| TROUBLE SHOOTING |
THE TOOL OR LOAD IS HARD TO PULL DOWN
|
The operator
is complaining about the effort it takes to use the tool. The job is causing work related
injuries.
|
The tension is not set correctly.
Rotate the worm gear counter clockwise until the rubber buffer falls slightly away from
the nozzle. If the safety detent engages locking up the drum, the balancer must be changed
to a lighter capacity. Weigh the load and select the model that places it between the mid
and high side of the range. |
| The load retracts
so fast that when the buffer hits the nozzle the entire balancer bounces upwards. |
Reduce the tension on the spring
until the buffer falls away slightly from the nozzle. Then increase the tension until the
load slowly retracts without effort. The spring tension is set to the high side of the
range and is suspending a load that places it on the low side of the range. Reduce the
tension and add weight to the load. |
| The cable is
binding on the cable drum. |
If possible, extend the cable to
full extension and carefully examine it for fraying, kinking or damage. If there is any
sign of wear on the cable, drum or nozzle, replace the unit and have it inspected
immediately. Make sure the cable clamp is tight. Verify the cable from the load end to the
clamp does not exceed specifications of 4.9 feet on 7228, 6.5 feet on 7221, 7230, and
7241, and 9.8 feet on 7251 single and double spring units. |
| The cable is
wrapped around the shaft. |
If the cable is visibly wrapped
around the shaft, by observing through the nozzle, the balancer will have to be
disassembled to disengage it. See above for cause relating to cable clamp slipping. |
| The hanging
suspension is not rotating and swinging, and cables, hoses or the safety chain are
preventing freedom of movement of the balancer housing. |
The balancer can’t track the
work if rotation and floatation are inhibited. The cable may be generating nozzle or angle
friction. The nozzle will show wear and must be replaced. The balancer may be hung too low
for the job. If there is a long travel area, make sure the cone area encompasses the
entire work area. Raise the balancer if necessary. The other alternative would be to
install an additional rail and trolley to insure the work area stays within the cone work
area |
| The shaft is
clicking or scraping as the drum rotates. |
See cable binding above. The
bearings may need cleaning or greasing. The shaft may have been installed out of line with
the worm, and is wearing on the inner lip of the drum cover, housing cover and worm. It
must be inspected. |
| THE CABLE WON’T PULL DOWN FAR ENOUGH TO REACH THE WORK.
|
If the cable has
engaged the cable limiter, or is bottoming out in the drum, the maximum travel has been
reached. |
Extend the load as far as
possible. Look into the side window of the balancer to verify that the cable is extended
to the cable anchor. Models 7241 or larger will not extend to the anchor. The cable
limiter will be visible through the window in the bottom of the balancer next to the
nozzle. If it is engaged, a longer cable is indicated. Determine the length of cable
needed and compare to the specifications. The job may require a larger balancer with a
larger drum and more travel. If the tool can be positioned lower in the retracted
position, add a cable extension or install a longer cable in the balancer. Longer cables
are available up to 15 feet long for models 7221, 7228, and 7230, and 22 feet long for
models 7241, 7251 and the 7251 double spring balancers. Always verify that the drum is
completely loaded before adding a cable extension. Do not lower the tool by reducing the
cable travel from off the drum. This significantly reduces spring life. Follow "quick
changing the cable" procedures. The maximum tension on the spring has been
exceeded. This can damage the spring. Remove the load and rotate the worm until the buffer
falls away from the nozzle. Refer to the "Load Range Table and add the required
number or rotations to the shaft to fully load the balancer. The cable can be extended
completely as long as the maximum tension has not been exceeded. |
| THE CABLE WON’T MOVE UP OR DOWN AND THE DRUM APPEARS TO
BE LOCKED UP.
|
The drum lock is
engaged. The drum will not rotate at all. |
Look on the cone end of the
balancer on models 7230 and 7241, and on the bottom of the 7251 and 7251 Double and
determine if the drum locking pin is depressed. If so and the cable is retracted, pull
down slightly on the cable to take the spring pressure off the pin, and press in and
rotate 1/4 turn counter clockwise and release. It will spring out flush with the housing.
If the cable will extend, no further action is necessary. |
| The safety detent
is engaged. The drum will turn 1 inch until a metal or clicking noise is heard. The detent
is hitting the ridge in the housing. |
The tension has been released or
the spring is broken. If rotating the worm gear clockwise will not release the detent, the
unit will have to be replaced, and the spring changed. If additional tension releases the
detent, the balancer may be oversized. Weigh the load and verify that it falls between the
mid and high side of the spring capacity for the model. Refer to the specifications and
determine if the unit installed is correct. If so, load the balancer to the high side of
its range and then reduce the tension back off until the load falls away. If retraction is
necessary, add tension until the load retracts without effort. |
| The cable clamp
slipped, or was not tight enough to prevent more cable than the drum can hold to wind into
the cavity. |
Look up into the drum cavity
through the nozzle, and verify that cable is wound onto the shaft at the end of the cable
grooves on the drum. The balancer will have to be dismantled to be repaired. |
| There is a
foreign object blocking the drum. |
Use a flashlight to inspect the
drum through the nozzle and through the side window on the housing. If an object is
visible, lock the drum, and take the unit down, open the housing lid and remove the
object. Inspect for drum damage, and if uncertain replace the unit. |
| On double spring
balancers one safety detent can be engaged and not the other. |
Refer to the load range table,
and only add tension. If the balancer remains locked up after rotating the shaft one full
rotation, replace the unit. |
| THE OPERATOR IS HAVING TO LIFT PART OR ALL OF THE WEIGHT OF
THE LOAD.
|
The tension has
been reduced to position the tool. The cable limiter is engaged in the bottom of the
housing. |
Look through the nozzle and
determine if the drum is fully loaded with cable. If not, the spring tension must be
increased until the balancer retracts effortlessly on its own. As soon as the drum has the
maximum cable wound onto the drum, according to the specifications, lock the drum. Move
the cable clamp up against the nozzle and tighten securely. Determine whether there is
sufficient travel and external cable to perform the job. Either replace the cable with a
longer version or add a cable extension below the socket, and then reduce tension until
the load starts to fall. Add only enough tension to retract the load without effort, only
if retraction is necessary. (See adjusting tension.) |
| The balancer is
under sized for the load. |
Weigh the load, and determine
which model should be installed. Confirm the load falls within the spring capacity or if a
secondary balancer should be used to suspend the cable’s etc. which can take up to 46
pounds off the primary balancer. If a secondary balancer cannot be used, change the unit
out for the next larger model or change series. |
| A SCRAPING NOISE IS HEARD WHEN EXTENDING THE CABLE, AND/OR THE DRUM IS ROTATING.
|
The
balancer needs immediate attention. Pending
balancer failure. The
bearings are failing, or the safety detent is almost engaged and the unit is being used on
the bottom of the load range. |
Raise the tension by rotating the
worm gear clockwise until the buffer is against the nozzle. Then reduce it until the load
starts to fall away from the nozzle. If the clicking persists, weigh the load and verify
it falls between the mid and high side of the load range. Replace the unit if necessary. |
| THE TOOL WILL NOT BALANCE.
|
The tool falls or
retracts but will not float in any position along the cable travel. |
Try the next smaller version of
the series on the high side, rather than being on the low side of a higher capacity unit. If
the smaller unit can’t handle the load, weigh the load, verify the correct range, and
add some weight to the fixture, or above the tool to position the load above the mid level
of the range. |
*For
additional help or technical assistance with your  "Zero Gravity" Tool
Balancer feel free to contact us. CLICK HERE for information on contacting us. |
