carefully position the module housing (10)
on top of the handle body (15), replace and
tighten the four allen screws (17).
E) Test the control handle for correct
operation.
F) Replace the computer module (2).
G) Replace and tighten the three phillips head
screws (11) and calibration port screw (18).
H) Replace the two AA Alkaline batteries (9).
Use the directions on the label found inside
the battery housing for correct battery
orientation.
I) Replace battery cover assembly (6, 7, and
8) and tighten the screw (5).
J) Firmly tighten the swivel assembly (31)
K) Replace the boot (1).
L) Test the control handle for correct
operation.
PGE-55 Parts List
* To be used with exible hose
outlet when used as pistol style.
(see page 3) for control handles
prior to 5/03 only)
ITEM PART NO. QTY. IN KIT DESCRIPTION
1 830727 1 - Boot
2 831251 1 - Electronic Module
3 - - N/A
4 - - N/A
5 - 1 - Battery Cover Screw
6 - 1 - O-Ring
7 - 1 - Battery Cover
8 - 1 - O-Ring
9 - 2 - AA Alkaline Batteries
10 - 1 - Module Housing
11 - 3 - M 3x6 Taptite Screws
12 - 2 - Magnets
13 - 2 - Oval Gear Set
14 - 1 - O-Ring
15 - 1 - Control Handle Body
16 - 1 - Valve Cam
17 - 4 - M 6x20 Taptite Screws
18 - 1 - Calibration Screw
19 - 2 O-Ring
20 - 1 Washer**
21 - 1 - Latch Plate Assembly
22 - 1 - Latch Pivot Pin
23 - 1 - Spring
24 - 1 - Plunger
25 - 1 Seal
26 - 1 - Valve Body
27 - 1 Valve Spring
28 - 1 - Handle Sleeve
29 - 1 - Washer
30 1 O-Ring
31 830728 1 - Swivel, Control Handle
32 - 2 M4x6 C/Sunk Screws
34 - 1 - Lever Latching
35 - 1 - Button Spring
36 - 1 - Lever Plug
37 - 1 Mesh
38 - 1 O-Ring
39 - 1 - O-Ring*
** Prior to 7/03 (stamped on handle 0283)
use metal washer.
After 7/03 (stamped on handle 0293)
use plastic washer.
Outlet
Extensions
Model
Number Nozzle / Tip
Extensions
Before 5/03
3/8” NPT
After 5/03
3/8” NPS
Rigid 3330-054 3332-086 829648
831471 plus
sealing nut
831470
Flex 3330-055 3332-086 829973 831469*
Flex 900 3330-057 3332-086 830276 831429*
Straight 3330-059 3332-086
81334 plus
jam nut
831333
831472 plus
sealing nut
831470
* 806895 (-112) o-ring included with extension.

7
PGE-55 Electronic Control Handle Parts Diagram
!
PGE-55 Parts List
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(Item 37)

Balcrank Corporation
Weaverville, NC 28787
800-747-5300
800-763-0840 Fax
www.balcrank.com
Distributed by:
SERVICE BULLETIN SB 3026
Rev. D 11/09
831152
Balcrank Lubrication Equipment Warranty Statement
All Balcrank equipment sold by authorized Balcrank distributors is warranted to their original customer to be free from defects in materials and workmanship
for a period of one year from the date of sale to that customer. Selected Balcrank equipment carries warranty terms for a more extended period as dened in
the Balcrank Lubrication Equipment & Accessories User Price List, wherein a “lifetime” warranty represents a warranty period of thirty years. Within the initial
one-year warranty period, Balcrank will repair or replace all Balcrank equipment determined by Balcrank to have defective materials or workmanship. For
equipment carrying more extended warranties, Balcrank will repair or replace the product including parts and labor during the rst full year and will provide
parts only for the remainder of the warranty period.
This warranty applies only to equipment installed and operated according to applicable Balcrank Service Bulletins and Installation Instructions.
Any equipment claimed to be defective must be returned, freight prepaid, to an Authorized Balcrank Service Center (ASC). Upon receiving candidate warranty
equipment from a customer, ASC will: 1) diagnose to determine the warrantable condition of the equipment, 2) submit, prior to repair or replacement, a
request to Balcrank for warranty authorization, then 3) in cooperation with Balcrank, proceed with repair locally or forward the equipment to Balcrank and
obtain replacement. If the part(s) or equipment items are found defective upon inspection by Balcrank, they will be repaired or replaced, and then will be
returned to the ASC. If Balcrank nds the claimed part(s) or equipment not to be defective, the ASC will receive written authorization from the original
customer, and then repair them for a reasonable charge to the customer, which will include all applicable parts, labor, and return transportation costs.
Optionally, the customer may submit certain eligible products directly to Balcrank for warranty return by using Balcrank Lubrication Equipment Direct Service
Warranty Procedure. Eligible products are dened in the Balcrank Lubrication Equipment & Accessories User Price List. Refer to the Balcrank web site www.
balcrank.com for a copy.
Any equipment returned to Balcrank must have the Warranty Service Claim number (WSC#) clearly marked on the outside of the carton. Balcrank’s sole
responsibility is for defects in material and workmanship, and Buyer’s sole and exclusive remedy hereunder, shall be limited to repair or replacement of the
defective part or equipment.
This warranty does not cover, nor shall Balcrank be liable for repair or replacement of parts or equipment resulting from general wear and tear through use,
or damage or failure caused by improper installation, abuse, misapplication, abrasion, corrosion, insufcient or improper maintenance, negligence, accident,
alteration, or substitution of non-Balcrank parts.
Furthermore, the Warranty for Lubrication Equipment and Accessories does not cover the following specic conditions:
• Failure or damage to equipment caused by dirt or debris in compressed air lines and uid lines. This includes, but is not limited to, clogged inlet lters,
strainers, or regulators; uid meters; control handles; uid tips; and valves.
• Failure of normal wear parts including but not limited to: o-rings, packings, seals and valves unless originally improperly installed by the
factory.
• Products placed in applications for which their use was not intended. Examples include but are not limited to Lubricant pump being used
to pump solvents, or placing equipment intended strictly for indoor use outdoors
• Damage to equipment resulting from operation above and beyond Balcrank’s recommendations.
• Leaks at air and uid ttings and connections.
• Damage caused by thermal expansion whenever adequate pressure relief was not included in the system.
• Loose suction tubes on pumps.
• Incorrect hose reel spring tension, requiring adjustment.
THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. IN NO EVENT SHALL BALCRANK BE LIABLE FOR ANY SPECIAL, CONSEQUENTIAL, OR OTHER DAMAGES OF SIMILAR
NATURE, INCLUDING BUT NOT LIMITED TO LOST PROFITS, LOST PRODUCTION, PROPERTY DAMAGE, PERSONAL INJURY, WHETHER SUFFERED
BY BUYER OR ANY THIRD PARTY, IRRESPECTIVE OF WHETHER CLAIMS OR ACTIONS, LEGAL OR EQUITABLE, FOR SUCH DAMAGES ARE BASED
UPON CONTRACTS, WARRANTY, NEGLIGENCE, STRICT LIABILITY, OR OTHERWISE. ANY CLAIM OR ACTION FOR BREACH OF WARRANTY MUST
BE BROUGHT WITHIN TWO (2) YEARS FROM THE DATE OF SALE TO THE ORIGINAL CUSTOMER.
Revision Log:
Rev. A - Added item 39 and 831335 kit
Rev. B - Changed from 3/8” NPT to 3/8” NPS on outlet port.
Rev. C - Added note on washer (item 20).
Rev. D - Removed semi-automatic tip models and changed part
number for automatic tip to 3332-086.