KROMERTM

“Zero Gravity” Tool Balancers

FEATURES:• Floating Rotating Suspension• Recessed Safe Adjustments• Stepless Tension Adjustment• Automatic Safety Detent• Cold Rolled Containerized Spring• Locking Safety Hook

• Easy Load Leveling• Safety Drum Lock• Quick Change Cable• Safety Chain Installed• Exclusive Cable Limiter• Easy Spring Change

PHYSICAL DIMENSIONS

Rotation 360°Clearance 6"Hook Opening 15/16" IDSafety Chain Length 15"Safety Chain Rating 3880 Lbs.Tool Mounting Point 1"Depth 7"Diameter 9.8"Length 28"Weight 45 Lbs.Cable Travel 6.5 FeetCable Extension 43"Cable Diameter 5 mm

MODEL

7241-17241-27241-37241-47241-57241-67241-7

POUNDS

26-4444-6666-9999-132

132-165165-198198-220

KILOGRAMS

12-2020-3030-4545-6060-7575-9090-100

PRE-LOAD TABLE

X=5X=6X=5X=5X=4X=4X=3

“Quality and Performance that sets the Standard for the World”

6720 North 16th Street • Omaha, NE 68112-3497In Nebraska, Call (402) 451-1252

(800) 279-7326 Fax (402) 451-6513In Canada, Call (800) 443-2515

sales@packerskromer.com • www.packerskromer.com

ENGINEERING & EQUIPMENT CO., INC.

PARTS DESCRIPTIONSeries 7241

1. Nameplate, Model, Capacity2. Hanging Suspension3. Load Leveling Bolt4. Safety Chain5. Nozzle6. Rubber Buffer7. Cable Clamp8. Cable Socket9. Cable Ferrule

10. Worm11. Drum Lock12. Housing Window13. Rear Cover Disk

1

3

4

6

7

8

9

5

11

2

3

13

10

67

9

8

2

11

12

>=100m

mor

3.9"

5

7241 Series – Installation, Operating and Maintenance Instructions

PLEASE NOTE: This series replaces series 7240. All component parts areidentical except the spring and drum. Complete parts list, parts explosionand ordering information are available at www.packerskromer.com.

Packers 7241 Instructions 6/30/08 1:29 PM Page 1

KROMERTM

“Zero Gravity” Tool Balancers

FEATURES:• Floating Rotating Suspension• Recessed Safe Adjustments• Stepless Tension Adjustment• Automatic Safety Detent• Cold Rolled Containerized Spring• Locking Safety Hook

• Easy Load Leveling• Safety Drum Lock• Quick Change Cable• Safety Chain Installed• Exclusive Cable Limiter• Easy Spring Change

PHYSICAL DIMENSIONS

Rotation 360°Clearance 6"Hook Opening 15/16" IDSafety Chain Length 15"Safety Chain Rating 3880 Lbs.Tool Mounting Point 1"Depth 7"Diameter 9.8"Length 28"Weight 45 Lbs.Cable Travel 6.5 FeetCable Extension 43"Cable Diameter 5 mm

MODEL

7241-17241-27241-37241-47241-57241-67241-7

POUNDS

26-4444-6666-9999-132

132-165165-198198-220

KILOGRAMS

12-2020-3030-4545-6060-7575-9090-100

PRE-LOAD TABLE

X=5X=6X=5X=5X=4X=4X=3

“Quality and Performance that sets the Standard for the World”

6720 North 16th Street • Omaha, NE 68112-3497In Nebraska, Call (402) 451-1252

(800) 279-7326 Fax (402) 451-6513In Canada, Call (800) 443-2515

sales@packerskromer.com • www.packerskromer.com

ENGINEERING & EQUIPMENT CO., INC.

PARTS DESCRIPTIONSeries 7241

1. Nameplate, Model, Capacity2. Hanging Suspension3. Load Leveling Bolt4. Safety Chain5. Nozzle6. Rubber Buffer7. Cable Clamp8. Cable Socket9. Cable Ferrule

10. Worm11. Drum Lock12. Housing Window13. Rear Cover Disk

1

3

4

6

7

8

9

5

11

2

3

13

10

67

9

8

2

11

12

>=100m

mor

3.9"

5

7241 Series – Installation, Operating and Maintenance Instructions

PLEASE NOTE: This series replaces series 7240. All component parts areidentical except the spring and drum. Complete parts list, parts explosionand ordering information are available at www.packerskromer.com.

Packers 7241 Instructions 6/30/08 1:29 PM Page 1

SAFETY WARNINGSInstallation, service and maintenancerepairs must be carried out by qualifiedpersonnel.They should be alerted to thedangers associated with spring bal-ancers. The user must read and fullyunderstand these instructions beforeinstallation, placing the unit in service orattempting any repair. DO NOT STANDUNDER SUSPENDED LOADS.

The balancer and safety chain MUSTbe installed to structurally sound andindependent mounting points comply-ing with local safety standards, beforeplacing the unit in service. The loadleveling procedure must be followedto prevent cable and drum wear.

THE CABLE CLAMP AND RUBBERBUFFER MUST BE AGAINST THENOZZLE BEFORE ANY SERVICE ORREPAIR PROCEDURE IS SAFE.IMMEDIATELY LOCK THE DRUMAND MOVE THE CLAMP ANDBUFFER UP TO THE NOZZLE ANDTIGHTEN SECURELY BEFORE PRO-CEEDING.

DO NOT REMOVE THE LOAD ORUNLOCK THE DRUM UNLESS THECABLE IS FULLY RETRACTED.ALLOWING AN UNLOADED CABLETO RACE BACK INTO THE BAL-ANCER IS VERY DANGEROUS ANDWILL DAMAGE THE SPRING.

THE SAFETY DETENT IS AN INTE-GRAL PART OF THE SPRING CANIS-TER. IT IS MANDATORY TO REPLACETHE SPRING WITH THE 7241 VER-SION ONLY. DO NOT ATTEMPT TOOPEN THE SPRING CANISTER. IT ISVERY DANGEROUS.

THE CABLE MUST BE INSPECTEDREGULARLY AND REPLACED IMME-DIATELY IF THERE IS ANY SIGN OFDAMAGE. THE CABLE FERRULEMUST BE INSTALLED FLUSH, ONLYON THE FREE END OF THE CABLE.(Figure 1.) NEVER CRIMP THE LOADSIDE OF THE CABLE.

Do not exceed the capacity or reducetension below the minimum rating of thespring as damage will occur and dura-bility will be adversely affected.

Do not use an impact tool or high speedwhen adjusting tension. Disregardingthis warning may dislodge the worm,crack the housing or ruin the spring.

This product requires factory sup-plied replacement parts only.

INSTALLATIONSuspend the balancer from a structural-ly sound mounting point. Immediatelyattach the safety chain to an indepen-dent mounting point which prevents thebalancer from falling more than 4 inches.Rotation and floatation of the balancermust not be restricted by the safety chainor other cables and hoses. It must swingfreely so the cable and load can extendfully without creating angle friction. Toload level the balancer, loosen the boltlocated on the bottom of the hangingsuspension using an 8-mm Allenwrench. Attach the load and adjust thesuspension towards the cone or back ofthe unit until the nozzle hangs horizontaland the front cover lid is vertical with thefloor. Positioning of the suspension isdetermined by the actual weight of theload, and the maximum capacity of theunit. The chart below indicates theapproximate distance the suspensionwill be set at, from the inside edge of thefront housing cast holder.

7241- 1 approx. 8 mm7241- 2 approx. 8 mm7241- 3 approx. 8 mm7241- 4 approx. 9 mm7241- 5 approx.10 mm7241- 6 approx.11 mm

Tighten the load leveling bolt securelyand remove the load. Monitor the plasticnozzle to verify correct cable tracking onthe drum. Any sign of wear indicatesfurther adjustment to the hangingsuspension is required.

This series has 6.5 feet of cable for trav-el and 6.6 feet of external cable for loadpositioning. NEVER REDUCE SPRINGTENSION TO POSITION THE LOAD.

Positioning can be adjusted on site byremoving the trigger snap and thewedge and pushing both sides of thecable through the socket until thedesired length is obtained. THECABLE SOCKET MUST BE POSI-TIONED AT LEAST 4 INCHESBELOW THE CABLE CLAMP. Thewedge must be inserted into thesocket, and the trigger snap or safe-ty hook installed to prevent the loadfrom falling. Cut off any unused cableat least 1 inch above the socket andcrimp the cable ferrule flush, only on thefree end of the cable. THIS IS A SAFE-TY REQUIREMENT. (Figure 1)

TENSION ADJUSTMENTThis product is delivered with the maxi-mum spring tension installed. Do not

attempt to exceed the maximum ratingor operate below the minimum rating orspring damage will occur. Tension isincreased by rotating the worm clock-wise and decreased by rotating theworm counter clockwise. Determinethe total load weight including allattachments using a spring scale, and

compare to the model’s capacity print-ed on the label. The optimum perfor-mance occurs when it falls betweenthe mid and high side of the range.Refer to the “Load Range Table” toascertain the number of rotations of theshaft required to load the unit from zeroto the high side of the spring’s capacity,and therefore to unload it to zero.

Attach the load and rotate the wormcounter clockwise using a 17-mmsocket until therubber buffer falls slight-ly away from the nozzle. An accuratecounter balance has been obtainedwhen the load can be positioned any-where along the cable travel withoutincreasing or decreasing forces. If theload must retract, add tension by rotat-ing the worm clockwise until the loadretracts without effort. The upwardspring tension required to retractthe load must be overcome by theoperator and may result in repetitiveand cumulative stress injuries.Extend the load several times to allowthe adjustment to pass completelythrough the spring.

TENSION SHOULD NEVER BEADJUSTED SO HIGH THAT THERETRACTION OF THE TOOL CAUS-ES THE ENTIRE BALANCER TOBOUNCE UPWARDS FROM THESHOCK OF THE RUBBER BUFFERHITTING THE NOZZLE. THIS WILLCAUSE AN UPLOAD CONDITIONWHICH WILL RESULT IN PREMA-TURE SPRING AND/OR CABLEFAILURE. IT WILL ALSO SHOCKTHE TOOL, THE HOOK, THE SOCK-ET, AND THE WEDGE.

FABRICATING A CABLEASSEMBLYAll parts required except the ferrulemay be reused from an old cableassembly. Refer to the parts’ list todetermine the items that need to beordered. The basic cable (007.335152)has a cable ferrule compressed on theload side of the cable for anchoring inthe cable drum. Slide the rubber bufferon the free end and attach the cableclamp 6.5 feet from the ferrule. Securea new cable ferrule without crimping thecable directly below the cable clamp.

Feed the free end of the cable up andback down through the socket. Installthe wedge, pull the load and free side ofthe cable tight forcing the wedge downinto the socket and attach the lockingtrigger snap. THE CABLE SOCKETMUST BE INSTALLED AT LEAST 4INCHES BELOW THE CABLECLAMP. Slip a ferrule onto the free endof the cable for use during installation.

QUICK CHANGE CABLE PROCEDUREWhen height permits, extend the cablewith the load attached until the cablelimiter prevents further rotation of thedrum. Depress the cable limiter andextend the cable completely. Lock thedrum by depressing and rotating thedrum lock pin located on the back of thebalancer, clockwise 1/4 turn. The slot inthe drum lock pin must be turned fromleft to right and when locked remainsdepressed. Verify that the drum issecured by attempting to raise or lowerthe cable. Unhook the load, and pushthe cable upwards from below the noz-zle until the cable anchor disengagesfrom its slot in the drum and pull thecable down and out of the nozzle.Install a new cable assembly bysliding the ferrule end up through thenozzle and secure in the drum anchorslot. Reattach the load, pull down onthe cable and unlock the drum bydepressing and rotating the drum lockpin counter clockwise 1/4 turn allowingit to spring back flush to its original posi-tion. The load will retract when thedrum lock is released. If there is insuf-ficient clearance to extend the cablefully, remove the balancer to the repairarea and use a hoist.

DISASSEMBLY & REASSEMBLYWARNING AN UNLOADED CABLERACING INTO A BALANCER ISEXTREMELY DANGEROUS ANDCAN CAUSE SEVERE INJURY. THECABLE CLAMP AND RUBBERBUFFER MUST BE AGAINST THENOZZLE BEFORE ANY SERVICE ORREPAIR PROCEDURE IS SAFE. IFEXTENDED, IMMEDIATELY LOCKTHE DRUM AND MOVE THE CABLECLAMP AND BUFFER UP TO THENOZZLE AND TIGHTEN SECURELY

BEFORE PROCEEDING. Lock thedrum by depressing and rotating thedrum lock pin located on the back of thebalancer 1/4 turn clockwise. The lock-ing pin will remain depressed whenproperly engaged. A 4-mm Allenwrench is used to move the cableclamp. Once the clamp is tightenedsecurely, unlock the drum.

Use an impact driver to remove thescrews from the housing cover.Remove the housing cover and deter-mine the position of the safety detentlocated in the cut out section of thedrum. Use a 17-mm socket to rotatethe worm counter clockwise until thesafety detent releases from the outeredge of the spring into the wall of thehousing. As soon as this occurs,stop rotation of the worm.

Use an impact driver to remove thescrews from the drum lid. Continue therotation of the worm slowly until thespring canister can be moved freely.This minor adjustment of the shaft maybe required to allow the outer lip of thespring to disengage from its anchoringslot. The spring will then fall easily outof the drum. Turn the balancer facedown holding onto the housing anddrop the spring canister out. Do notcontinue reducing tension beyondthe amount necessary to release theouter lip. Do not drop the balanceronto the end of the shaft whileremoving the spring.

Place the open drum face down andremove the rear cover disc and thesnap lock ring from off the shaft. Inserta 6-x 15mm cap head screw into theend of the shaft until it bottoms out.Back out 1/4 turn, and tap on the caphead until the shaft slides out throughthe worm gear. This will prevent dam-age to the shaft. Remove the wormgear and key and rotate the housing tolift the drum and shaft out of the hous-ing. Remove the cable by sliding it upand out of its anchoring position in thedrum.

INSPECTIONInspect the housing, worm, nozzle, sus-pension, safety chain and shackle for

damage or wear. The hook shouldrotate freely, and the safety latch mustfunction properly. Wear on the nozzleindicates that the unit was improperlyload leveled, and is an indication ofdrum wear. Replace the worn nozzle sothat future wear may be monitored.Insure that all cotter pins on the sus-pension and safety shackle are secureand unbroken. Grease the suspensionand all friction parts. Lock and unlockthe drum locking pin and verify that it isfunctioning properly The drum must bereplaced if there is any indication ofwear or damage to the groves, or if thedrum wall is cracked. Verify that thecable limiter is tight and working prop-erly. Rotate the shaft to insure that thebearings rotate freely, and grease themif needed.

Examine the spring to determine if it isfunctional. The inner lip must slide intothe lip of the shaft and engage. If it willnot center in the canister, it must bereplaced. Depress the safety detent onthe outer edge of the spring canister toensure it is functioning properly. Discarda broken spring in an appropriate con-tainer for disposal. Move the cableclamp and inspect the entire cable andreplace it if there is any sign of wear.Verify that the trigger snap is workingproperly and that the cable ferrule isinstalled correctly. Lubricate all wearparts including the trigger snap and thecable with acid free grease.This will sig-nificantly improve their durability.

REPLACING THE SUSPENSIONIf the hook will not rotate freely, or thesafety latch on the hook is damaged orbroken, remove the cotter pin, and slidethe pin holder through the bushing andremove the cast holder. Replace theentire suspension with a new assemblyand loosen the load leveling pin on thecast holder with an 8-mm Allen Wrench.Inspect the safety chain and shackle pinfor damage and replace if necessary.Grease the bearing and wear parts.

REPLACING THE HOUSINGRemove the hanging suspension anddiscard the housing should there be anycracks or visible damage. The housing

and safety chain must always bereplaced in the event of suspension fail-ure. It must also be inspected carefullyfor damage in the event of spring break-age or a cable failure above the rubberbuffer where the cable drum rotated athigh speed until the safety detentreleased with severe force into the hous-ing wall. Attach the suspension to thenew housing assembly, and verify thatthe safety chain is installed securely.

REPLACING THE CABLE DRUMThe drum must be replaced if there isany indication of wear or damage to thegroves, or if the drum wall is cracked.Remove the shaft by inserting a 6-mmcap head screw into the end of the shaftand back out 1/4 turn. Tap on the caphead screw until the shaft slides out ofthe bearing. Place the shaft into thenew drum through the bearing, andinstall the bottom drum washer on thebottom of the shaft. Slide the shaft anddrum into the housing and tap lightlywith a soft mallet on the top of the shaftuntil it bottoms out in the drum. This willprevent dislodging the bearing. Afterinstalling the shaft, pack the new bear-ings with an acid free grease. Install thebottom drum washer again on the bot-tom of the shaft, and slide the drum intothe housing until the end of the shaft isflush with the outer edge of the housing.Install the worm gear into the wormgrooves and slide the shaft through theworm gear. Turn the balancer facedown keeping the shaft in place. Installthe key into the key way and verify thatthe snap ring groove on the shaft is vis-ible. Install the snap lock ring and therear cover disc nipple side down intothe key way.

REPLACING THE CABLEThe cable assembly is installed by rotat-ing the drum until the cable anchoringslot is visible in the side window of thehousing. Slide the ferrule end of thecable through the nozzle and pull itdown into the anchoring slot in thedrum. Rotate the drum counter clock-wise until the rubber buffer is near thenozzle. Watch the cable as it winds onthe drum to insure it does not crossthread and impede rotation. The cable

clamp must be positioned 6.5 feet fromthe cable ferrule to avoid over loadingthe drum. (See Cable Fabrication.)

REPLACING THE SPRINGMatch the capacity and model numberof the replacement spring with the ver-sion indicated on the housing cover. Ifconverting the model from its presentcapacity to a different version, the labelmust be replaced or the new load rangeshould be painted on the housing.

Install the new spring with the label fac-ing up. The outer lip of the spring willalways face left. Position the drum sothat the outer lip anchoring slot is posi-tioned at 12:00. Look at the outer lip ofthe spring and position it at 12:00.Determine the position of the inner lipon the spring, and rotate the worm untilthe slot on the shaft matches the spring.Guide the inner lip of the spring into theshaft while aligning the outer lip into itsanchoring slot and drop the spring con-tainer down into the drum. Install thedrum cover and housing cover usingnew lock washers. Position the housingcover so the label can be read from thefloor.

FINAL ASSEMBLYOnce the balancer is assembled, use a17-mm socket and rotate the wormclockwise until the rubber buffer is firm-ly against the nozzle. Refer to the loadrange table to determine the number ofrotations of the shaft ( X= ) required toload the balancer to the high side of therange. Mark the rear cover disc androtate the worm until the cover disc (andshaft) have been rotated according tothe instructions. Test the unit prior toreturning it to service.

7241 SAFETY, INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS

Figure 1Proper cable ferruleinstallation

Figure 2 *

Packers 7241 Instructions 6/30/08 1:29 PM Page 4

SAFETY WARNINGSInstallation, service and maintenancerepairs must be carried out by qualifiedpersonnel.They should be alerted to thedangers associated with spring bal-ancers. The user must read and fullyunderstand these instructions beforeinstallation, placing the unit in service orattempting any repair. DO NOT STANDUNDER SUSPENDED LOADS.

The balancer and safety chain MUSTbe installed to structurally sound andindependent mounting points comply-ing with local safety standards, beforeplacing the unit in service. The loadleveling procedure must be followedto prevent cable and drum wear.

THE CABLE CLAMP AND RUBBERBUFFER MUST BE AGAINST THENOZZLE BEFORE ANY SERVICE ORREPAIR PROCEDURE IS SAFE.IMMEDIATELY LOCK THE DRUMAND MOVE THE CLAMP ANDBUFFER UP TO THE NOZZLE ANDTIGHTEN SECURELY BEFORE PRO-CEEDING.

DO NOT REMOVE THE LOAD ORUNLOCK THE DRUM UNLESS THECABLE IS FULLY RETRACTED.ALLOWING AN UNLOADED CABLETO RACE BACK INTO THE BAL-ANCER IS VERY DANGEROUS ANDWILL DAMAGE THE SPRING.

THE SAFETY DETENT IS AN INTE-GRAL PART OF THE SPRING CANIS-TER. IT IS MANDATORY TO REPLACETHE SPRING WITH THE 7241 VER-SION ONLY. DO NOT ATTEMPT TOOPEN THE SPRING CANISTER. IT ISVERY DANGEROUS.

THE CABLE MUST BE INSPECTEDREGULARLY AND REPLACED IMME-DIATELY IF THERE IS ANY SIGN OFDAMAGE. THE CABLE FERRULEMUST BE INSTALLED FLUSH, ONLYON THE FREE END OF THE CABLE.(Figure 1.) NEVER CRIMP THE LOADSIDE OF THE CABLE.

Do not exceed the capacity or reducetension below the minimum rating of thespring as damage will occur and dura-bility will be adversely affected.

Do not use an impact tool or high speedwhen adjusting tension. Disregardingthis warning may dislodge the worm,crack the housing or ruin the spring.

This product requires factory sup-plied replacement parts only.

INSTALLATIONSuspend the balancer from a structural-ly sound mounting point. Immediatelyattach the safety chain to an indepen-dent mounting point which prevents thebalancer from falling more than 4 inches.Rotation and floatation of the balancermust not be restricted by the safety chainor other cables and hoses. It must swingfreely so the cable and load can extendfully without creating angle friction. Toload level the balancer, loosen the boltlocated on the bottom of the hangingsuspension using an 8-mm Allenwrench. Attach the load and adjust thesuspension towards the cone or back ofthe unit until the nozzle hangs horizontaland the front cover lid is vertical with thefloor. Positioning of the suspension isdetermined by the actual weight of theload, and the maximum capacity of theunit. The chart below indicates theapproximate distance the suspensionwill be set at, from the inside edge of thefront housing cast holder.

7241- 1 approx. 8 mm7241- 2 approx. 8 mm7241- 3 approx. 8 mm7241- 4 approx. 9 mm7241- 5 approx.10 mm7241- 6 approx.11 mm

Tighten the load leveling bolt securelyand remove the load. Monitor the plasticnozzle to verify correct cable tracking onthe drum. Any sign of wear indicatesfurther adjustment to the hangingsuspension is required.

This series has 6.5 feet of cable for trav-el and 6.6 feet of external cable for loadpositioning. NEVER REDUCE SPRINGTENSION TO POSITION THE LOAD.

Positioning can be adjusted on site byremoving the trigger snap and thewedge and pushing both sides of thecable through the socket until thedesired length is obtained. THECABLE SOCKET MUST BE POSI-TIONED AT LEAST 4 INCHESBELOW THE CABLE CLAMP. Thewedge must be inserted into thesocket, and the trigger snap or safe-ty hook installed to prevent the loadfrom falling. Cut off any unused cableat least 1 inch above the socket andcrimp the cable ferrule flush, only on thefree end of the cable. THIS IS A SAFE-TY REQUIREMENT. (Figure 1)

TENSION ADJUSTMENTThis product is delivered with the maxi-mum spring tension installed. Do not

attempt to exceed the maximum ratingor operate below the minimum rating orspring damage will occur. Tension isincreased by rotating the worm clock-wise and decreased by rotating theworm counter clockwise. Determinethe total load weight including allattachments using a spring scale, and

compare to the model’s capacity print-ed on the label. The optimum perfor-mance occurs when it falls betweenthe mid and high side of the range.Refer to the “Load Range Table” toascertain the number of rotations of theshaft required to load the unit from zeroto the high side of the spring’s capacity,and therefore to unload it to zero.

Attach the load and rotate the wormcounter clockwise using a 17-mmsocket until therubber buffer falls slight-ly away from the nozzle. An accuratecounter balance has been obtainedwhen the load can be positioned any-where along the cable travel withoutincreasing or decreasing forces. If theload must retract, add tension by rotat-ing the worm clockwise until the loadretracts without effort. The upwardspring tension required to retractthe load must be overcome by theoperator and may result in repetitiveand cumulative stress injuries.Extend the load several times to allowthe adjustment to pass completelythrough the spring.

TENSION SHOULD NEVER BEADJUSTED SO HIGH THAT THERETRACTION OF THE TOOL CAUS-ES THE ENTIRE BALANCER TOBOUNCE UPWARDS FROM THESHOCK OF THE RUBBER BUFFERHITTING THE NOZZLE. THIS WILLCAUSE AN UPLOAD CONDITIONWHICH WILL RESULT IN PREMA-TURE SPRING AND/OR CABLEFAILURE. IT WILL ALSO SHOCKTHE TOOL, THE HOOK, THE SOCK-ET, AND THE WEDGE.

FABRICATING A CABLEASSEMBLYAll parts required except the ferrulemay be reused from an old cableassembly. Refer to the parts’ list todetermine the items that need to beordered. The basic cable (007.335152)has a cable ferrule compressed on theload side of the cable for anchoring inthe cable drum. Slide the rubber bufferon the free end and attach the cableclamp 6.5 feet from the ferrule. Securea new cable ferrule without crimping thecable directly below the cable clamp.

Feed the free end of the cable up andback down through the socket. Installthe wedge, pull the load and free side ofthe cable tight forcing the wedge downinto the socket and attach the lockingtrigger snap. THE CABLE SOCKETMUST BE INSTALLED AT LEAST 4INCHES BELOW THE CABLECLAMP. Slip a ferrule onto the free endof the cable for use during installation.

QUICK CHANGE CABLE PROCEDUREWhen height permits, extend the cablewith the load attached until the cablelimiter prevents further rotation of thedrum. Depress the cable limiter andextend the cable completely. Lock thedrum by depressing and rotating thedrum lock pin located on the back of thebalancer, clockwise 1/4 turn. The slot inthe drum lock pin must be turned fromleft to right and when locked remainsdepressed. Verify that the drum issecured by attempting to raise or lowerthe cable. Unhook the load, and pushthe cable upwards from below the noz-zle until the cable anchor disengagesfrom its slot in the drum and pull thecable down and out of the nozzle.Install a new cable assembly bysliding the ferrule end up through thenozzle and secure in the drum anchorslot. Reattach the load, pull down onthe cable and unlock the drum bydepressing and rotating the drum lockpin counter clockwise 1/4 turn allowingit to spring back flush to its original posi-tion. The load will retract when thedrum lock is released. If there is insuf-ficient clearance to extend the cablefully, remove the balancer to the repairarea and use a hoist.

DISASSEMBLY & REASSEMBLYWARNING AN UNLOADED CABLERACING INTO A BALANCER ISEXTREMELY DANGEROUS ANDCAN CAUSE SEVERE INJURY. THECABLE CLAMP AND RUBBERBUFFER MUST BE AGAINST THENOZZLE BEFORE ANY SERVICE ORREPAIR PROCEDURE IS SAFE. IFEXTENDED, IMMEDIATELY LOCKTHE DRUM AND MOVE THE CABLECLAMP AND BUFFER UP TO THENOZZLE AND TIGHTEN SECURELY

BEFORE PROCEEDING. Lock thedrum by depressing and rotating thedrum lock pin located on the back of thebalancer 1/4 turn clockwise. The lock-ing pin will remain depressed whenproperly engaged. A 4-mm Allenwrench is used to move the cableclamp. Once the clamp is tightenedsecurely, unlock the drum.

Use an impact driver to remove thescrews from the housing cover.Remove the housing cover and deter-mine the position of the safety detentlocated in the cut out section of thedrum. Use a 17-mm socket to rotatethe worm counter clockwise until thesafety detent releases from the outeredge of the spring into the wall of thehousing. As soon as this occurs,stop rotation of the worm.

Use an impact driver to remove thescrews from the drum lid. Continue therotation of the worm slowly until thespring canister can be moved freely.This minor adjustment of the shaft maybe required to allow the outer lip of thespring to disengage from its anchoringslot. The spring will then fall easily outof the drum. Turn the balancer facedown holding onto the housing anddrop the spring canister out. Do notcontinue reducing tension beyondthe amount necessary to release theouter lip. Do not drop the balanceronto the end of the shaft whileremoving the spring.

Place the open drum face down andremove the rear cover disc and thesnap lock ring from off the shaft. Inserta 6-x 15mm cap head screw into theend of the shaft until it bottoms out.Back out 1/4 turn, and tap on the caphead until the shaft slides out throughthe worm gear. This will prevent dam-age to the shaft. Remove the wormgear and key and rotate the housing tolift the drum and shaft out of the hous-ing. Remove the cable by sliding it upand out of its anchoring position in thedrum.

INSPECTIONInspect the housing, worm, nozzle, sus-pension, safety chain and shackle for

damage or wear. The hook shouldrotate freely, and the safety latch mustfunction properly. Wear on the nozzleindicates that the unit was improperlyload leveled, and is an indication ofdrum wear. Replace the worn nozzle sothat future wear may be monitored.Insure that all cotter pins on the sus-pension and safety shackle are secureand unbroken. Grease the suspensionand all friction parts. Lock and unlockthe drum locking pin and verify that it isfunctioning properly The drum must bereplaced if there is any indication ofwear or damage to the groves, or if thedrum wall is cracked. Verify that thecable limiter is tight and working prop-erly. Rotate the shaft to insure that thebearings rotate freely, and grease themif needed.

Examine the spring to determine if it isfunctional. The inner lip must slide intothe lip of the shaft and engage. If it willnot center in the canister, it must bereplaced. Depress the safety detent onthe outer edge of the spring canister toensure it is functioning properly. Discarda broken spring in an appropriate con-tainer for disposal. Move the cableclamp and inspect the entire cable andreplace it if there is any sign of wear.Verify that the trigger snap is workingproperly and that the cable ferrule isinstalled correctly. Lubricate all wearparts including the trigger snap and thecable with acid free grease.This will sig-nificantly improve their durability.

REPLACING THE SUSPENSIONIf the hook will not rotate freely, or thesafety latch on the hook is damaged orbroken, remove the cotter pin, and slidethe pin holder through the bushing andremove the cast holder. Replace theentire suspension with a new assemblyand loosen the load leveling pin on thecast holder with an 8-mm Allen Wrench.Inspect the safety chain and shackle pinfor damage and replace if necessary.Grease the bearing and wear parts.

REPLACING THE HOUSINGRemove the hanging suspension anddiscard the housing should there be anycracks or visible damage. The housing

and safety chain must always bereplaced in the event of suspension fail-ure. It must also be inspected carefullyfor damage in the event of spring break-age or a cable failure above the rubberbuffer where the cable drum rotated athigh speed until the safety detentreleased with severe force into the hous-ing wall. Attach the suspension to thenew housing assembly, and verify thatthe safety chain is installed securely.

REPLACING THE CABLE DRUMThe drum must be replaced if there isany indication of wear or damage to thegroves, or if the drum wall is cracked.Remove the shaft by inserting a 6-mmcap head screw into the end of the shaftand back out 1/4 turn. Tap on the caphead screw until the shaft slides out ofthe bearing. Place the shaft into thenew drum through the bearing, andinstall the bottom drum washer on thebottom of the shaft. Slide the shaft anddrum into the housing and tap lightlywith a soft mallet on the top of the shaftuntil it bottoms out in the drum. This willprevent dislodging the bearing. Afterinstalling the shaft, pack the new bear-ings with an acid free grease. Install thebottom drum washer again on the bot-tom of the shaft, and slide the drum intothe housing until the end of the shaft isflush with the outer edge of the housing.Install the worm gear into the wormgrooves and slide the shaft through theworm gear. Turn the balancer facedown keeping the shaft in place. Installthe key into the key way and verify thatthe snap ring groove on the shaft is vis-ible. Install the snap lock ring and therear cover disc nipple side down intothe key way.

REPLACING THE CABLEThe cable assembly is installed by rotat-ing the drum until the cable anchoringslot is visible in the side window of thehousing. Slide the ferrule end of thecable through the nozzle and pull itdown into the anchoring slot in thedrum. Rotate the drum counter clock-wise until the rubber buffer is near thenozzle. Watch the cable as it winds onthe drum to insure it does not crossthread and impede rotation. The cable

clamp must be positioned 6.5 feet fromthe cable ferrule to avoid over loadingthe drum. (See Cable Fabrication.)

REPLACING THE SPRINGMatch the capacity and model numberof the replacement spring with the ver-sion indicated on the housing cover. Ifconverting the model from its presentcapacity to a different version, the labelmust be replaced or the new load rangeshould be painted on the housing.

Install the new spring with the label fac-ing up. The outer lip of the spring willalways face left. Position the drum sothat the outer lip anchoring slot is posi-tioned at 12:00. Look at the outer lip ofthe spring and position it at 12:00.Determine the position of the inner lipon the spring, and rotate the worm untilthe slot on the shaft matches the spring.Guide the inner lip of the spring into theshaft while aligning the outer lip into itsanchoring slot and drop the spring con-tainer down into the drum. Install thedrum cover and housing cover usingnew lock washers. Position the housingcover so the label can be read from thefloor.

FINAL ASSEMBLYOnce the balancer is assembled, use a17-mm socket and rotate the wormclockwise until the rubber buffer is firm-ly against the nozzle. Refer to the loadrange table to determine the number ofrotations of the shaft ( X= ) required toload the balancer to the high side of therange. Mark the rear cover disc androtate the worm until the cover disc (andshaft) have been rotated according tothe instructions. Test the unit prior toreturning it to service.

7241 SAFETY, INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS

Figure 1Proper cable ferruleinstallation

Figure 2 *

Packers 7241 Instructions 6/30/08 1:29 PM Page 4

SAFETY WARNINGSInstallation, service and maintenancerepairs must be carried out by qualifiedpersonnel.They should be alerted to thedangers associated with spring bal-ancers. The user must read and fullyunderstand these instructions beforeinstallation, placing the unit in service orattempting any repair. DO NOT STANDUNDER SUSPENDED LOADS.

The balancer and safety chain MUSTbe installed to structurally sound andindependent mounting points comply-ing with local safety standards, beforeplacing the unit in service. The loadleveling procedure must be followedto prevent cable and drum wear.

THE CABLE CLAMP AND RUBBERBUFFER MUST BE AGAINST THENOZZLE BEFORE ANY SERVICE ORREPAIR PROCEDURE IS SAFE.IMMEDIATELY LOCK THE DRUMAND MOVE THE CLAMP ANDBUFFER UP TO THE NOZZLE ANDTIGHTEN SECURELY BEFORE PRO-CEEDING.

DO NOT REMOVE THE LOAD ORUNLOCK THE DRUM UNLESS THECABLE IS FULLY RETRACTED.ALLOWING AN UNLOADED CABLETO RACE BACK INTO THE BAL-ANCER IS VERY DANGEROUS ANDWILL DAMAGE THE SPRING.

THE SAFETY DETENT IS AN INTE-GRAL PART OF THE SPRING CANIS-TER. IT IS MANDATORY TO REPLACETHE SPRING WITH THE 7241 VER-SION ONLY. DO NOT ATTEMPT TOOPEN THE SPRING CANISTER. IT ISVERY DANGEROUS.

THE CABLE MUST BE INSPECTEDREGULARLY AND REPLACED IMME-DIATELY IF THERE IS ANY SIGN OFDAMAGE. THE CABLE FERRULEMUST BE INSTALLED FLUSH, ONLYON THE FREE END OF THE CABLE.(Figure 1.) NEVER CRIMP THE LOADSIDE OF THE CABLE.

Do not exceed the capacity or reducetension below the minimum rating of thespring as damage will occur and dura-bility will be adversely affected.

Do not use an impact tool or high speedwhen adjusting tension. Disregardingthis warning may dislodge the worm,crack the housing or ruin the spring.

This product requires factory sup-plied replacement parts only.

INSTALLATIONSuspend the balancer from a structural-ly sound mounting point. Immediatelyattach the safety chain to an indepen-dent mounting point which prevents thebalancer from falling more than 4 inches.Rotation and floatation of the balancermust not be restricted by the safety chainor other cables and hoses. It must swingfreely so the cable and load can extendfully without creating angle friction. Toload level the balancer, loosen the boltlocated on the bottom of the hangingsuspension using an 8-mm Allenwrench. Attach the load and adjust thesuspension towards the cone or back ofthe unit until the nozzle hangs horizontaland the front cover lid is vertical with thefloor. Positioning of the suspension isdetermined by the actual weight of theload, and the maximum capacity of theunit. The chart below indicates theapproximate distance the suspensionwill be set at, from the inside edge of thefront housing cast holder.

7241- 1 approx. 8 mm7241- 2 approx. 8 mm7241- 3 approx. 8 mm7241- 4 approx. 9 mm7241- 5 approx.10 mm7241- 6 approx.11 mm

Tighten the load leveling bolt securelyand remove the load. Monitor the plasticnozzle to verify correct cable tracking onthe drum. Any sign of wear indicatesfurther adjustment to the hangingsuspension is required.

This series has 6.5 feet of cable for trav-el and 6.6 feet of external cable for loadpositioning. NEVER REDUCE SPRINGTENSION TO POSITION THE LOAD.

Positioning can be adjusted on site byremoving the trigger snap and thewedge and pushing both sides of thecable through the socket until thedesired length is obtained. THECABLE SOCKET MUST BE POSI-TIONED AT LEAST 4 INCHESBELOW THE CABLE CLAMP. Thewedge must be inserted into thesocket, and the trigger snap or safe-ty hook installed to prevent the loadfrom falling. Cut off any unused cableat least 1 inch above the socket andcrimp the cable ferrule flush, only on thefree end of the cable. THIS IS A SAFE-TY REQUIREMENT. (Figure 1)

TENSION ADJUSTMENTThis product is delivered with the maxi-mum spring tension installed. Do not

attempt to exceed the maximum ratingor operate below the minimum rating orspring damage will occur. Tension isincreased by rotating the worm clock-wise and decreased by rotating theworm counter clockwise. Determinethe total load weight including allattachments using a spring scale, and

compare to the model’s capacity print-ed on the label. The optimum perfor-mance occurs when it falls betweenthe mid and high side of the range.Refer to the “Load Range Table” toascertain the number of rotations of theshaft required to load the unit from zeroto the high side of the spring’s capacity,and therefore to unload it to zero.

Attach the load and rotate the wormcounter clockwise using a 17-mmsocket until therubber buffer falls slight-ly away from the nozzle. An accuratecounter balance has been obtainedwhen the load can be positioned any-where along the cable travel withoutincreasing or decreasing forces. If theload must retract, add tension by rotat-ing the worm clockwise until the loadretracts without effort. The upwardspring tension required to retractthe load must be overcome by theoperator and may result in repetitiveand cumulative stress injuries.Extend the load several times to allowthe adjustment to pass completelythrough the spring.

TENSION SHOULD NEVER BEADJUSTED SO HIGH THAT THERETRACTION OF THE TOOL CAUS-ES THE ENTIRE BALANCER TOBOUNCE UPWARDS FROM THESHOCK OF THE RUBBER BUFFERHITTING THE NOZZLE. THIS WILLCAUSE AN UPLOAD CONDITIONWHICH WILL RESULT IN PREMA-TURE SPRING AND/OR CABLEFAILURE. IT WILL ALSO SHOCKTHE TOOL, THE HOOK, THE SOCK-ET, AND THE WEDGE.

FABRICATING A CABLEASSEMBLYAll parts required except the ferrulemay be reused from an old cableassembly. Refer to the parts’ list todetermine the items that need to beordered. The basic cable (007.335152)has a cable ferrule compressed on theload side of the cable for anchoring inthe cable drum. Slide the rubber bufferon the free end and attach the cableclamp 6.5 feet from the ferrule. Securea new cable ferrule without crimping thecable directly below the cable clamp.

Feed the free end of the cable up andback down through the socket. Installthe wedge, pull the load and free side ofthe cable tight forcing the wedge downinto the socket and attach the lockingtrigger snap. THE CABLE SOCKETMUST BE INSTALLED AT LEAST 4INCHES BELOW THE CABLECLAMP. Slip a ferrule onto the free endof the cable for use during installation.

QUICK CHANGE CABLE PROCEDUREWhen height permits, extend the cablewith the load attached until the cablelimiter prevents further rotation of thedrum. Depress the cable limiter andextend the cable completely. Lock thedrum by depressing and rotating thedrum lock pin located on the back of thebalancer, clockwise 1/4 turn. The slot inthe drum lock pin must be turned fromleft to right and when locked remainsdepressed. Verify that the drum issecured by attempting to raise or lowerthe cable. Unhook the load, and pushthe cable upwards from below the noz-zle until the cable anchor disengagesfrom its slot in the drum and pull thecable down and out of the nozzle.Install a new cable assembly bysliding the ferrule end up through thenozzle and secure in the drum anchorslot. Reattach the load, pull down onthe cable and unlock the drum bydepressing and rotating the drum lockpin counter clockwise 1/4 turn allowingit to spring back flush to its original posi-tion. The load will retract when thedrum lock is released. If there is insuf-ficient clearance to extend the cablefully, remove the balancer to the repairarea and use a hoist.

DISASSEMBLY & REASSEMBLYWARNING AN UNLOADED CABLERACING INTO A BALANCER ISEXTREMELY DANGEROUS ANDCAN CAUSE SEVERE INJURY. THECABLE CLAMP AND RUBBERBUFFER MUST BE AGAINST THENOZZLE BEFORE ANY SERVICE ORREPAIR PROCEDURE IS SAFE. IFEXTENDED, IMMEDIATELY LOCKTHE DRUM AND MOVE THE CABLECLAMP AND BUFFER UP TO THENOZZLE AND TIGHTEN SECURELY

BEFORE PROCEEDING. Lock thedrum by depressing and rotating thedrum lock pin located on the back of thebalancer 1/4 turn clockwise. The lock-ing pin will remain depressed whenproperly engaged. A 4-mm Allenwrench is used to move the cableclamp. Once the clamp is tightenedsecurely, unlock the drum.

Use an impact driver to remove thescrews from the housing cover.Remove the housing cover and deter-mine the position of the safety detentlocated in the cut out section of thedrum. Use a 17-mm socket to rotatethe worm counter clockwise until thesafety detent releases from the outeredge of the spring into the wall of thehousing. As soon as this occurs,stop rotation of the worm.

Use an impact driver to remove thescrews from the drum lid. Continue therotation of the worm slowly until thespring canister can be moved freely.This minor adjustment of the shaft maybe required to allow the outer lip of thespring to disengage from its anchoringslot. The spring will then fall easily outof the drum. Turn the balancer facedown holding onto the housing anddrop the spring canister out. Do notcontinue reducing tension beyondthe amount necessary to release theouter lip. Do not drop the balanceronto the end of the shaft whileremoving the spring.

Place the open drum face down andremove the rear cover disc and thesnap lock ring from off the shaft. Inserta 6-x 15mm cap head screw into theend of the shaft until it bottoms out.Back out 1/4 turn, and tap on the caphead until the shaft slides out throughthe worm gear. This will prevent dam-age to the shaft. Remove the wormgear and key and rotate the housing tolift the drum and shaft out of the hous-ing. Remove the cable by sliding it upand out of its anchoring position in thedrum.

INSPECTIONInspect the housing, worm, nozzle, sus-pension, safety chain and shackle for

damage or wear. The hook shouldrotate freely, and the safety latch mustfunction properly. Wear on the nozzleindicates that the unit was improperlyload leveled, and is an indication ofdrum wear. Replace the worn nozzle sothat future wear may be monitored.Insure that all cotter pins on the sus-pension and safety shackle are secureand unbroken. Grease the suspensionand all friction parts. Lock and unlockthe drum locking pin and verify that it isfunctioning properly The drum must bereplaced if there is any indication ofwear or damage to the groves, or if thedrum wall is cracked. Verify that thecable limiter is tight and working prop-erly. Rotate the shaft to insure that thebearings rotate freely, and grease themif needed.

Examine the spring to determine if it isfunctional. The inner lip must slide intothe lip of the shaft and engage. If it willnot center in the canister, it must bereplaced. Depress the safety detent onthe outer edge of the spring canister toensure it is functioning properly. Discarda broken spring in an appropriate con-tainer for disposal. Move the cableclamp and inspect the entire cable andreplace it if there is any sign of wear.Verify that the trigger snap is workingproperly and that the cable ferrule isinstalled correctly. Lubricate all wearparts including the trigger snap and thecable with acid free grease.This will sig-nificantly improve their durability.

REPLACING THE SUSPENSIONIf the hook will not rotate freely, or thesafety latch on the hook is damaged orbroken, remove the cotter pin, and slidethe pin holder through the bushing andremove the cast holder. Replace theentire suspension with a new assemblyand loosen the load leveling pin on thecast holder with an 8-mm Allen Wrench.Inspect the safety chain and shackle pinfor damage and replace if necessary.Grease the bearing and wear parts.

REPLACING THE HOUSINGRemove the hanging suspension anddiscard the housing should there be anycracks or visible damage. The housing

and safety chain must always bereplaced in the event of suspension fail-ure. It must also be inspected carefullyfor damage in the event of spring break-age or a cable failure above the rubberbuffer where the cable drum rotated athigh speed until the safety detentreleased with severe force into the hous-ing wall. Attach the suspension to thenew housing assembly, and verify thatthe safety chain is installed securely.

REPLACING THE CABLE DRUMThe drum must be replaced if there isany indication of wear or damage to thegroves, or if the drum wall is cracked.Remove the shaft by inserting a 6-mmcap head screw into the end of the shaftand back out 1/4 turn. Tap on the caphead screw until the shaft slides out ofthe bearing. Place the shaft into thenew drum through the bearing, andinstall the bottom drum washer on thebottom of the shaft. Slide the shaft anddrum into the housing and tap lightlywith a soft mallet on the top of the shaftuntil it bottoms out in the drum. This willprevent dislodging the bearing. Afterinstalling the shaft, pack the new bear-ings with an acid free grease. Install thebottom drum washer again on the bot-tom of the shaft, and slide the drum intothe housing until the end of the shaft isflush with the outer edge of the housing.Install the worm gear into the wormgrooves and slide the shaft through theworm gear. Turn the balancer facedown keeping the shaft in place. Installthe key into the key way and verify thatthe snap ring groove on the shaft is vis-ible. Install the snap lock ring and therear cover disc nipple side down intothe key way.

REPLACING THE CABLEThe cable assembly is installed by rotat-ing the drum until the cable anchoringslot is visible in the side window of thehousing. Slide the ferrule end of thecable through the nozzle and pull itdown into the anchoring slot in thedrum. Rotate the drum counter clock-wise until the rubber buffer is near thenozzle. Watch the cable as it winds onthe drum to insure it does not crossthread and impede rotation. The cable

clamp must be positioned 6.5 feet fromthe cable ferrule to avoid over loadingthe drum. (See Cable Fabrication.)

REPLACING THE SPRINGMatch the capacity and model numberof the replacement spring with the ver-sion indicated on the housing cover. Ifconverting the model from its presentcapacity to a different version, the labelmust be replaced or the new load rangeshould be painted on the housing.

Install the new spring with the label fac-ing up. The outer lip of the spring willalways face left. Position the drum sothat the outer lip anchoring slot is posi-tioned at 12:00. Look at the outer lip ofthe spring and position it at 12:00.Determine the position of the inner lipon the spring, and rotate the worm untilthe slot on the shaft matches the spring.Guide the inner lip of the spring into theshaft while aligning the outer lip into itsanchoring slot and drop the spring con-tainer down into the drum. Install thedrum cover and housing cover usingnew lock washers. Position the housingcover so the label can be read from thefloor.

FINAL ASSEMBLYOnce the balancer is assembled, use a17-mm socket and rotate the wormclockwise until the rubber buffer is firm-ly against the nozzle. Refer to the loadrange table to determine the number ofrotations of the shaft ( X= ) required toload the balancer to the high side of therange. Mark the rear cover disc androtate the worm until the cover disc (andshaft) have been rotated according tothe instructions. Test the unit prior toreturning it to service.

7241 SAFETY, INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS

Figure 1Proper cable ferruleinstallation

Figure 2 *

Packers 7241 Instructions 6/30/08 1:29 PM Page 4