JB Balancer Series Service Manual
Contents
1. Woodhead Asia PTE LTD Woodhead Canada LTD Aero Motive Company Ww A Woodhead Industries Inc Subsidiary PO Box 2678 Kalamazoo MI 49003 2678 616 337 7700 800 999 8559 FAX 800 333 6119 SM1142 01B W A Woodhead Industries Inc Subsidiary Nijverheidsweg 14 Box 54 NL 3771 ME Barneveld NL 3771 AB Barneveld Holland 011 31 3420 14022 FAX 011 31 3420 92384 Aero Motive UK Limited W A Woodhead Industries Inc Subsidiary Rassau Industrial Estate Ebbw Vale Gwent NP3 58D United Kingdom 0495 350436 FAX 0495 350877 Page 6 of 6 W A Woodhead Industries Inc Subsidiary 401 Commonwealth Drive 04 04 Haw Par Technocentre Singapore 0314 65 479 6533 FAX 65 479 3588 W A Woodhead Industries Inc Subsidiary 1090 Brevik Place Mississauga Ontario L4W 3Y5 Canada 905 624 6518 FAX 905 624 9151 Sep 012. 0 Aluminum H41220102 1 Spring assembly JB100 Red H41220103 1 Spring assembly JB110 Blue H41220104 1 Spring assembly JB120 Gold 8 C00400102 2 Groove pin 3 16 x 1 1 4 9 M08730002 1 Auto stop SM1142 01B Page 5 of 6 Sep 01 10 M15250006 11 M04840001 12 3105800000 13 1106000000 14 M04360014 15 C00640106 16 M28850024 17 01240P0007 18 00151P0070 19 00228P0012 21 3123400000 22 H16510012 23 00576P0044 24 3129400000 25 00229P0010 26 3164300000 27 3129500000 28 M57710001 29 C03520153 30 H13120013 H13120014 H13120024 H13120025 31 M16300005 32 M70780010 34 00053P0222 35 H16510015 36 C00640130 37 C01010222 38 00228P0012 39 C01810425 KIT C 4963900000 Af Om Om mm Sf me mm mS AIO OM mS mS me mS NS DAO Mm SB Sm DA A Om A Ome AKAPP Electro Industrie Torsion spring Drum Gear Bushing Front case Clevis Pin Hex head capscrew drilled Shackle body Hex nut Cotter pin Washer Support block assembly 00 option Retaining ring Manual drum lock lever Drive pin Manual drum lock spring Manual drum lock shaft Cable guide M6 x 16 Counter sunk head Standard 2 meter cable assembly JBXXX00 option Bullard 2 meter cable assembly JBXXX03 option Standard 1 5 meter cable assembly JBXXXS0O option Bullard 1 5 meter cable assembly JBXXXS3 option Worm gear Cable anchor Set screw Bullard support block assembly 03 option 5 16 x 1 1 2 Clevis pin 3 8 washer Cotter pin Retaining ring Safety chain
3. JB Balancer Series Service Manual AERO MOTIVE COMPANY wW A Woodhead Industries Inc Subsidiary IMPORTANT SAFETY INSTRUCTIONS Please read this manual carefully and follow its instructions Improper use or failure to follow these instructions could result in serious injury death or property damage Operators should be instructed in the safe and proper use and maintenance of this product Keep this manual for future reference The following safety precautions call attention to potentially dangerous conditions A DANGER Immediate hazards which WILL result in severe personal injury or death A WARNING Hazards or unsafe practices which COULD result in severe personal injury or death 2 Hazards or unsafe practices which MAY result in minor personal injury or product or CAUTION property damage NOTE Instruct operators in the safe proper use and maintenance Keep this manual for future reference INSTALLATION MAIN SUPPORT A WARNING To prevent hazards or unsafe practices that COULD result in severe personal injury or death main support device must have break strength exceeding five times the weight of the load NOTE To prevent nut from turning on shackle pin ALWAYS use new cotter pin when reassembling Install main support device directly over work area CORRECT WRONG i Balancer not directl Attach balancer to main support installed previously with Balancer directly SPA area gt shackle and sha
4. ckle pin Secure shackle pin with nut Secondary support Secondary support and attached to attached to same support cotter pin separate support wt Cable rubs v on cable guide hangs straight SE a O E ee NY ee SM1142 01B Page 1 of 6 Sep 01 SECONDARY SUPPORT A DANGER Installation of a secondary support chain or cable is needed Immediate hazards WILL result in severe personal injury or death A WARNING Do not attach secondary support to same structure that supports balancer Hazards or unsafe practices COULD result in severe personal injury or death NOTE Aero motive offers secondary supports as an accessory item See Kit C under replacement parts Attach a secondary support to clevis pin between the housing holes on the side of the balancer housing Secure clevis pin with washer and cotter pin Attach secondary support to clevis pin between the housing holes which are on the side of the balancer housing Secure clevis pin with washer and cotter pin Attach other end of the secondary support to a separate support so that the balancer will drop no more than twelve inches if main support fails ADJUSTMENT TOOL ATTACHMENT A WARNING Never pull cable to device to be retracted Always lift object to hook If the hook is accidentally released when extended it will snap back Hazards or unsafe practices COULD result in severe personal injury or death NOTE After tool is attached make sure retaining latc
5. h on tool clip has snapped back to the closed position Lift the complete tool including any hose cable fittings and attachments up to the tool clip SPRING TENSION ADJUSTMENT Please observe the following before making any spring tension adjustments Tool and all tool accessories are attached to the tool clip Tool will lower if the weight of the tool exceeds the existing tension adjustment of the balancer main spring The auto stop may prevent drum from rotating when unit is under tensioned See Automatic Lock Tension adjustment worm gear must be turned twenty times to equal one turn on the spring CLOCKWISE INCREASE COUNTER CLOCKWISE DECREASE MANUAL DRUM LOCK LIFT TO SET iru CASE FRONT TENSION eee INCREASE amp DECREASE TENSION NOTE If the drum locks up cable will not pull out when reducing spring tension increase tension until the automatic lock disengages See Automatic Lock NOTE Do not over tension balancer main spring This will reduce travel and spring life To increase tension turn the worm gear in a clockwise direction indicated by the symbol on the case Repeat this process until desired tension is achieved To decrease tension turn worm gear ina counter clockwise direction indicated by the symbol on the case Repeat this process until desired tension is achieved SM1142 01B Page 2 of 6 Sep 01 CABLE STOP ADJUSTMENT NOTE Make all cable stop adjustments after tool and access
6. lling load on tool clip Cable and tool clip will retract rapidly Hazards or unsafe practices COULD result in severe personal injury or death Do not adjust main spring tension until tool and attachments are suspended from CAUTION agi balancer Hazards or unsafe practices MAY result in minor personal injury or product or property damage Pull tool down to full pay out exposing cable anchor in housing window Lock drum by lifting manual drum lock lever allowing drum lock shaft to engage drum Remove tool from tool clip Swing cable anchor out into housing window Loosen set screw in cable anchor Remove cable by pulling it through cable guide Install new cable by feeding it in through cable guide and out housing window Insert swaged end on cable into cable anchor Tighten setscrew Pull down on cable until cable anchor swings back into position Install tool onto tool clip Unlock drum by pulling manual drum lock lever and folding it back to its original position ets SM1142 01B Page 3 of 6 Sep 01 SPRING ASSEMBLY REPLACEMENT WARNING Never remove spring from drum and spring assembly Replacement springs are sealed for safety Hazards or unsafe practices which COULD result in severe personal injury or death NOTE Auto stop must be held out to release mainspring assembly NOTE Cable must be fully wound onto drum before attaching rear case Remove balancer from service Remove all spring tensio
7. n from balancer by turning worm gear counter clockwise Remove four screws and rear case Remove four screws and mainspring assembly Install replacement mainspring onto drum Reassemble screws and rear case in reverse order MAINTENANCE INSPECTION The balancer is designed to require little maintenance Periodically check cable tool clip and shackle for wear Replace all worn parts immediately The balancer is lubricated at the factory no additional lubrication is required REPLACEMENT PARTS PARTS REPLACEMENT NOTE When ordering replacement parts always include the balancer model number and serial number All parts shown on parts list are replaceable in the field without special tools JB X XJ X 0 Standard Upper amp Lower Hooks Balancer Model 3 Bullard Upper amp Lower Hooks 0 Standard 2 Meter Cable Length SzShort1 5 Meter Cable Length ES AME capacity in ib 20 2 Meter cable length not available on units pacity i above 100 Ibs SM1142 01B Page 4 of 6 Sep 01 00161 bmp Reference Number Part Number Qty Description 1 C03500258 4 M6 x 30 Pan head screw 2 M04360015 1 Rear case 3 M26830002 1 Mainshaft 4 00751P0010 1 Woodruff key 5 00376P0010 1 Bearing 6 C03500253 4 M6 x 16 Pan head screw 7 H41220097 1 Spring assembly JB045 Orange H41220098 1 Spring assembly JB060 Black H41220099 1 Spring assembly JB070 Brown H41220100 1 Spring assembly JB080 Green H41220101 1 Spring assembly JBO9
8. ories have been attached to the tool clip and after adjusting the spring tension See Spring Tension Adjustment NOTE Moving cable stop and bumper closer to the cable guide will shorten the active travel of the cable If additional cable is required extension cable assemblies are offered as an accessory Loosen hex on cable stop and dislodge lead inserts clamping cable Slide cable stop up or down on cable so that tool is positioned at desired working height Reinsert lead inserts into cable stop thimble Tighten loosened hardware to hold cable stop at set position AUTOMATIC LOCK If tension is reduced to below the rated range the automatic lock will engage and prevent cable drum from turning Increase tension until automatic lock disengages If a spring should break the automatic lock will engage to prevent drum from rotating The lock will disengage when a new spring assembly is installed and tension is applied See Spring Replacement SERVICE TOOL REPLACEMENT WARNING Do not release manual drum lock lever without installing load on tool clip Cable amp Tool Clip will retract rapidly Hazards or unsafe practices COULD result in severe personal injury or death Pull tool down to convenient height and lock drum by lifting manual drum lock lever Install new tool and unlock drum by pulling manual drum lock lever and folding it back to its original position CABLE REPLACEMENT WARNING Do notrelease drum lock lever without insta
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