Balcrank Premium EV Series Instruction Manual

SERVICE BULLETIN SB2004
Rev. E 9/03
Thoroughly read and understand this manual before
installing, operating or servicing this equipment.
OPERATION, INSTALLATION,
MAINTENANCE AND REPAIR GUIDE
Models:
See pages 1 and 3 for Hose Reel
Model Numbers and Technical Data.
PREMIUM™ REELS
EV SERIES
EXTRA VOLUME TRANSFER
®

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
uids that have a ash point
below 100°F (38°C). Examples:
gasoline, alcohol. Sparking could
result in an explosion which could result in
death.

2310-003 50’ x1/2” 3000 psi 8241-050 8241-002 2310-002
2310-004 60’ x 1/2” 3000 psi 8241-060 8241-002 2310-002
2310-005 70’ x 1/2” 3000 psi 8241-070 8241-002 2310-002
2310-006 40’ x 3/4” 2250 psi 8263-040 8266-002 2310-001
2310-007 50’ x 3/4” 2250 psi 8263-050 8266-002 2310-001
2310-008 60” x3/4” 2250 psi 8263-060 8266-002 2310-001
2310-009 40’ x 1” 250 psi 8181-040 8181-002 2310-001
2310-010 50’ x 1” 250 psi 8181-050 8181-002 2310-001
Table of Contents
General Safety Information ........................... 2 Installation .................................................. 5-8
Model Numbers ............................................. 3 Maintenance............................................. 9-12
Product Descriptions ..................................... 4 Troubleshooting Guide .................................12
Technical Data............................................... 4 Parts Listings.......................................... 13-14
Dimensions and Mounting Diagram .............. 4 Notes ............................................................15
Warranty .......................................................16
Model Numbers
Type of Model Hose Maximum Outlet Inlet Bare
Service No. Size Working Hose Hose(1) Reel
Pressure
Low/Medium
Pressure
Air, Water,
Oil, ATF, &
Antifreeze
2310-002 70’ 1/2” 3000 psi 1/2” 1/2” 19” 14” 24.5”
2310-001 60’ 1” 3000 psi 1” 1” 19” 14” 24.5”
Model Hose Capacity Bare Reel Thread Size Reel Dimensions
No. Lgth. Dia W.P. (psi) Inlet Outlet L. W. H.
Bare Reels

Fittings:
Item Qty Description
1 2 Male Connector 3/8 tubing x 3/8 npt
2 1 Pipe Nipple 3/8 npt x 6” long
3 2 Bushing 3/4 npt x 3/8 npt
4 2 Male Branch Tee 3/8 tubing x 1/4 npt
5 1 Union 3/8 tubing x 3/8 tubing
6 1 Male Elbow 3/8 tubing x 1/4 npt
7 4 90 Deg. Female Elbow 5/8 tubing x 1/2 npt
8 2 Union 5/8 tubing x 5/8 tubing
9 - 3/8 OD x .083 wall, soft copper tubing
10 - 5/8 OD x .083 wall, dead soft
Note: Due to random length of tubing additional
unions (8) may be required.
7A * Female Connector 5/8 tubing x 1/2 npt, two
required, replacing 2 units (7) for alternate
piping at pumps.

Note:
A pressure relief kit is recommended on
all Balcrank supply systems. The lack
of installing this kit will void all product
warranties if system fails because of
thermal expansion.

1/2” I.D X 40 FT.
1/2” I.D X 50 FT.
1/2” I.D X 60 FT.
3/4” I.D X 40 FT.
3/4” I.D X 50 FT.
3/4” I.D X 60 FT.
1” I.D X 40 FT.
1” I.D X 50 FT.

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
!

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
!

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
!

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 10)
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 39)
Swivel leaking Worn o-rings or block. Replace swivel (item 35).
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.(see page 8)

35

831488
Parts Listing for Premium Series (BARE) Reels
Item Part # Description Qty
2310-002
2310-001
Item Part # Description Qty
2310-002
2310-001
Parts Listing for Premium Series (BARE) Reels
Hose Clips
Swivel Repair Kits

NOTES
Quality Checklist
Bill of Material checked for current content.
I ________________________________________ certify that this
product
meets or exceeds Balcrank's high quality
standards.
Revision Log:
Rev. D - Changed swivel to 831488.
Rev. E - Added Troubleshooting Table.

Balcrank® Products, Inc.
115 Reems Creek Road
Weaverville, NC 28787
800-747-5300
800-763-0840 Fax
www.balcrank.com
Distributed by:
SERVICE BULLETIN SB2004
Rev. E 9/03
822027
WARRANTY
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 the equipment was sold to the
original customer. Select equipment carries extended warranty terms as individually noted within the Balcrank®
Lubrication Equipment & Accessories User Price List. Any Balcrank® equipment carrying an extended warranty will
be warranted for the period indicated; those items carrying a “lifetime” warranty are warranted for a period of thirty
years. All Balcrank® equipment determined by Balcrank® to have defective materials or workmanship within the
one year warranty period will be repaired or replaced. For equipment carrying extended warranties Balcrank®will
repair or replace the product including parts and labor for the rst full year and will provide parts only for the
remaining period of the specied warranty.
This warranty only covers 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. If the part(s) or equipment is found to be defective, it will be repaired or replaced, and
returned freight prepaid from the Authorized Service Center. If the claimed part(s) or equipment is found not to
be defective, the Authorized Balcrank® Service Center will, upon written authorization being received from the
original customer, repair them for a reasonable charge to the customer which will include all applicable parts,
labor, and return transportation costs. 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 component parts. Furthermore the Balcrank® Warranty for Lubrication Equipment and
Accessories does not cover the following specic conditions:
n Failure or damage to equipment that is caused by dirt or debris in air and uid lines. This includes, but is not
limited to clogged inlet lters, strainers, or regulators; uid meters; control handles; uid tips; and valves.
n Failure of normal wear parts including but not limited to: “o”-rings, packings, seals and valves unless originally
improperly installed by the factory.
n Products placed in applications for which their use was not intended. Examples include but are not limited to: A
lubricant pump being used to pump solvents, or placing a piece of equipment intended strictly for indoor use in
an outdoor application.
n Damage to equipment resulting from operation above and beyond Balcrank’s recommendations.
n Leaks at air and uid ttings and connections.
n Damage caused by thermal expansion when adequate pressure relief was not included in the system.
n Loose suction tubes on pumps.
n Reel spring tension adjustment.
THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MER-
CHANTABILITY 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.