Balcrank Products Inc.

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• Balcrank Products Inc.
• Installation / Maintenance / Operation
• Training 1/2007

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Balcrank UniversityImportant terms to know

• Lubrication Control of friction and wear by the
  introduction of a friction-reducing (lubricant)
  film between moving surfaces in contact.
• Fluid Friction Friction due to the viscosity of
  friction.
• Flow Rate The volume, mass or weight of a fluid
  passing through any conductor per unit measure.
• Head Pressure The pressure due to the height of
  a column or body of fluid.
• Static Pressure The pressure in a fluid at
  rest.
• Viscosity A measure of a fluids resistance to
  flow.
• Poise Measurement unit of a fluids resistance
  to flow. I.e., Viscosity, defined by the sheer
  stress required to move one layer of fluid along
  another over a total layer thickness of one
  centimeter at a velocity of one centimeter per
  second.
• Flow The rate or volume of a fluid in
  transference of energy.
• Resistance The tendency of lubricant to oppose
  the flow of energy.
• Working Pressure Pressure at which an apparatus
  is being operated in a given application.
• Surge Pressure The pressure increase resulting
  from pressure fluctuations in a hydraulic system.
• Pressure Relief The pressure at which the
  relief is set for actuation. The pressure is
  generally slightly higher then the system working
  pressure.
• Compressibility The change in volume of a unit
  of fluid when subjected to a unit change in
  pressure.
• Tube Hollow, cylindrical product having outside
  diameter that are not standardized for threading.
  Tube is dimensionally classified in terms of the
  outside diameter and wall thickness.
• Pipe A tubular metal product that includes iron
  pipe size (I.P.S.) and schedule number in its
  classification.
• Fitting A connector or closure for fluid power
  lines and passages.
• Annealing Heat-treating process used to soften
  metals or to stabilize their structures.
• Scaling Forming of a layer of oxidation on
  metals, which results in flaking or peeling.

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Balcrank UniversityPicking the right pump

• With the variety of air motor sizes, ratios,
  cycles per gallon and gallons per minute
  available on air operated pumps, selecting the
  right pump
• for an application seems complicated. First and
  foremost, know the use of the pump.
• Here are several questions to ask
• What type of product is to be pumped?
• How many gallons per year will be pumped?
• What is the furthest distance to be pumped?
• How many restrictions are in the fluid line
  (tees, elbows, control valves, and pipe
  diameter).
• How many dispensing points are required?
• How many will be used simultaneously?
• What is the customers flow rate requirement in
  gallons per minute?
• With these questions answered, all that is left
  to do is to study the manufacturers literature
  and select the smallest-ratio pump that fits the
• requirements.
• For instance, take the Balcrank Bobcat series 31
  ratio pump and the Balcrank Panther 31 ratio
  pump. They both are 31 ratios but that is
• there only similarity. Same is true for the
  Balcrank Panther VS Tiger, both are 51 ratios
  but again that is the only similarity.
• Lets compare the differences
• Bobcat 31 Panther 31 Panther 51 Tiger
  51 Lion 51

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Balcrank UniversityPump Installation and
Maintenance

• Do
• Assure clean dry air to the pump, use a
  water-separating filter foreign debris will
  damage seals in the pump. Water will affect the
  operation and life span of the air motor.
• Always use a regulator on each pump, keep the
  pump operating at the lowest air pressure
  possible. The correct operating range for a pump
  should be between 40 to 80 psi. If your customer
  has the air pressure set higher than recommended,
  the pump and/or tubing may be to small for the
  system application.
• Assure the pump is being lubricated. All
  air-operated equipment should be lubricated to
  extend the life of the equipment. Lubrication
  is good Check airline lubricator often and keep
  it filled with a 10w non-detergent lubricant
  this will reduce your downtime, service costs and
  keep your customer-pumping product.
• Blow out traps, drain filters, and compressors
  daily Traps and filters that are not maintained
  become non-productive and will contribute to
  wearing out your air-operated equipment
  prematurely.
• Remove the air supply to the pump and bleed the
  system completely prior to any maintenance
  Extra caution on a high-pressure system is very
  important. A high-pressure system can cause
  bodily harm.
• Relieve air pressure when the pump will remain
  idle for any extended period of time. (Weekend)
  A pressure relieving ball-valve on the air side
  of the pump is recommended.
• Dont
• Point a dispensing device at yourself or any
  other person Accidental discharge of fluids
  under pressure can result in bodily harm.
• Exceed recommended air pressures to a pump
  normal operating range should run between
  40-80psi. If your customer is exceeding this
  limit, pump and/or tubing may be to small for
  system application.
• Set pump tube on ground when exchanging drums
  Foreign debris will get into pump tube and will
  damage seals and checks. This damage is not
  covered under warranty.
• Use worn or leaking equipment, personal injury
  and/or property damage may result.
• Exceed the pressure rating of the lowest rated
  component Your system is only as strong as its
  weakest component, i.e. hose.

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Balcrank UniversityPump / System Installation
and Maintenance

• Keys on Installation
• Always use a filter and regulator on each pump.
• Thermal relief valve is recommended on all pipe
  or tubing installations, required on all remote
  systems.
• Proper tubing size should be considered to obtain
  proper flow rates.
• Note an increase in flow will be achieved using
  the same size steel tubing versus pipe.
• Going from 5/8 to ¾ yields 50 increase in
  maximum flow.
• Going from 5/8 to 7/8 yields 96 increase in
  maximum flow.
• Going from 5/8 to 1 yields 164 increase in
  maximum flow.
• To prime system open control valve. Slowly
  increase air pressure to pump until pump begins
  to cycle. Let pump slowly cycle until oil system
  is fully primed. System is not primed until all
  air has left system. Oil should not be aerated
  and the flow should not be erratic. Raise air
  pressure between 40psi and 80psi. Air pressure
  should be set as low possible while attaining
  proper flow.
• All systems should be flushed prior to installing
  equipment. Start at pump, pump product through
  first outlet. Connect Equipment. Go to second
  and repeat until whole system is flushed. Test
  system at 25 over maximum pressure under which
  system will be operated.
• Always ensure proper regulatory compliance.
• Always use/wear proper safety equipment.

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Balcrank UniversityAir System Design
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Balcrank UniversityHose Reel Equipment
Maintenance

• Procedures for adjusting hose reel spring tension
• If the hose does not completely wind-up onto
  the spool, the reel most likely needs to be
  re-tensioned. This procedure is not a warranty
  issue All hose reels need to be adjusted to its
  application at start-up
• Simply Remove air from pump
• Completely bleed the fluid pressure in the
  system.
• Pull 4 to 5 feet of hose on reel down just enough
  to allow the stop pawl to engage ratchet, this
  will lock reel into position.
• For the Signature Series reels simply unwind or
  wind one loop of hose from reel spool.
• For the Premium Series reels you need to remove
  the dispense valve and feed the hose back through
  the outlet assembly. Then simply unwind or wind
  one loop of hose from the reel spool.
• For the Signature Series reel, after the
  adjustment has been made pull hose back through
  the roller outlet assembly and check the spring
  tension. Note The hose must pull out fully and
  retract fully.
• For the Premium Series reel, after the adjustment
  has been made pull the hose back through the
  roller outlet assembly, replace the dispense
  valve and check the spring tension. Note The
  hose must pull out fully and retract fully.
• Continue to remove and/or wrap more loops, one at
  a time, until the power spring has the desired
  tension.
• Carefully prime the system.
• All reels, even new ones will need to have the
  spring tension adjusted for the job application
  and/or installation requirements.

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Balcrank UniversityCustomer Operation and
Responsibilities

• Preventative Maintenance - Pumps
• Always use a airline filter. The air-filter
  ensures the pump will receive clean, moisture
  free air. Check and maintain the air-filter on a
  weekly basis to ensure your pump is getting
  clean-dry air. (Moisture is the number one cause
  of pump failure.)
• Always use a regulator. The regulator is used to
  adjust the pressure of the pump. Run the pump at
  the minimum pressure required to achieve the
  desired flow rate. (Regulator should not exceed
  80 psi for normal operation.)
• Use a lubricator when required by the
  manufacturer. Keep the lubricator filled with
  NON-DETERGENT-10W tool oil. (Using non-detergent
  oil will prevent the air motor from becoming
  gummed-up and prevent it from slowing down and/or
  stopping operation.) Check monthly. Average
  sized bowl should last 3-months, refill as
  needed.
• Thermal relief valve is recommended on all pipe
  or tubing installations, required on all M.E.P.
  systems. (Thermal relief will help reduce normal
  wear, route vent tube back to main reservoir.)
• Keep the fluid free of trash and debris.
  Periodically check pump inlet for foreign matter
  and clean when necessary. (DO NOT set pump-tube
  on dirty ground.)
• NEVER allow a pump to run dry of fluid being
  pumped. A dry pump will speed up, possibly
  damaging the air-motor and fluid seals. If your
  pump suddenly speeds up, cut off air supply
  immediately and check the fluid supply. If the
  supply is empty and air has been pumped into the
  line, prime the pump and the line with fluid.
  When priming a pump, slowly increase air pressure
  to pump until pump begins to cycle. Let pump
  slowly cycle, it should prime in 7 to 10 strokes.
  You may need to loosen swivel fitting at pump to
  bleed air out of pump allowing pump to prime.
  After pump is primed, raise air pressure between
  40psi and 80psi. Air pressure should be set as
  low possible while attaining proper flow.
• NOTE The low-level cut-off valve accessory kit
  (4411-010) closes the pump fluid intake when the
  fluid level is low, causing the pump to stall, to
  avoid running dry.
• NOTE A pump runaway Valve accessory kit
  (3241-002) can be installed on the air inlet of
  pump not equipped with a low level cut-off valve,
  to automatically shut off air supply to the pump,
  to prevent it from running too fast.
• If the pump will be unattended for any period of
  time, or to shut off system at the end of the
  work shift, always follow the Pressure Relief
  Procedure Warning.
• Close the pump air regulator and/or bleed type
  air valve
• Hold the dispensing valve firmly into a used oil
  container and trigger the dispensing valve to
  relieve the fluid pressure from the system.
• Always use/wear proper safety equipment when
  maintaining your equipment.

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Balcrank UniversityTest Quiz

• Test your knowledge
• System performance is based on 4 variables. Name
  them.
• 1) 2) 3) 4)
• What every pump needs for proper performance?
• 1) 2)
• When priming a pump what should you do?
• When a fluid shows signs of aeration, what should
  be the first thing to be checked?
• What is the recommended air pressure range for a
  pump?
• What is the most common failure for a grease pump
  and what causes it?
• Thermal expansion is caused by what?

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Balcrank UniversityTest Quiz

• Test your knowledge
• System performance is based on 4 variables. Name
  them.
• 1) Viscosity 2) Distance 3) Flow Rate 4)
  Tubing Size
• What every pump needs for proper performance?
• 1) Filter/Regulator/Lubricator 2) Pressure
  Relief Valve
• When priming a pump what should you do?
• Start Pump slowly. Gradually increase air
  pressure until pump is primed.
• When a fluid shows signs of aeration, what should
  be the first thing to be checked?
• Suction tube leading to pump for leaks, loose
  threads, bad threads or lack of thread sealant.
• What is the recommended air pressure range for a
  pump? 40 to 80psi
• What is the most common failure for a grease pump
  and what causes it?
• Foreign debris getting into the pick-up tube.
  Technician setting pump on ground.
• Thermal expansion is caused by what? a change in
  fluid temperature approx. 45psi for deg. In temp
  change

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Balcrank UniversityTrouble Shooting Pumps

• If air motor doesnt cycle (No Sound)
• Check air supply, is compressor ON
• Check shut off valves on air and fluid lines.
• Make sure manual tip (nozzle) is open and control
  valve is functioning.
• Check air eliminator and/or suction tube for
  debris.
• If inventory control is used be sure air and
  fluid solenoids are working.
• If air motor doesnt cycle but it is blowing air
  out the exhaust
• Disconnect air coupler to pump and replace, pump
  should cycle, if not
• Inject some 10W non-detergent lubricant and
  replace air supply
• Check seals and springs in air motor for any
  debris or damage.
• Inspect air motor cylinder wall for any damage
  such as scoring or corrosion.
• If air motor is cycling but not delivering
  product
• Check drum or tank for product level
• Check for trash or debris lodged in pump-tube
  and/or ball checks.
• Possibly worn lower piston seals and/or balls not
  checking.
• Check suction tube, double tap bushing, check
  entire suction side of pump for air leak. Pump
  keeps loosing prime
• If product is coming through pump exhaust, check
  upper tube seal to see if damaged.

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Balcrank UniversityTrouble Shooting Inventory
Control System

• Upon receiving a complaint of a Fluid Inventory
  Control (FIC) system over or under dispensing
  product the system should first be tested by the
  service technician before any service work is
  done or any components changed, replaced or
  adjusted. After it has been confirmed that the
  system in not functioning properly the following
  steps should be taken
• Check the in-line meter for proper cam rotation
  and see that the micro-switch is opening and
  closing on each lobe of the in-line meter.
  (Mechanical) Micro-switch can be adjusted
  slightly to increase or decrease flow by
  approximately one ounce.
• Check fluid for aeration, if aeration is
  occurring this will cause the system to
  under-fill the meter is reading the air that
  passes as fluid. If the fluid is aerated there
  is air getting into the system. The source will
  be the suction side of the pump, move on to step
  three.
• Check the suction tube leading to pump for leaks,
  loose threads, bad threads or lack of thread
  sealant. All the above will cause the system to
  loose prime or leak air into the system. (If a
  telescoping tube is used check o-ring seals).
• If the system is over-filling, check the fluid
  solenoid and see that it is closing properly.
• If you are experiencing low flow conditions,
  check pump-tube for debris, clean y-strainer, if
  no y-strainer is present then Strainers in the
  impulse meter and/or fluid solenoid may be
  clogged. Clean strainers in the impulse meter
  and/or fluid solenoid.
• Anytime that a component of the system has been
  changed or adjusted be sure to test system before
  any other adjustments or changes are made
• Check to see that the impulse meter is mounted
  before the pressure relief valve. If not the
  impulse meter may be reading a back flow
  condition caused when the pressure relief valve
  vents fluid back to the tank. Always mount a
  check valve before the impulse meter and the
  pressure relief valve after the impulse meter.