Balcrank Signature DEF Series Instruction Manual

®
SIGNATURE™DEF REELS
OPERATION, INSTALLATION,
MAINTENANCE AND REPAIR GUIDE
Thoroughly read and understand this manual before
installing, operating or servicing this equipment.
SERVICE BULLETIN SB2023
Rev C 7/11
Models: 2400-006 Bare Reel
2400-007 16’ Reel
2400-008 20’ Reel
2400-009 30’ Reel

2
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.
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
!
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 gives 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.
Pressure Relief Procedure:
To reduce the risk of serious bodily injury,
including uid injection or splashing into the eyes
and/or onto the skin, follow this procedure below
before maintaining and/or repairing the pump,
solenoid and/or impulse meter or any part of your
system.
1. Disconnect the air supply from the pump.
2. Open the dispensing valve into an approved
waste container to relieve pressure on the
system.
3. Leave any bleed-type drain valves open until
you are ready to use the system again.

TABLE OF CONTENTS
Cover...................................................................... 1
General Safety Information..................................... 2
Technical Data & Notes .......................................... 3
Mounting Dimensional Data ................................... 4
Installation ........................................................4 & 5
TECHNICAL DATA
Maintenance........................................................ 6-9
Parts Listing...........................................................11
Warranty ............................................................... 12
Model No. Hose
Size
Maximum
Working
Pressure
Outlet
Hose
Inlet
Hose Bare Reel Wetted Parts
2400-007 16’ X 3/4” 150 psi 8569-016 8562-003 2400-006 Stainless Steel, Viton
2400-008 20’ X 3/4” 150 psi 8569-020 8562-003 2400-006 Stainless Steel, Viton
2400-009 30’ X 3/4” 150 psi 8569-030 8562-003 2400-006 Stainless Steel, Viton
Bare Reel (1) Model Bare Reel
W.P. (psi)
Thread Size Reel Dimensions Shipping
Weight
Inlet Outlet L. W. H.
2400-006 150 PSI 3/4” BSPP 3/4” BSPP 16” 8” 17.5” 46 lbs.
(1) DEF Reels come in blue powder coat only.
3
Notes

INSTALLATION
Tank/Wall Mounting:
The hose reel is shipped ready to use; the power
spring tension has been adjusted for table/wall
mounting unless ordered without hose. If a bare reel
has been ordered see installation of hose instructions
and power spring adjustment on following steps.
1. Select the mounting location. Be sure the
mounting structure is secure and will not tip
when reel is in operation. Tables should be
bolted to oor and wall should be part of building
structure.
2. Locate the mounting holes for drilling, using
measurements on previous page.
3. Adjust the outlet arm position as required by
loosening and removing the four 10-32 locknuts
(43). Once arm is positioned correctly retighten
to 80 to 90 inch pounds.
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.
6. If you are installing a hose onto a Bare Reel,
connect the service hose to the swivel union (2).
Then wrap the hose loosely around the spool.
Extend the hose fully and engage the stop pawl.
Wrap one to two loops around the spool, then
retract the hose again.
NOTE: Check the power spring tension; the hose
must pull out fully and retract fully. Wrap ONE
more loop onto spool, extend the hose, and latch
it. Do this as many times as necessary until the
power spring has the desired tension.
7. Install the hose stop and dispensing valve.
Position the hose stop so the hose extends far
enough for all operators to reach it. CAUTION:
Always Fully Extend hose before pressurizing or
damage may occur to side panels.
PRODUCT DESCRIPTION
The Signature™Series Diesel hose reel is designed to
provide efcient delivery of diesel fuel through various
hose lengths, at an economical price. The inlet (shaft)
and outlet (swivel) are threaded. The roller outlet arm
can be adjusted to any one of ve positions, which
allows oor, table, wall or ceiling mounting (when
mounting directly to I-beam, clamping kit no. 2230-
017 is available for ease of assembly.)
8”
1-5/8”
3/4” BSPP
16” Rim dia
11” Holes for (4)
3/8” bolts
17-1/2”
9-3/4”
15-1/2”
Figure 1
Figure 2
DIMENSIONS &
MOUNTING DIAGRAM
(Mounting Footprint located on page 10)
Do not hard pipe inlet/swivel to any existing
structure/system. Flexible connection hose must
be used to maintain swivel performance.
!
NOTE
4
!
CAUTION: 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.

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 steps.
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 H-Beam use mounting kit 2230-017
(no drilling required).
3. Adjust the outlet arm position as required by
loosening and removing the four 10-32 locknuts
(43). Once arm is positioned correctly retighten
to 80 to 90 inch pounds.
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.
6. Hose reels shipped with hoses come from the
factory with the tension preset for a typical
table/wall installation. For a ceiling installation
you will need to adjust for more or less tension,
by removing or adding one to two wraps of hose
from spool.
7. If your are installing a hose onto a Bare Reel,
connect the service hose to the swivel union
(2). Then wrap the hose loosely around the
spool. Extend the hose fully and engage the stop
pawl.
8. Wrap one to two loops around the spool, then
retract the hose again.
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.
NOTE: Check the power spring tension; the hose
must pull out fully and retract fully. Wrap ONE more
loop onto spool, extend the hose, and latch it Do this
as many times as necessary until the power spring
has the desired tension.
!
9. Install the hose stop and dispensing valve.
Position the hose stop so the hose extends far
enough for all operators to reach it.
CAUTION: Always Fully Extend hose before
pressurizing or damage may occur to side
panels.
TYPICAL INSTALLATIONS
2230-017
MOUNTING
BRACKET KIT
(FOR I-BEAM MOUNTING)
Ceiling Mounting
Typical Inlet Line
Conguration
ELBOW DROP
TO REEL
SUPPLY
LINE
SHUTOFF
VALVE
3 ft. CONNECTING HOSE
TO REEL INLET
Model 2230-014
Hose Reel Mounting Plate
1. Bolt the hose reel mounting plate onto the
mounting channel.
2. Install rear bolts loosely on the mounting plate.
3. Slide the slotted side of the hose reel base into
position and hold with the integrated swing clamp
which is part of the adapter plate.
4. This leaves both hands free to install and tighten
the nuts and bolts which secure the hose reel in
nal installed position.
Figure 3
Figure 4
Figure 5
5

MAINTENANCE
Replacing Power Spring:
1. Be sure the system pressure has been relieved.
Follow the pressure relief procedures.
2. Disconnect inlet hose. Remove the reel to work
bench and clamp reel base securely.
Wrapping Hose
ROLLER OUTLET
DELIVERY
HOSE
HOSE
LOOP
BUMPER STOP
SIDE PANEL
HOSE LOOP
Figure 7
Pressure Relief Procedure:
To reduce the risk of serious bodily injury,
including uid injection or splashing into the eyes
and/or onto the skin, follow this procedure below
before maintaining and/or repairing the pump,
solenoid and/or impulse meter or any part of your
system.
1. Disconnect the air supply from the pump.
2. Open the dispensing valve into an approved
waste container to relieve pressure on the
system.
3. Leave any bleed-type drain valves open until
you are ready to use the system again.
6
MAINTENANCE
Replacing Service Hose:
1. Be sure the pressure supply has been
relieved. Follow the pressure relieve
procedures below.
2. Pull hose on reel down just enough to allow
stop pawl to engage ratchet. This will lock
reel into position.
3. Remove the dispensing valve and hose
stop.
4. Wearing Heavy Leather Gloves, firmly
grab the outside edge of the spool with both
hands. Let the spool rotate slowly through
your hands until the spool stops. When
the spool stops the spring tension will be
released. The hose can now be unwrapped
and removed from the reel.
5 From open side of reel begin to wrap new
hose around spool in a clockwise direction.
6. Pull hose out through roller outlet and
reassemble hose bumper stop and
dispensing Control Handle.
7. Position the bumper stop so that the hose
will extend enough so that all operators can
reach it.
WARNING: Wear Heavy Leather
Gloves when replacing service hose and/or
replacing power spring to protect your hands
from injury.
!
Installing the Derail Bracket
The derail bracket is included with all Signature
Series DEF hose reels.
1. Loosen the two mounting screws,indicated
in the diagram, to allow Derail Bracket
to be inserted under the Mounting Base
(#824455).
2. Adjust Derail Bracket to allow sufcient
clearance for the Hose Reel to spin freely.
Maximum clearance should be no more
than 1/4”.
3. Retighten mounting screws.
Derail
Bracket
Mounting Screws
Hose
Reel
Mounting Base

Hose Clamps
Keeper
(Safety Ring)
Power Spring
3. Retract the hose and remove necessary
wraps until all power spring tension has been
removed.
4. Remove lock nut (44) from shaft (5).
5. Pull out side panels and shaft assembly from
base collar (27).
6. Remove reel from clap and lay it on a at work
surface so the base plate (25) of the reel is on
the bottom.
7. Remove nuts (13) and then remove spring case
assembly (20 & 23) with both screws (35 & 36)
and spacers (45 & 46) still attached.
8. Be sure case is laying at on the work surface.
Then using extreme caution, remove both safety
cotter pins from sides of case and lift up on the
spring case cover (20) to expose the power
spring.
9. Carefully Inspect the Power Spring; If either end
of the power spring is worn or damaged and
will not engage the ratchet properly replace the
power spring.
If the power spring has become uncoiled inside
the spring case, the “keeper” has failed. (See
Figure 8) 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.
10. Removing the power spring; use locking type
pliers to compress and hold several rows of the
power spring together, then lift out the power
spring slowly and place two hose clamp style
clamps around the power spring and keeper
before disposing of power spring. (See Figure 8
below & Figure 9 on next page)
11. Apply a light coat of grease inside the spring case
and cover. Install new power spring.
12. Install the new power spring, making sure that it
is laid into the spring case Clockwise and that
the outside end loop is around spring case bolt
(35) and spacer (46).
13. Replace spring case cover (20) and insert cotter
pins through sides of spring case (23) and cover.
Tighten case and cover to reel base (25) and
insert side panel and shaft assembly into base
collar (27).
14. Tighten 1-3/8”-20 nut (44) onto shaft, 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.
Figure 8
Keeper & Safety Clamps
!
Pressure Relief Procedure:
To reduce the risk of serious bodily injury,
including uid injection or splashing into the eyes
and/or onto the skin, follow this procedure below
before maintaining and/or repairing the pump,
solenoid and/or impulse meter or any part of your
system.
1. Disconnect the air supply from the pump.
2. Open the dispensing valve into an approved
waste container to relieve pressure on the
system.
3. Leave any bleed-type drain valves open until
you are ready to use the system again.
7
WARNING: USE EXTREME
CAUTION WHEN HANDLING THE POWER
SPRING! 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 (20). Be sure the spring case is
lying at, and then carefully lift up the cover
to expose the power spring.

Figure 10
Spring Case
Power Spring
Vise Grip
Pliers
Figure 9
Power Spring Removal
Using Locking Pliers
13
45
46
8

MAINTENANCE
Stop Pawl Replacement:
1. Be sure the system pressure has been relieved.
Follow the pressure relieve procedures on this
page.
2. Disconnect inlet hose. Remove the reel to work
bench and clamp reel base securely.
3. Retract the hose and remove necessary
wraps until all power spring tension has been
removed.
4. Remove lock nut (44) from shaft (5).
5. Pull out side panels and shaft assembly from
base collar (27).
6. Stop pawl assembly item’s 12, 14, 15, 17, 20,
21 and 32 is now exposed for inspection and
replacement of parts as needed.
Pressure Relief Procedure:
To reduce the risk of serious bodily injury, including
uid injection or splashing into the eyes and/or
onto the skin, follow this procedure below before
maintaining and/or repairing the pump, solenoid
and/or impulse meter or any part of your system.
1. Disconnect the air supply from the pump.
2. Open the dispensing valve into an approved
waste container to relieve pressure on the
system.
3. Leave any bleed-type drain valves open until
you are ready to use the system again.
CAUTION: Before servicing reduce uid
supply pressure to zero.
!
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.
!
Figure 11
7. Once repaired, replace side panels and shaft
assembly into base collar (27).
8. Tighten lock nut (44) onto shaft, 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.
Trouble Probable Cause Remedy
No spring tension Power spring broken (item 22) Replace power spring (see page 6)
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: Following the directions on
page 6 paragraph 4, 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 14)
Swivel leaking Worn o-rings or block Replace o-rings in swivel block
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 illustrated on
page 6 gure 7
TROUBLESHOOTING GUIDE
9

NOTE: High Pressure Swivel parts can be purchased separately, but it is recommended that the complete swivel be replaced if/or when swivel fails.
Figure 12
45
46
88
.44
x6 places
4.94
11.00
R
.22 3.55
7.55
10.30
.88
2.50
4.00
.80
Signature Reel
Mounting Foot Print
SIGNATURE™REELS MOUNTING FOOTPRINT
PARTS DIAGRAM SIGNATURE™REELS
45
46
10

PARTS LISTING SIGNATURE™DEF REEL
Parts Listing for Signature
DEF Reel
2400-007
2400-008
2400-009
2400-006
ITEM PART # DESCRIPTION QTY
1 832895 Stainless Steel Swivel (not shown) 1 x x x x 2 832894 Stainless Steel Elbow (not shown) 1 x x x x 3 4 832919 O-Ring, 2-212, Viton (not shown) 2 x x x x 5 832893 Stainless Steel Shaft (not shown) 1 x x x x 6 832920 Snap Ring Truarc #5160-87 1 x x x x 7 824474 Snap Ring Truarc #5160-98 1 x x x x 8 831489 Grounding Terminal Ring 1 x x x x 9 824480 1/4” - 20 Screw 4 x x x x
10 832921 Side Panel - Deep 1 x x x x
11 824462 (1) Side Panel - Shallow 1 x x x x
12 824472 Snap Ring Truarc #5100-50 1 x x x x 13 813561 1/4” - 20 Nylok Nut 6 x x x x 14 824483 Spring “Stop Pawl Assy” 1 x x x x 15 824453 Pawl 1 x x x x 16 824477 10-32 Flanged Nut 4 x x x x 17 824454 Pawl Arbor 1 x x x x
18 824460 Ratchet 1 x x x x 19 828152 Hose Clip, 3/4” I.D. 1 x x x x 20 827536 Spring Case Cover 1 x x x x
21 824476 10-32 x 3/4” Stud 4 x x x x 22 808966 Power Spring 1 x x x x 23 824459 Spring Case 1 x x x x
NOT IN USE 2 x x x x
25 832923 (1) Mounting Base 1 x x x x
Parts Listing for Signature
DEF Reel
2400-007
2400-008
2400-009
2400-006
ITEM PART # DESCRIPTION QTY
26 832922 Outlet Arm 1 x x x x 27 832918 1-3/8” I.D. Internal Tooth Washer 1 x x x x 28 824972 Roller Pin - Short 2 x x x x 29 826191 Roller Pin - Long 2 x x x x 30 824956 Rollers / Nylon 8 x x x x 31 831252 Roller Support 2 x x x x 32 824478 10-32 Nylok Nut 2 x x x x 33 824479 Set Screw 1 x x x x 34 820793 10-32 Screw 1 x x x x 35 805989 1/4”-20 x 1-1/2” Bolt 1 x x x x 36 808300 1/4”-20 x 1-3/4” Bolt 4 x x x x 38 821373 Decal (Balcrank) 1 x x x x 39 826983 Serial No. Tag 1 x x x x 40 817342 Hose Guard 1 x x x x 41 831252 Roller Support 2 x x x x 43 813561 1/4”-20 Nut 4 x x x x 44 832917 1-3/8” - 12 Nut 1 x x x x 45 831730 Spacer (Spring Case) 1 x x x x 46 831729 Spacer with Shoulder 1 x x x x 47 830161 Derail Bracket (not shown) 1 x x x x 48 826398 Hose Stop, 3/4” (not shown) 1 x x x x 49 8562-003 Hose, DEF Fuel, 3/4” x 3’ (not shown) 1 x x x 50 8569-016 Hose, DEF Fuel, 3/4” x 16’ (not shown) 1 x 51 8569-020 Hose, DEF Fuel, 3/4” x 20’ (not shown) 1 x 52 8569-030 Hose, DEF Fuel, 3/4” x 30’ (not shown) 1 x
(1) When ordering these components please specify blue paint for DEF reels.
11

Revision Log:
Rev. A - Release
Rev. B - Added instructions for installing derail
bracket, changed qty. of item 13 to
six and removed item 24 (NOT IN USE)
Rev. C - Added note about inlet connection on
page 4
Balcrank™Corporation
115 Reems Creek Road
Weaverville, NC 28787
800-747-5300
800-763-0840 Fax
www.balcrank.com
SERVICE BULLETIN SB2023
Rev C 7/11
For Warranty Information Visit:
www.balcrank.com