SM112001 BF 616 Service Manual

User Manual: BF 616

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BF Series
Service Manual
Aero-Motive Company
A Woodhead Industries, Inc. Subsidiary

IMPORTANT SAFETY INFORMATION
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. All reference numbers are located on page 5.
The following safety precautions call attention to potentially dangerous conditions.
DANGER:

Immediate hazards which WILL result in severe personal injury or death.

WARNING:

Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION:

Hazards or unsafe practices which COULD result in minor personal injury or product or
property damage.

INSTALLATION
WARNING:

Main support device must have break strength exceeding five times weight of load.
Hazards or unsafe practices COULD result in severe personal injury or death.

CAUTION:

Use new cotter pin when re-assembling clevis pin. Hazards or unsafe practices COULD
result in minor personal injury or product or property damage.

MAIN SUPPORT
Install the main support device directly over work area. (See illustration). Attach balancer to main
support with swivel fork and clevis pin. Secure clevis pin with washer and cotter pin.
SECONDARY SUPPORT CHAIN
A hole has been provided at side of housing to permit installation
of secondary support chain. All balancers mounted over head
must 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 other end of secondary
support chain or cable to a support component other than that
which supports balancer. Chain or cable should be as short as
possible allowing balancer to drop no more than 6 to 12 inches if
primary connection is released. (See Illustration) A secondary
support is offered as an accessory item.
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.

ADJUSTMENT
CAUTION:

Do not pull cable down to tool clip. Raise tool to clip. Hazards or unsafe practices
COULD result in minor personal injury or product or property damage.

TOOL ATTACHMENT
Lift the complete tool (including any hose, cable, fittings and attachments) up to the tool clip. After tool is
attached, make sure the retaining latch on tool clip has snapped back to the closed position.

SM1120-01E

Page 1 of 4

©Aero-Motive Company Sep-01

SPRING TENSION ADJUSTMENT
CAUTION:

Do not push tension lock lever without placing wrench onto mainshaft first. Extreme
amounts of stored spring torque will turn mainshaft rapidly clockwise. Hazards or unsafe
practices COULD result in minor personal injury or product or property damage.

NOTE: Do NOT over-tension balancer main spring. This will reduce cable travel and spring life.
NOTE: If drum locks up (cable will not pull out) when reducing spring tension, increase tension until
automatic lock disengages. (See Automatic Lock)
Observe following before making spring tension adjustments:
• Tool and all accessories are attached to tool clip.
• All balancers are factory pre-set.
• Tool will lower if the weight of tool exceeds tension
adjustment of balancer mainspring.
• If cable stop is up against cable guide prior to adjustment,
there is too much tension on balancer mainspring.
To increase spring tension, turn mainshaft with wrench ¼ turn
(one click at a time) in a counter-clockwise direction ( “+” symbol
on case). Repeat process until desired tension is achieved.
To reduce spring tension, turn mainshaft with wrench in counterclockwise direction until tension lock lever disengages. Hold
tension lock lever in disengaged position and allow mainshaft to
turn clockwise. Repeat process until desired tension is achieved.
CABLE STOP ADJUSTMENT
NOTE: Make all cable stop adjustments after tool and accessories have been attached to tool clip and
after adjusting spring tension. (See Spring Tension Adjustment)
NOTE: Moving cable stop and bumper closer to the cable guide will shorten active travel of cable.
Loosen two hex nuts and machine screws. Slide cable stop and bumper up or down on cable so that tool
is positioned at desired working height. Tighten loosened hardware to hold cable stop at set position.
AUTOMATIC LOCK
WARNING:

Never remove spring from drum and spring assembly. Replacement springs are sealed
for safety. Hazards or unsafe practices COULD result in severe personal injury or death.

If tension is reduced to below rated range, automatic lock will engage and prevent cable drum from
turning. Increase tension until automatic lock disengages. If a spring should break, automatic lock will
engage to prevent drum from turning. Lock will disengage after new spring assembly is installed.

SERVICE
TOOL REPLACEMENT
When replacing tool and attachments, make sure cable is fully retracted. (See Tool Attachment).
DRUM & SPRING ASSEMBLY REPLACEMENT
Remove balancer from service and remove all spring tension from balancer. (See Spring Tension
Adjustment). Remove two screws and cable guide. Remove four screws and nuts. Remove rear case
assembly & retaining ring from mainshaft. Remove mainshaft, hub and tension lock and cable assembly
with all attached parts from drum and spring assembly. Remove cable assembly from old drum and
spring assembly. Attach cable assembly to new drum and spring assembly (See Cable Replacement).
Reassemble unit in reverse order. Place balancer back in service and attach tool. (See Tool
Attachment). Set spring tension with tool and attachments in place. (See Spring Tension Adjustment.).

SM1120-01 E

Page 2 of 4

©Aero-Motive Company Sep-01

CABLE REPLACEMENT
CAUTION:

Do not disassemble balancer without reducing all spring tension first. (See Spring
Tension Adjustment). Also, do not adjust mainspring tension until tool and attachments
are suspended from balancer. Hazards or unsafe practices COULD result in minor
personal injury or product or property damage.

To replace cable, remove balancer from service and remove all
spring tension from balancer. (See Spring Tension Adjustment).
Remove two screws at cable guide, four (4) screws and nuts.
Remove case rear assembly, auto stop shaft, auto stop with
compression spring, and cable assembly. Remove cable guide,
bumper, cable-stop, hex nuts, machine screw and tool clip from
old cable assembly. Attach these items to the new cable
assembly. Place the swaged cable assembly end into the slot.
Reassemble unit in reverse order. Place balancer back in service
and attach tool. (See Tool Attachment). Set spring tension. (See
Spring Tension Adjustment)
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.
MAINTENANCE INSPECTION
The balancer is designed to require little maintenance. Periodically check cable, tool clip, swivel, and
hanger for wear. Replace all worn parts immediately. The balancer is lifetime lubricated at the factory.
No additional lubrication is required.

REPLACEMENT PARTS

SM1120-01 E

Page 3 of 4

©Aero-Motive Company Sep-01

Reference
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
KIT B
KIT A

Part Number
C20850137
01235P0008
H22510061
M15120003
M26830001
M08720004
H42160027
H42160023
H42160024
H42160025
H42160026
C01880416
M08710005
M15120004
H22510079
00126P0050
00228P0011
C22180115
01235P0009
H16510014
C01700119
M67310001
C03550100
1003100000
1361400000
00002P0202
H13120009
01146P0015
00151P0015
M04600000
M25360212
H13760000
H13120012

Aero-Motive Company