Balcrank PREMIUM 2110 Series Instruction Manual

SERVICE BULLETIN SB2001
REV. K 7/11
Thoroughly read and understand this manual before
installing, operating or servicing this equipment.
Models: 2110-XXX
See page 3 for Hose Reel Model
Numbers and Technical Data
OPERATION, INSTALLATION,
MAINTENANCE AND REPAIR GUIDE
PREMIUM SERIES
TM
HOSE REELS
Multi-Purpose Dispense
®

2
Product Description
The Heavy Duty Premium SeriesTM hose reel is
designed for service where larger volumes of
deliveries are required. The swivel is balanced with
equalized pressure on both internal sides of the
seals to eliminate undue unbalanced friction. The
roller outlet is quickly adjusted to any of the three
mounting positions (i.e. wall, ceiling, or table).
General Safety
Thoroughly read and understand this
manual before installing, operating or
servicing this equipment.
Because this Hose Reel can be
incorporated into a pressurized
systems, the following safety
precautions should be observed.
Check equipment regularly and repair or
replace worn and damaged parts.
Never alter or modify any parts of this hose
reel, doing so may cause damage to hose reel
and/or personal injury.
Under no circumstances should the dispensing
valve be aimed at any person at any time.
Personal injury may result.
Release pressures built up in the system
before any service or repair is begun. See the
pressure relief procedure below.
Do not operate bare air/water or lube reels
above 3000 psi (206.9 bar). Do not operate
bare grease reel above 5000 psi (620.6 bar).
NOTE: If reel is equipped with hose, reel
maximum pressure will be determined by the
lowest working pressure rating of the hose,
bare reel, or dispense valve.
Always read and follow the uid manufacturer’s
recommendations regarding the use of
protective eyewear, clothing and respirators.
IMPORTANT
!
Pressure Relief Procedure:
Follow this procedure before maintaining
and/or repairing your Premium Hose Reel
and/or any part of system.
1) Disconnect the air to the pump.
2) Point dispensing valve away from
yourself and others.
3) Open dispensing valve until
pressure is relieved.
WARNING
!
The spring is ALWAYS under great tension and
could be propelled from the case with enough
force to cause serious bodily injury.
CAUTION
USE EXTREME CARE WHEN
HANDLING THE POWER SPRING!
!
Be sure the mounting surface
is strong enough to support
the reels, the weight of the
uids and the stress caused
by hard pulls on the service hoses. See
page 3 for dry weights of the hose reel
assemblies.
WARNING
!
WARNING
!
The MAXIMUM WORKING
PRESSURE of a hose reel is
determined by the lowest rated component
in the assembly. The hose reel Technical
Data chart on page 3 give the maximum
working pressure of bare reels and reels
assembled at the factory with hose. The
maximum working pressure of a hose reel
is indicated on the hose reel identication
plate located near the base of the reel.
If adding a service hose and dispensing
valve to a bare reel, BE SURE you know
the maximum working pressure of ALL
components!
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.
CAUTION
!
Be aware of possible uid thermal expansion! A
pressure relief valve should be properly installed in
any system where this product is used. Should this
product fail as a result of thermal expansion and
no pressure relief valve was installed, the product
warranty will be voided.

3
2110-021 60’ 3/8” 8000 psi 1/4” (F) 1/4” (F) 19” 7.5” 23”
2110-022 60’ 1/2” 3000 psi 1/2” (F) 1/2” (F) 19” 7.5” 23”
2110-023 60’ 1/2” 3000 psi 1/2” (F) 1/2” (F) 19” 7.5” 23”
2110-024 40’ 1/2” 3000 psi 1/2” (F) 1/2” (F) 19” 7.5” 23”
2110-025 40’ 3/8” 8000 psi 1/4” (F) 1/4” (F) 19” 7.5” 23”
2110-026 60’ 1/2” 3000 psi 1/2” (F) 1/2” (F) 19” 7.5” 23”
Type of Model Hose Maximum Outlet Inlet Bare
Service No. Size Working Hose Hose(1) Reel
Pressure
2110-013 30’ x 3/8” 250 psi 8136-030 8141-002 2110-024
2110-014 40’ x 3/8” 250 psi 8136-040 8141-002 2110-024
2110-015 50’ x 3/8” 250 psi 8136-050 8141-002 2110-023
2110-016 60’ x 3/8” 250 psi 8136-060 8141-002 2110-023
2110-017 30’ x 1/2” 250 psi 8141-030 8141-002 2110-024
2110-018 40’ x 1/2” 250 psi 8141-040 8141-002 2110-024
2110-019 50’ x 1/2” 250 psi 8141-050 8141-002 2110-023
2110-020 60’ x 1/2” 250 psi 8141-060 8141-002 2110-023
2110-009 30’ x 1/2” 3000 psi 8241-030 8249-002 2110-024
2110-010 40’ x 1/2” 3000 psi 8241-040 8249-002 2110-024
2110-011 50’ x 1/2” 3000 psi 8241-050 8249-002 2110-022
2110-012 60’ x 1/2” 3000 psi 8241-060 8249-002 2110-022
2110-001 30’ x 1/4” 5000 psi 8321-030 8332-002 2110-025
2110-002 40’ x 1/4” 5000 psi 8321-040 8332-002 2110-025
2110-003 50’ x 1/4” 5000 psi 8321-050 8332-002 2110-021
2110-004 60’ x 1/4” 5000 psi 8321-060 8332-002 2110-021
2110-005 30’ x 3/8” 4000 psi 8331-030 8332-002 2110-025
2110-006 40’ x 3/8” 4000 psi 8331-040 8332-002 2110-025
2110-007 50” x 3/8” 4000 psi 8331-050 8332-002 2110-021
2110-008 60’ x 3/8” 4000 psi 8331-060 8332-002 2110-021
Model Numbers
Technical Data
Maximum Fluid Working Pressure:
Low Pressure Reels (bare)................................. 3000 psi
Medium Pressure Reels (bare)........................... 3000 psi
High Pressure Reels (bare)................................ 8000 psi
Wetted Parts:
General Lube................... Steel (plated), Buna-N, Bronze
Brake Fluid (Model 2110-026) ....................Steel (plated),
........................................................ EPDM Seals, Bronze
Hose Working Pressure Ratings:
Air/Water Hose ......................................... 5/16” – 300 psi
3/8” – 300 psi
½” – 250 psi
Med. Pressure .......................................... 3/8” – 3000 psi
½” – 3000 psi
High Pressure............................................. ¼” – 5000 psi
3/8” – 4000 psi
Shipping Weight Bare Reels:
Std. Frame (35 ft hose or less).............................. 63 lbs.
Lrg. Frame (40 ft & above) .................................... 74 lbs.
Low Pressure
Air, Water
New Model Hose Capacity Bare Reel Thread Size Reel Dimensions
Lgth. Dia W.P. (psi) Inlet Outlet L. W. H.
Med. Pressure
Oil, ATF
High Pressure
Grease
Bare Reels
NOTE (1): Inlet hoses are included with Premium Series Open
()
Outlet Fitting
1/4” nptm
(
)
Outlet Fitting
1/2” nptm
Outlet Fitting
1/4” nptm
(
)
Dimensions
23”
19”
11”
9-3/4”
7-1/2”
1-5/8”
18-7/8”
Rim Dia.
Holes for
Four 3/8”
bolts

4
1. Locate or measure the length and size of your
hose in the charts below. Note how many times
you must turn the spool of the reel to properly
adjust spring tension.
Installing a Service Hose on a Bare
Reel:
2. Place a piece of tape on the side of the spool
to help when counting the number of turns
made.
3. Wearing heavy leather gloves, rmly grab the
outside edge of the spool with both hands. Wind
the reel to the proper number of turns, rotating
it in a clockwise direction, stopping only at the
latching locations, stop the reel where the hose
swivel is accessible and where the stop pawl
is securely latched.
1/4” I.D. x 30 ft. 11
1/4” I.D. x 40 ft. 13
1/4” I.D. x 50 ft. 15
1/4” I.D. x 60 ft. 17
3/8” I.D. x 30 ft. 12
3/8” I.D. x 40 ft. 14
3/8” I.D. x 50 ft. 16
3/8” I.D. x 60 ft. 18
High Pressure No. of
Hose Description Turns
Low/Med. Pressure No. of
Hose Description Turns
5/16” I.D. x 30 ft. 11
5/16” I.D. x 40 ft. 13
5/16” I.D. x 50 ft. 15
3/8” I.D. x 30 ft. 12
3/8” I.D. x 40 ft. 14
3/8” I.D. x 50 ft. 16
3/8” I.D. x 60 ft. 18
1/2” I.D. x 30 ft. 12
1/2” I.D. x 40 ft. 15
1/2” I.D. x 50 ft. 17
1/2” I.D. x 60 ft. 19
Installation
Tank/Wall Mounting:
The hose reel has been shipped for a ceiling mount
application unless specied differently. The outlet
arm will need to be adjusted for tank/wall mounting.
If a bare reel has been ordered see installation of
hose instructions and power spring adjustment on
following pages.
1. Select the mounting location. Be sure the
mounting structure is secure and will not tip
when reel is in operation.
2. Locate the mounting holes for drilling.
3. Adjust the outlet arm position. Before removing
the roller outlet assembly and the top tie bracket,
the power spring tension should be released
and the uprights should be secured to prevent
accidental separation. Once the outlet arm is
positioned correctly retighten bolts 80 to 90
inch pounds. (Refer to illustrations on page 5
for further details on changing the outlet arm
position).
4. Fasten the base using bolts of a sufficient
strength to prevent the reel from “shearing bolts”
during operation when hose is pulled.
5. Connect supply line to the inlet of hose reel.
(Low & Med. Pressure… inlet ½” NPTF & High
Pressure … inlet ¼” NPTF).
6. Install the hose stop and dispensing valve.
Position the hose stop so the hose extends far
enough for all operators to reach it.
Ceiling Mounting:
The power spring tension will need to be adjusted
for the ceiling height of the building. If a bare
reel has been ordered see installation of hose
instructions and power spring adjustment on the
following pages.
1. Select the mounting location. If the ceiling is very
high, suspend a suitable support structure for the
reels, so the hoses will be long enough to reach
service area.
2. Locate the mounting holes for drilling, using
measurements on previous page. If mounting
directly to I-Beam use mounting kit 2230-013 (no
drilling required).
3. Fasten the base using bolts of a sufficient
strength to prevent the reel from “shearing bolts”
during operation when hose is pulled.
4. Connect supply line to the inlet of hose reel.
(Low & Med. Pressure… inlet ½” NPTF & High
Pressure … inlet ¼” NPTF).
5. Install the hose stop and dispensing valve.
Position the hose stop so the hose extends far
enough for all operators to reach it.
Be sure the mounting surface
is strong enough to support the reels, the
weight of the uids and the stress caused by
hard pulls on the service hoses. See page 3
for dry weights of the hose reel assemblies.
WARNING
!
WARNING
!
The MAXIMUM WORKING
PRESSURE of a hose reel is
determined by the lowest rated component in
the assembly. The maximum working pressure
of a hose reel is indicated on the hose reel
identication plate located near the base of
the reel.
If adding a service hose and dispensing valve to
a bare reel, BE SURE you know the maximum
working pressure of ALL components!
Do not hard pipe inlet/swivel to any existing
structure/system. Flexible connection hose must
be used to maintain swivel performance.
!
NOTE

5
4. Before installing the hose, secure spool from
accidental rotation by placing a clamp on the
spool. See figure 1 for proper placement of
clamp. This will keep the spool from rotating
while installing the hose.
5. Uncoil the hose and attach bumper stop.
Attach the hose to the reel then remove clamp
carefully.
6. Firmly grasp the hose and pull it to release the
stop pawl. Then slowly retract the hose.
NOTE: Check the power spring tension. The
hose must pull out fully and retract fully. To adjust,
add or remove ONE loop from the spool, extend
the hose, and latch it. Do this as many times as
necessary until the power spring has the desired
tension.
7. Position the bumper stop so the hose extends
far enough for all operators to reach it.
WARNING: Wear Heavy Leather
Gloves when replacing service hose and/or
replacing power spring to protect your hands from
injury.
!
WARNING: Never allow the reel to
spin freely. Doing so will cause the hose to
spin out of control, which could cause serious
bodily injury.
CAUTION: Do Not put so many loops
onto the reel that the power spring winds tightly
before the hose is fully extended. A power spring
that has been wound too tight stops rotating
before the hose is fully extended. This condition
will wear the hose and power spring prematurely.
To decrease tension, remove one to two loops of
hose from the reel.
Figure 1
Clamping
Spool
Place
C-Clamp Here
x
Installation
Increasing Power Spring Tension:
1. Pull the hose out fully and engage the stop
pawl.
2. Be sure the system pressure has been relieved.
Follow the pressure relieve procedures
below.
3. Remove the bumper stop and dispensing
valves.
4. Pull the hose back through the roller outlet and
wrap one loop of hose around the spool.
5. Pull the hose back through the roller outlet
assembly and check the spring tension; the hose
must pull out fully and retract fully. Continue to
wrap more loops, one at a time until the power
spring has the desired tension.
CAUTION: Before removal of the
roller outlet assembly and the top tie bracket,
the power spring tension should be removed
and the uprights should be secured against
accidental separation.
!
Adjusting the Outlet Arm Position:
Ceiling/Wall Mounting Position:
The hose reel is shipped ready to use. No assembly
is required for basic operation. (See gure 2)
Figure 2
Ceiling/Wall Outlet
Arm Position
Pressure Relief Procedure:
Follow this procedure before maintaining
and/or repairing your Premium Hose Reel
and/or any part of system.
1) Disconnect the air to the pump.
2) Point dispensing valve away from
yourself and others.
3) Open dispensing valve until
pressure is relieved.
WARNING
!
!
!

6
Maintenance
Replacing Service Hose:
1. Be sure the pressure supply has been relieved
when replacing the service hose. Follow the
pressure relieve procedures below.
2. Fully extend the service hose. Stop the reel
where the hose swivel union is accessible and
where the stop pawl is securely latched.
3. Secure spool from accidental rotation by placing
a C-Clamp onto the spool. See figure 4 for
proper placement of C-Clamp. This will keep
the spool from rotating while installing the new
service hose.
4. Disconnect and remove service hose.
5. Uncoil the new hose and assemble the bumper
stop, attach the new hose to the reel, and
remove the C-Clamp carefully.
6. Firmly grasp the hose and pull it to release the
stop pawl. Then slowly retract the hose.
WARNING: Never allow the reel
to spin freely. Doing so will cause the
hose to spin out of control, which could
cause serious injury.
NOTE: Check the power spring tension. The
hose must pull out and retract fully. Wrap ONE
more loop onto or off the spool, extend the
hose, and latch it. Do this as many times as
necessary until power spring has the desired
tension.
Replacing the Swivel:
1. Be sure the pressure supply has been relieved,
when replacing the swivel. Follow the pressure
relieve procedures below.
2. Disconnect the inlet hose.
3. Remove the old swivel assembly and replace
it with the new assembly. NOTE: The new
assembly may look different from the old
assembly. The important item to be sure of
is thread size and pressure style (ex: L.P.,
M.P. or H.P.) used on your reel. (Refer to part
listing on page 11, for proper swivel repair or
replacement kit.)
NOTE: A spring wound too tightly stops rotating
before the hose is fully extended. This condition
will place excessive strain on the hose and
power spring that could damage and/or shorten
the life of the reel.
Figure 4
Clamping
Spool
Place
C-Clamp Here
x
Tank/Mobile Mounting Position:
1. Pull the hose out fully and engage the stop pawl.
Place C-Clamp on spool to prevent possible
bodily injury. (See gure 3)
2. Remove screws (11) from roller outlet assembly
and remove screw (11 & 12) which hold the
top tie bracket and outlet arm assembly to the
uprights. Reverse the position of the roller outlet
assembly as shown in figure 3 and replace
screws. (See gure 3)
Figure 3
Tank/Mobile Outlet
Arm Position
Place C- Clamp
Here
Outlet Arm
Assembly
Outlet Roller
Assembly
(12)
(11)
(11)
X
Pressure Relief Procedure:
Follow this procedure before maintaining
and/or repairing your Premium Hose Reel
and/or any part of system.
1) Disconnect the air to the pump.
2) Point dispensing valve away from
yourself and others.
3) Open dispensing valve until
pressure is relieved.
WARNING
!
!

7
Maintenance
Replacing Power Spring:
1. Be sure the pressure supply has been
relieved when. Follow the pressure relieve
procedures below.
7. Be sure case is laying flat on the work
surface, now remove bolts (24). Then using
extreme caution, remove both safety cotter
pins from sides of case and lift up on the
spring case cover (23) to expose the power
spring.
8. Carefully Inspect the Power Spring. If either
end of the power spring is worn or damaged
and will not engage the center plates (26)
properly, replace the power spring.
2. Disconnect inlet hose. Remove the reel to
work bench and clamp reel base securely.
3. Remove hose stop and control dispensing
valve, retract the hose and remove
necessary wraps until all power spring
tension has been removed.
4. Remove screws (11, 12 & 16) from base
(40), hub (29) and top tie bar (19).
5. Unclamp the reel from the workbench and
lay it on a at work surface so the spring
case (21) is facing up.
6. Twist the complete spring case assembly
to the left or right and once the upright (15)
is clear of the base (40) and the top tie bar
(19) lift to remove the assembly.
NOTE: Be sure that both bolts (24) and
safety cotter pins (20) are still in place on
each side of the case before lifting. (See
gure 7 for placement of cotter pins)
9. Apply a light coat of grease inside the spring
case and cover.
10. Install the new power spring, making sure
that it is laid into the spring case counter-
clockwise and that the outside end loop
is around spring case bolt (24) and spacer
(55).
11. Replace spring case cover (23) and insert
cotter pins (30) through sides of spring
case and cover. Tighten case and cover
to upright (15).
WARNING: If the power spring has
become uncoiled inside the spring case, the
“keeper” has failed. It is strongly advised
that you replace the complete spring case
assembly. The “keeper” is a metal band that
is placed around the power spring to keep it
from uncoiling when removed from the case.
If you attempt to remove the power spring
when this condition has occurred the spring
will uncoil quickly and can cause serious
bodily injury. (See gure 5)
Pressure Relief Procedure:
Follow this procedure before maintaining
and/or repairing your Premium Hose Reel
and/or any part of system.
1) Disconnect the air to the pump.
2) Point dispensing valve away from
yourself and others.
3) Open dispensing valve until
pressure is relieved.
WARNING
!
The spring is ALWAYS under great tension and
could be propelled from the case with enough
force to cause serious bodily injury. To reduce
the risk of serious bodily injury, use extreme
caution when removing the top cover (23).
Be sure the spring case if lying at, and then
carefully lift up the cover to expose the power
spring.
CAUTION
USE EXTREME CARE WHEN
HANDLING THE POWER SPRING!
!
!

8
12. Twist the complete spring case assembly to
the left or right, making sure that the power
spring is centered and has engaged the
spring center plates (26).
13. Align upright assembly (15) with base (40)
and tip tie bar (19). Place bolts (11 & 12)
back through the base and top tie bar and
tighten to 100 - 110 inch pounds. Inspect
complete reel for proper function and adjust
power spring as needed by adding one to
two loops of hose at a time to increase
power spring tension.
Replacing Power Spring continued
Figure 5
Keeper & Safety Clamps
Figure 6
Power Spring Removal
Using Locking Pliers
Figure 7
Power Spring & Case Pictorial
Hose Clamps
Keeper
(Safety Ring)
Power Spring
Spring Case
Power Spring
Vise Grip
Pliers
55

9
Maintenance
Stop Pawl Replacement:
1. Allow the hose to retract as far as the hose
stop to remove tension from the power
spring and to be sure that the stop pawl is
not engaged with the ratchet.
2. With the stop pawl assembly free to be
moved by hand, remove the cotter pin (38),
spring (37) and snap ring (39). Once this
has been done the complete assembly can
be removed.
3. Item (36) bronze bearing will need to be
knocked out of the upright (41), using a
punch and hammer.
4. With the stop pawl kit in hand replace the
bronze bearing by pressing the new bearing
into the upright (41).
5. Apply a light coat of grease to the stop pawl
stud (35), reassemble by placing the stop
pawl stud (35) back through the bronze
bearing (36) and insert the snap ring (39)
into the groove on the shaft of the stop
pawl stud (35).
6. Replace the spring (37) and cotter pin (38)
with the new ones provided in the kit.
7. Check the stop pawl assembly by hand for
free movement. The stop pawl assembly
should not stick or drag and it should return
to its central position each time it is moved
off center.
CAUTION: Never alter or modify
any parts of this reel. Doing so may cause
damage to reel and/or personal injury.
Always use genuine Balcrank replacement
parts.
NOTE: Number with “*” is a component of the
stop pawl repair kit # 811128.
!
Figure 8
Stop Pawl Replacement
NOTE: If the assembly does not appear to
be returning back to its neutral position, the
spring tension may need to increased. You
can increase the spring tension by bending
the cotter pin closer to the stop pawl shaft
which will stretch the spring slightly.
Trouble Probable Cause Remedy
No spring tension Power spring broken (item 22) Replace power spring (see page 7)
Low or high tension Lost wraps or too many wraps of
on hose hose on reel
Hose will not retract Stop pawl lock-up CAUTION: Wearing heavy leather
gloves, rmly grab the outside edge
of the spool with both hands. Release
the tension on the stop pawl by hand
for one or two revolutions.
Stop pawl will not engage Spring broken or unhooked Replace or repair (item 37)
Swivel leaking Worn o-rings, block, or packing. Replace swivel (item 42 or 43).
Troubleshooting Guide
Add or take off wraps of hose
by pulling hose on reel down
just enough to allow stop pawl to
engage ratchet. Now wraps can be
added or taken off as needed.

10
Figure 9
Parts Pictorial
1
55