110KA through 200KA & 9110KA through 9150KA
Contents
1. 110KA through 200KA amp 9110KA through 9150KA Balancer Series Service Manual AERO MOTIVE COMPANY wy 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 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 Failure to read understand or follow these instructions could lead to hazards or unsafe practices COULD result in severe personal injury or death Instruct operators in the safe proper use and maintenance of this product Hazards or CAUTION a k nie unsafe practices MAY result in minor personal injury or product or property damage MOUNTING Hang balancer in the desired location by the shackle provided at the top The balancer should be2. 2 9 Screw Hex Head Cap 31 00156P0020 1 Nut Hex Jam SAE 1 4 20 32 00101P0016 1 Lockwasher Spring 1 2 33 00576P0041 1 Retaining ring external 0 750 34 00053P0400 2 Soc Head set screw 5 16 18x3 8 35 3106600000 1 Bearing worm shaft 36 4261200000 1 Worm shaft assembly 37 00229P0010 1 Drive pin 1 8x5 16 SM115001C Page 6 of 7 Jun 01 38 3129400000 1 Lever manual drum lock 39 3164300000 1 Spring manual drum lock 40 3129500000 1 Shaft manual drum lock 41 3127900000 1 Lever safety lock 42 5952000000 1 Screw safety lock lever 43 00230P0120 1 Drive pin 0 312x3 4 44 3133200001 1 Cable Only 7 110 200Ka Kit B 3133200002 1 Cable Only 9 9110 9150Ka Kit B 45 1102600000 1 Bumper 46 3116800000 1 Retainer 47 3128500000 1 Spring 48 3162500001 1 Stop 49 00655P0010 2 Clamp 50 00677P0015 1 Thimble 51 3108500000 1 Hook xxxKa 5949700000 1 Bullard hook xxxKa 03 xxxKa 04 52 5957200000 1 Cable guide assembly 53 01235P0002 2 Clevis pin 54 4260700000 1 Sleeve assembly velocity control 55 3125800000 1 Spring velocity control friction 56 3125900000 1 Plug velocity control friction spring 57 3125200000 1 Screw velocity control retainer 58 00053P0509 1 Set screw slot headless 3 8 24x1 59 00156P0045 1 Hex jam nut SAE 3 8 24 60 1422700000 1 Washer wear 3 8 inch 61 5951900000 1 Spacer lock lever KITS Kit A 4968000000 1 Upper shackle assembly xxxKa xxxKa0
3. 5 xxxKa06 3145400000 1 Upper bullard hook assembly xxxKa03 xxxKa04 Kit B H13120029 1 Cable assembly 7 ft complete 110 200Ka H13120030 1 Cable assembly 9 ft complete 9110 9160Ka 3145500001 1 Cable assembly 7 ft w bullard hook 110 200Ka03 3145500002 1 Cable assembly 9 ft w bullard hook 9110 9160Ka03 H13120018 1 Cable 7 ft w insulator and bullard 110 200Ka04 110 200Ka05 H13120019 1 Cable 9 ft w insulator and bullard 9110 9160Ka04 4261600001 1 Cable Assembly 7 ft w adjustable clamps 110 200Ka06 Kit C 4963900000 1 Safety Chain Kit D 4960600001 1 Overhang Cable 5 4960600002 1 Overhang Cable 10 4960600003 1 Overhang Cable 15 4960600004 1 Overhang Cable 20 4960600005 1 Overhang Cable 3 4960600006 1 Overhang Cable 25 4960600007 1 Overhang Cable 30 4960600008 1 Overhang Cable 35 Recommended Spare Parts NOTE Item 44 is the Cable w swage but without Items 45 51 Order Kit B if Complete cable assembly with items 45 51 is needed Do not confuse Kit D with cable with Kit B balancer cable Overhang does not retract into the balancer but is attached to hook item 51 to extend the hook connection down Aero Motive Company WwW A Woodhead Industries Inc Subsidiary PO Box 2678 Kalamazoo MI 49003 2678 616 337 7700 800 999 8559 FAX 800 333 6119 SM115001C AKAPP Electro Industrie WwW A Woodhead Industries Inc Subsidiary Nijverheidsweg 14 Box 54 NL 3771 ME Barneveld NL 3771 AB Barne
4. ATIGUE amp EXCESSIVE LOAD CABLE AND DRUM WEAR do HANGING E TROLLEY MOUNT ALLOWS BALANCER PERPENDICULAR TO FUNCTION PROPERLY amp PROVIDES VARIABLE WORK AREA TOOL ATTACHMENT WARNING Never pull cable to device to be retracted Always lift object to hook If the hook is accidentally released when it is extended it will snap back Hazards or unsafe practices which COULD result in severe personal injury or death When attaching tool to lower hook the tool should be lifted to hook rather than pulled to the empty hook against the reel tension The drum lock can be engaged to prevent cable from retracting see illustration in Tool Replacement The retaining latch on lower hook MUST be snapped back in the closed position after tool is attached SPRING TENSION ADJUSTMENT Only use adjusting nut to set tension Hazards or unsafe practices MAY result in minor CAUTION ae personal injury or product or property damage NOTE Items 24 25 on parts list last page are factory set and should not be adjusted Only use adjusting nut to set tension The complete tool including all attachments and connections must be in place before adjusting spring tension If load exceeds spring tension tool will move downward If tension exceeds load tool will move upward Spring tension can be adjusted by turning the adjustment nut clockwise to increase tension or counterclockwise to decrease tension DECREA
5. Periodic inspection of cable lower hook and upper swivel mount assembly Kit A is strongly SM115001C All parts are replaceable in the field without special tools recommended for safe operation Bearings and guide rollers should also be inspected periodically to insure efficient operation All bearings springs etc are permanently lubricated at the factory and should require no further lubrication REPLACEMENT PARTS KIT B BREAKDOWN R D 3 aa A Leen o me e a o e m ae 00447 bmp Page 5 of 7 Jun 01 Reference Number Part Number Qty Description 1 00030P0144 6 Screw 1 4 20 x 3 hex head 2 00101P0030 20 Washer Spring Lock 1 4 3 3123700001 1 Cover Main Housing 4 5907800000 1 Extension Housing 5 00030P0116 4 Screw 1 4 20 x 2 3 4 Hex Head 6 3127600110 1 Outer Mainspring amp Housing 110 9110Ka 3127600120 1 Outer Mainspring amp Housing 120 9120Ka 3127600130 1 Outer Mainspring amp Housing 130 9130Ka 3127600140 1 Outer Mainspring amp Housing 140 9140Ka 3127600150 1 Outer Mainspring amp Housing 150 9150Ka 3127600160 1 Outer Mainspring amp Housing 160 9160Ka 3127600170 1 Outer Mainspring amp Housing 170Ka 3127600190 1 Outer Mainspring amp Housing 190Ka 3127600200 1 Outer Mainspring amp Housing 200Ka 7 3123900001 1 Ring Spring Separator 8 3127700110 1 Inner Mainspring amp Housing 110 9110Ka 3127700120 1 Inne
6. SE TENSION SPOT BRAKE NOTE See Automatic Lock if balancer locks up A spot brake is provided for fine adjustment to eliminate any creeping tendency This adjustment is made only if desired and after adjustment as explained in Spring Tension Adjustment To adjust loosen lock nut and back up brake adjusting screw until the balancer works freely Next apply pressure to spot brake by turning adjustment screw in until desired setting is reached Reset lock when adjustment is completed SPOT BRAKE SM115001C Page 2 of 7 Jun 01 AUTOMATIC LOCK NOTE If tension is removed well below rated range of the balancer during spring adjustment lock will engage It will be necessary to apply more tension to release the lock If a spring should break or lose tension for any reason an automatic lock will engage to prevent drum from turning Lock will disengage when tension is applied to a new spring CABLE STOP ADJUSTMENT Adjusting cable stop is not recommended due to reduction in active travel distance and difficulty If additional cable extension is required extension cable assemblies are offered as an accessory item In addition special cables are available if needed SERVICE TOOL REPLACEMENT A WARNING Never release drum lock unless full load is hung on balancer If released with no load hook will retract rapidly Hazards or unsafe practices COULD result in severe personal injury or death Pull t
7. d strands Hazards or unsafe practices MAY result in minor personal injury or product or property damage NOTE Clamps are used for models xxxJa01 only A swage fitting sleeve should be used for all other models If lower hook is removed or replaced for any reason the thimble and clamps or sleeve must be replaced as shown in illustration If clamps are used turn back 3 inch of rope from thimble Apply u bolt over dead end of wire rope live end rests in saddle Tighten nuts evenly alternating from one nut to the other until reaching recommended torque 7 5 ft lbs Apply second clip as near the thimble as possible Tighten evenly alternating until reaching recommended torque 7 5 ft lbs 3 75 ae Eh T P DEAD _ Al r 2 pat TS aK O f H Lease MAINSPRING REPLACEMENT WARNING Never under any circumstances remove spring from its sheet metal cartridge Replacement springs are assembled in a sealed cartridge for safety and there is no need to remove them Removal of spring from its cartridge lead to hazards or unsafe practices which COULD result in severe personal injury or death Before removing mainspring remove all tension from balancer by turning tension CAUTION f es adjustment nut counterclockwise until all tension is released ref Spring Tension Adjustment Hazards or unsafe practices which MAY result in minor personal injury or product or property damage Remove balancer from service Remove
8. ool down to the most convenient height and set manual drum lock by lifting tab allowing pin to snap in see illustration This locks the drum in place Tool can now be removed and replaced After replacing tool the drum lock can be released by pulling outward on tab and folding it back into its original position MANUAL DRUM LOCK CABLE REPLACEMENT Never release drum lock unless full load is hung on the balancer If it is necessary to CAUTION h disassemble balancer to change cable always remove all spring tension prior to disassembly see Spring Tension Adjustment Hazards or unsafe practices MAY result in minor personal injury or product or property damage Whenever cable shows signs of deterioration it should be replaced p with a new cable To replace cable there is no need to disassemble balancer remove tension and or remove it from its location Simply pull cable to its extreme lower limit exposing threaded plug in the drum as shown in the illustration Engage manual drum lock as described in Tool Replacement and remove tool Remove plug i and old cable Insert new cable and replace plug securely i Reattach tool to lower hook and disengage drum lock PLUG CABLE CABLE REPLACEMENT SL Le Ly a er SM115001C Page 3 of 7 Jun 01 LOWER HOOK REPLEACEMENT i After securing clamps or sleeve tape may be placed around cable end to prevent injury CAUTION sn on fraye
9. r Mainspring amp Housing 120 9120Ka 3127700130 1 Inner Mainspring amp Housing 130 9130Ka 3127700140 1 Inner Mainspring amp Housing 140 9140Ka 3127700150 1 Inner Mainspring amp Housing 150 9150Ka 3127700160 1 Inner Mainspring amp Housing 160 9160Ka 3127700170 1 Inner Mainspring amp Housing 170Ka 3127700190 1 Inner Mainspring amp Housing 190Ka 3127700200 1 Inner Mainspring amp Housing 200Ka 9 3124000001 1 Shaft Assembly 10 00751P0010 1 Key Woodruff 1 8 x 1 2 11 00581P0070 1 Retaining Ring Internal 1 875 12 a b 00376P0010 2 Bearing x 1 x 5 8 Included with Item 6 13 00826P0305 1 Pipe Plug 1 4 14 3109100001 1 Drum Assembly 7 3109100002 1 Drum Assembly 9 15 3105800000 1 Gear Main Shaft Worm 16 01240P0007 1 Shackle Only See Kit A 17 00228P0012 2 Pin cotter 1 8 x 1 18 3123400000 3 Washer 19 5907500000 1 Housing 20 3107200000 1 Shaft Star Wheel 21 3107300000 1 Spring Washer Star Wheel 22 3107100000 1 Star Wheel 7 110 200Ka 3129100001 1 Star Wheel 9 9110 9160Ka 23 3117100000 1 Friction Plate Star Wheel 24 3138100000 1 Screw Safety Spring 25 00151p0035 1 Nut Heavy Hex Jam 3 8 16 26 3124600000 1 Retainer Spring 27 3126800000 2 SEAT Safety Lock Spring 28 3124400002 1 Spring Safety Lock 110 120 130 9110 9120Ka 3124400004 1 Spring Safety Lock 140 150 160 9140 9150 M15050010 1 Spring Safety Lock 170 190 200Ka 29 5907600000 1 Base Housing 30 00030P011
10. suspended directly over work area using an eyebolt or similar device with a break strength exceeding 6 times the combined weight of the balancer and the load it is supporting Balancer should be mounted in such a manner as to minimize cable contact with the cable guide If shackle is removed to make the connections be sure that the nut and cotter pin are properly replaced on the shackle pin SECONDARY SUPPORT CHAIN DANGER A secondary safety cable or chain is to be attached to all balancers mounted overhead to prevent balancer from falling Immediate hazards WILL result in severe personal injury or death A hole has been provided at the side of the housing to permit installation of a secondary support chain All balancers mounted over head should have a secondary support chain to protect personnel in case of structure or mounting component failure Attach one end of secondary support chain or cable to secondary support point shackle on balancer Attach the other end of secondary support chain or cable to a support component other than that which supports the balancer The chain or cable should be as short as possible allowing the balancer to drop no more than 6 to 12 inches if the primary connection is released See Illustration on Page 2 A secondary support is offered as an accessory item i tet SM115001C Page 1 of 7 Jun 01 WRONG RIGHT BALANCER MOUNTED t ON TROLLEY ma i WORKING WITH LOAD NOT PERPENDICULAR CAUSES OPERATOR F
11. the six 6 bolts and cover assembly with cover extension Now remove the four 4 bolts and pull spring assembly amp spacer from drum A new bearing is included with spring assembly Reassemble in reverse order and readjust tension as described in Spring Tension Adjustment To align springs with spring hub it may be necessary to rotate spring assembly back and forth slightly as the spring assembly is pushed back onto shaft STAR WHEEL POSITIONING If drum has been removed during service it is very important to Position star wheel properly when reassembling balancer If this is not done drum will be out of time and will either fail to return or extend The full distance of cable travels When reassembling with cable off the drum and when viewed from the spring side of housing the star wheel must be positioned as shown in relation to pin B The pin on the cable drum A must be positioned as shown in relation to point C on star wheel PARTS REPLACEMENT Always remove all spring tension as described in Spring Tension Adjustment before CAUTION s attempting to disassemble internal parts Always remove balancer from service Hazards or unsafe practices which MAY result in minor personal injury or product or property damage NOTE When ordering replacement parts always include the balancer model number and serial number a lt SM115001C Page 4 of 7 Jun 01 MAINTENANCE amp INSPECTION
12. veld Holland 011 31 3420 14022 FAX 011 31 3420 92384 Page 7 of 7 Aero Motive UK Woodhead Asia PTE LTD Woodhead Canada LTD Limited WwW A Woodhead Industries Inc Subsidiary WwW A Woodhead Industries Inc Subsidiary 1090 Brevik Place Mississauga Ontario L4W 3Y5 Canada 905 624 6518 FAX 905 624 9151 WwW A Woodhead Industries Inc Subsidiary 401 Commonwealth Drive 04 04 Haw Par Technocentre Singapore 0314 65 479 6533 FAX 65 479 3588 Rassau Industrial Estate Ebbw Vale Gwent NP3 5SD United Kingdom 0495 350436 FAX 0495 350877 Jun 01
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