SERVICE BULLETIN SB2024REV. A 11/10

Thoroughly read and understand this manual before installing, operating or servicing this equipment.

See page 3 for Hose Reel Model Numbers and Technical Data

OPERATION and INSTALLATION GUIDE

DEF HOSE REELS

®

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General SafetyThoroughly 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 fluid 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 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!

Be sure the mounting surface is strong enough to support the reels, the weight of the fluids and the stress caused by hard pulls on the service hoses. See page 3 for approximate dry weights of the hose reel assemblies.

WARNING!

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.

CAUTIONDO NOT under any circumstances remove the spring from the canister.

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CAUTION!Be aware of possible fluid 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.

WARNING: Never allow the reel to spin freely. Doing so will cause the hose to spin out of control, which could cause seri-ous bodily injury. Always hold on to the hose while it is rewinding.

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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 identification 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!

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X1

X2

X3

Model Numbers

Technical DataHose Working Pressure Ratings:DEF Hose .......................................... 3/4” – 150 psi

Inlet/Outlet fittings (bare reel)............3/4” BSPP(F)

Wetted Parts ...............................Stainless Steel & Viton

Approximate Weight of reel with hose:2400-002........................................................61 lbs.2400-003........................................................70 lbs.2400-005........................................................84 lbs.

Product DescriptionThe DEF hose reel has a twin pedestal heavy duty metal design using the highest quality, heavy gauge materials and is fitted with a purpose specific DEF hose and swivel.

NOTE (1): Max working pressure is for bare reel only

Dimensions

Type of Service ModelNo. Hose Size Hose Model

Max. Working Pressure

(with hose)Low PressureDiesel Exhaust Fluid (DEF)Inlet & Outlet Fitting - 3/4” BSPP(F)

2400-002 3/4” X 16’ 8569-016 150 psi2400-003 3/4” X 30’ 8569-030 150 psi2400-005 3/4” X 50’ 8569-050 150 psi

Bare DEF reelInlet & Outlet Fitting - 3/4” BSPP(F)

2400-001 3/4” X 30’ max 550 psi(1)

2400-004 3/4” X 50’ max 550 psi(1)

Model# X1 X2 X3

2400-001 19.50” 20.25” 14.88”

2400-004 21.00” 22.25” 14.88”

Installation1. You will need to purchase appropriate hardware for mounting your new reel.2. The reel base has four slots for mounting on a

suitable flat surface. See page 5 for mounting footprint.

3. Your reel has an angle adjustable hose roller guide. To adjust the angle of the roller guides. a. Loosening the bolts on either side of the

roller guide b. Adjust the guide to the required angle c. Re- tighten the bolts 4. Using the four holes in the base, mount the reel in the desired location. Be sure to use appropriate hardware and tighten securely. 5. Apply Teflon tape or pipe sealant to supply line threads, attach to reel inlet and tighten. The other end of incoming line can now be connected to desired supply source.6. Apply Teflon tape or pipe sealant to outlet fitting on reel hose, then attach to desired tool, or nozzle. Check connection for leakage, also check hose reel for correct operation. ( see Operation section.) 7. If hose stop adjustment is required, pull hose from reel and allow to latch at desired length.

Read these safety warnings and instructions in this manual completely, before installation and start-up of the reel. 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 reel and void factory warranty.

IMPORTANT!

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Adjusting Power Spring Tension:1. Pull out approximately 6 feet (2 meters) of hose

and allow the drum to latch. 2. Remove the hose stop from hose, and feed hose back through the roller outlet. 3. Wrap the hose one time around the drum to increase tension or un-wrap hose one time from drum to decrease tension. 4. Re-insert hose through roller outlet, and install the hose stop onto the hose end. 5. Unlatch the Drum and check tension. Pull hose from reel, and adjust hose stop position if necessary.

Operation1. Check reel for correct operation by slowly pulling out the hose. A “clicking” noise will be heard every half revolution of the drum. 2. To latch the reel, pull out the hose and allow it to retract after hearing the first, second or third “ click”. 3. To unlatch, slowly pull out the hose until the “clicking” noise stops, then let the hose retract until the hose stop rests against the hose guide. 4. Periodically check the hose condition for wear or damage, and check the swivel fitting for leak age. Replace any worn, damaged, or leaking parts.

MaintenanceReplacing Service Hose:

1. Turn off and disconnect the supply to reel and release hose line pressure.

2. Pull out approximately 2m (6ft) of hose and allow the drum to latch.

3. Remove the outlet nozzle, gun or tool and hose stop. Unlatch the reel and carefully allow the hose to slowly rewind until there is no spring tension remaining.

4. Lay the hose reel on the side – spring case side facing up. Carefully remove the spring canister by removing the nuts and washers located around the drum assembly. BE CAREFUL: there is a small R-key assembly that is located in the key shaft. This assembly is spring loaded and can pop out of the shaft or come off with the spring canister. Carefully remove the R-key from the key shaft as well as the spacers around the spring canister bolts.

5. Set the hose reel upright again and manually pull the hose all the way out.

6. Remove the set screw holding the hose clamp down.

7. Remove the snap ring that holds the hose swivel onto the inlet shaft.

8. Disconnect and remove the old hose from the swivel. Connect the new hose to the swivel and slide the assembly onto the inlet shaft.

9. Assemble the snap ring into place holding the hose swivel onto the shaft. Assemble hose clamp.

10. Manually rotate the drum assembly (away from the roller guides) and recoil the hose onto the drum.

11. Lay the hose reel on the side – spring case side facing up. Apply the spacers to the spring canister shafts. Replace the R-key assembly into the key shaft – Ensure the highest side of the R-key is facing the roller outlet side (see photo below).

Loosen hose stop bolts and slide stop to a position close to the hose guide. Re-tighten hose stop bolts and check operation.

R-Key

CAUTION!Truck mounting will require the reel to be disassembled to orient the outlet arm and hose clamp for proper operation. Special care is required to ensure saftey is observed. (see page 5)

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.

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CAUTIONDO NOT under any circumstances remove the spring from the canister.

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12. Apply the spring canister on to the shaft and connect using washers and nuts. Set the hose reel upright again.13. Add tension to the reel by carefully rotating the drum and hose assembly (towards the roller guides) 5 complete turns, slide the hose through the roller guides and allow the reel to latch.14. Fit the hose stop to the hose end, release the drum latch, and slowly allow the hose to rewind on to the reel.

Note: Final spring adjustment is accomplished by adding or removing wraps of hose around the drum. Refer to “Adjusting Power Spring Tension”.

NOTE!Hose reel is shipped in floor/wall mount configuration

Hose Reel Mounting Positions

Truck Mount1. Refer to “Replacing Service Hose” steps 1 - 72. Remove the four bolts connecting the outlet guide arms to the uprights.3. Reattach the outlet guide arms to the opposite lower side of the upright (outlet guide arm assembly must be flipped over to align with slots in the uprights).4. Reattach to hose swivel to the inlet shaft (ensure hose is wrapped as shown in the image below).5. Hose will be attached one spacer back to correct the timing of the ratchet stop assembly. The spacer on the opposite side of the ratchet

teeth is the CORRECT spacer to put the hose clamp. This will keep the ratchet from locking up (see Figure 1 on page).

Figure 1

6. Refer to “Replacing Service Hose” steps 9 - 14*. *NOTE: Manually rotate the drum assembly to

re-wrap hose towards the roller guides.

Mounting Footprint

Model# X1 X2

2400-001 14.88” 13.31”

2400-004 14.88” 13.31”

CURRENT HOSE CLAMP POSITION

NEW TRUCK MOUNT HOSE CLAMP POSITION

NEW HOSECLAMP POSITION

0.785

2.060

0.510

0.7107.870

X1

X2

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Balcrank Products Inc.115 Reems Creek RoadWeaverville, NC 28787800-747-5300800-763-0840 Faxwww.balcrank.com

SERVICE BULLETIN SB2024Rev. A 11/10

Revision Log:Rev A: Release

For Warranty Information Visit: www.balcrank.com