Atlas Copco WP40 Instruction sheet

WP40
Printed Matter No. 9836 9796 02 Balancer
2011-07-01 Product Instructions
WP 40-100 8202 0782 00
WP 40-115 8202 0782 01
WP 40-130 8202 0782 02
WP 40-140 8202 0782 03
WARNING
Read all safety warnings and instructions
Failure to follow the safety warnings and in-
structions may result in electric shock, fire and/
or serious injury.
Save all warnings and instructions for future
reference

2© Atlas Copco Industrial Technique AB - 9836 979602 02
Table of Contents
EN Product Instructions.......................................................................... 3

WP40 EN Safety and operating instructions
© Atlas Copco Industrial Technique AB - 9836 979602 02 3
Safety and operating instructions
Safety instructions
Safety instructions
• To reduce risk of injury, everyone using, installing, repairing, maintaining,
changing accessories on, or working near this balancer must read and under-
stand these instructions before performing any such task.
• Our goal is to produce tools that help you work safely and efficiently. The
most important safety device for this or any tool is YOU. Your care and
good judgement are the best protection against injury. All possible hazards
cannot be covered here, but we have tried to highlight some of the important
ones.
• Only qualified and trained operators should install, adjust or use this bal-
ancer.
• No changes may be made on the balancer or its accessories without the ex-
press written permission of the manufacturer.
• The safe use of these products is only ensured if you have fully read these
operating and safety instructions and strictly observe them during work.
• Hook or unhook the load only when the cable is fully retracted.
• The fixture(s) on which the balancer and the safety chain are installed must
be sufficiently stable.
• The balancer cable must be checked for potential damage at regular inter-
vals – at least once a year – by a competent person. Never use a balancer
when the cable is defective.
• The suspension, the anti-crash safety device and the safety chain must be
monitored continuously. If damage or wear is detected, withdraw the bal-
ancer from service at once.
• Please note that the cable can easily get displaced from its coupling if it is
moved backwards, or snaps back, in no-load condition during installation.
An incorrectly anchored cable can slip out under load and cause bodily in-
juries or other damage due to the load crashing down.
• Except for cable replacement (see section “Replacing the cable”), the spring
tension must be fully released before performing any service or repair work.
Disassembling the spring housing is extremely dangerous and therefore
strictly forbidden.
• It is strictly forbidden to operate the balancer without the safety components
supplied (safety chain, spring fracture safeguard, etc.).
• A safety chain strained by a falling balancer must be replaced at once, to-
gether with the balancer’s housing.
For additional safety information consult:
• Other documents and information packed with this tool.
• Your employer, union and / or trade association.
• “Safety Code for Portable Air Tools” (ANSI B186.1), available at the time
of printing from Global Engineering Documents at http://global.ihs.com/ ,
or call 1 800 854 7179. In case of difficulty in obtaining ANSI standards,
contact ANSI via http://www.ansi.org/

Safety and operating instructions EN WP40
4© Atlas Copco Industrial Technique AB - 9836 979602 02
• Further occupational health and safety information can be obtained from the
following web sites:
http://www.osha.gov (USA)
http://europe.osha.eu.int (Europe)
Installation hazards
• Make sure the balancer suspension method and supports have a minimum
safety factor of five times the combined maximum load capacity plus bal-
ancer weight.
• Attach an additional support cable or chain to a support independent of the
one holding the balancer.
• Examine the suspension hooks, cable and chain for wear. Replace any worn
parts before installation.
Use Hazards
• Examine suspension hooks, cables, cable stops and chains daily for wear.
Replace worn parts before further use.
• Never lift people or lift loads over people.
• Never use balancer cable or chain as a sling.
• Load chain must not be twisted, kinked or damaged when lifting a load.
• Centre balancer over load before lifting.
• Operators must be physically able to manoeuvre the balancer.
Workplace Hazards
• Slip/Trip/Fall is a major cause of serious injury or death. Be aware of excess
hose left on the walking or work surface.
• Hard hats are recommended in areas where balancers are in use.
• Proceed with care in unfamiliar surroundings. Be aware of potential hazards
created by your work activity.
• Balancers are not insulated from coming into contact with electric power
sources and are not intended for use in potentially explosive atmospheres.
Maintenance and repair hazards
• Read and understand instruction and parts book before servicing this prod-
uct.
• Maintenance personnel must be physically able to handle the bulk and
weight of the balancer.
• This product and its accessories must not be modified.
General information
General
• The balancer is used for relieving the weight of hand-held tools.
• The balancer makes using a hand-operated tools much easier.

WP40 EN Safety and operating instructions
© Atlas Copco Industrial Technique AB - 9836 979602 02 5
• The retraction forces remains nearly constant over the whole cable exten-
sion length.
• The load range differs depending on model, as per the nameplate.
EC DECLARATION OF CONFORMITY
We, Atlas Copco Industrial Technique AB, S-105 23 STOCKHOLM, SWE-
DEN declare that the product (with name, type and serial number, see front
page) is in conformity with the following Directive(s):
2006/42/EC
Harmonised standards applied:
EN ISO 12100
Technical file available from:
Quality Manager, Atlas Copco Industrial Technique, Stockholm, Sweden
Stockholm, 1 July 2013
Tobias Hahn, Managing Director
Signature of issuer
Installation
Installation
Prior to installing the balancer, verify that the suspension structure to which the
balancer and its safety chain are fastened provide adequate stability.
To install the balancer, be sure to proceed as follows:
• Via the safety suspension, suspend the balancer so that it can be easily
aligned and moved in any working direction.
• It is mandatory to mount the supplied safety chain in addition to the safety
suspension. Note that the maximum falling distance permitted is 100 mm! It
must be guaranteed that the anti-crash safety device does not interfere with
the balancer across its entire working range.
• Attach the load to the screw-type spring hook installed at the cable end, then
close the hook and screw the knurled lock nut in place.
• Adjust the balancer to the working load (see section “Adjusting the working
load”).
Adjusting the cable length
The balancer is delivered from the factory with a long cable, so that the cable
length can be individually adjusted to the onsite circumstances. Adjusting the
cable length is done with the cable wedge (7). After lengthening or shortening
the cable, the free cable end must be compressed with the supplied ferrule (8)
(or a clamp in accordance with DIN 3093 Pts. 1 to 3); the projecting cable end
must then be cut off flush.
A minimum distance of 100 mm must be maintained between the cable
clamp (6) and the cable wedge (7).

Safety and operating instructions EN WP40
6© Atlas Copco Industrial Technique AB - 9836 979602 02
Adjusting the suspension
Fine adjustment of the suspension is possible to ensure low-wear cable and
drum operation. To this end, adjust the suspension hook along the bolt so that
the balancer is suspended in a more or less horizontal position within the work-
ing area.
The hook distance to be maintained on the left above the housing slot should be
as follows for the various load ranges, relative to the specified maximum load
(factory setting):
8202 0782 00 = aprox. 1 mm
8202 0782 01 = aprox. 1 mm
8202 0782 02 = aprox. 1 mm
8202 0782 03 = aprox. 1 mm
Proceed as follows: Loosen the suspension’s clamping screw (3), move the sus-
pension appropriately, then retighten the clamping screw (3).
Adjusting the working load
The balancer has been factory-preset to the maximum load permissible for the
type/model in question.
• After attaching the load, apply a size-19 socket spanner/ wrench to the end-
less screw (9), then rotate the spanner in the direction of the “-” symbol until
the weight of the suspended working load is exactly counterbalanced.
• When setting the minimum load, never extend the cable beyond a length of
1.5 m, as otherwise the spring fracture safeguard may be tripped. In case the
safeguard mechanism has already been activated, first carefully preload the
spring in the “+” direction as far as it will go (the spring is now fully “on
block”), then adjust the tension again to the working load by rotating the
endless screw (9) in the “-” direction.
• To prevent spring destruction, do not slacken it too much! Full spring re-
lease is permitted only if no load is connected!
• Infinitely variable load adjustment is possible within the balancer’s load
range (see rating plate (1) for details). To adjust to lighter working loads,
simply rotate the endless screw (9) in the “-” direction; for heavier loads, ro-
tate it in the “+” direction. Note that the balancer may not be operated out-
side the working range indicated on the rating plate!
The manual drum lock should never be used for load replacement!
Cable stop buffer / Setting the cable extension
The cable stop buffer can be moved simply by moving the flexible cable stop
buffer and the cable clamp. The cable clamp should be secured each time.
WARNING The maximum cable extension length must not be exceeded
(even with a cable extension).
Drum lock
The drum lock (10) allows you to block the drum for cable replacement, with-
out any need to unload the spring (see description under Replacing the cable).

WP40 EN Safety and operating instructions
© Atlas Copco Industrial Technique AB - 9836 979602 02 7
Maintenance
Servicing / Inspection
The balancer must be serviced continuously. All external moving parts as well
as the friction points on the suspension and spring hook must be greased. For
cable care, we recommend non-corrosive grease because it significantly in-
creases the cable’s useful life.
The suspension, the safety chain, the spring hook and the cable must be moni-
tored continuously and needs to be checked by a competent person at least once
a year. If damage (such as broken strands, “cage-type” bulging, flattened places
or abrasion) is found on the cable, or if any of the above-mentioned parts show
significant signs of wear and tear, the balancer must be withdrawn from service
and replaced immediately. Should the cable, spring or other parts of the bal-
ancer need to be replaced, pre-assembled replacement sets are available.
Maintenance
The following sections refer exclusively to our pre-assembled replacement sets:
cable, spring & cable drum, housing, and suspension. Be sure to use only gen-
uine spare parts for replacement.
When replacing any of the above-mentioned components, always follow the
Operating Instructions supplied with the product.
Changing the cable
With this balancer it is possible to change the cable without releasing the spring
and without dismantling the device.
The “cable complete” replacement part set consists of the cable with a presse-
don clamp on the on the cable coupling, a separately enclosed brass bush, the
cable stop buffer with rubber ball and cable clamp, plus the pre-assembled ca-
ble socket with wedge and a ferrule for pressing onto the free cable end after
adjusting the cable length, supplied loose.
Pull the cable out of the housing as far as possible. (The cable coupling is visi-
ble in the lower part of the aperture in the housing.) Lock the cable drum by
turning the fixing pin (pin with elongated slot on the small housing diameter) is
pressed in with a screwdriver and in this position is turned optionally right or
left through 90°.
Ensure that the cable drum is securely locked. Snapping back of the cable
in a no-load condition by unlocking the cable drum can lead to injuries and
cause the spring to be destroyed.
Push the cable upwards out of the cable drum, remove the bush from the cable
and pull the cable downwards out of the balancer.
Introduce a new cable from below through the housing mouth and the hole in
the cable drum (“Tunnel”) and push it through upwards. Push the bush over the
cable onto the ferrule. Pull the cable in downwards into the cable drum hole
("Tunnel"). Ensure correct coupling: the cable with the bush must be clearly
and distinctly anchored in the cable drum.
Suspend the working load and set the cable drum in motion by pulling the cable
out slightly and pulling the steel pin out of the locking device.
An incorrectly anchored cable can break out of the coupling under load and
cause consequential damage.

Safety and operating instructions EN WP40
8© Atlas Copco Industrial Technique AB - 9836 979602 02
Suspend the working load and set the cable drum in motion by first pressing in
the fixing pin and then, optionally unloading by 90°, turning it right or left, until
it jumps back into the original position.
Replacing the spring assembly with the spring fracture
safeguard
(A) Removal:
Retract the cable fully, then remove the load. In the event of spring fracture,
lock the cable drum as described under Replacing the cable. Take the balancer
off its suspension.
Release the spring tension, proceeding as follows: Apply a size-19 socket span-
ner to the endless screw (9), then turn the spanner in the direction of the “-”
symbol until the cable no longer retracts. The spring fracture safeguard blocks
the cable drum.
To prevent spring destruction, do not slacken it too much!
Unscrew the housing cover and the cable drum cover, then remove the spring
assembly from the drum. For models with two spring assemblies : Remove the
upper spring now. Should the lower spring assembly still have some residual
tension, unload the spring completely by rotating the endless screw (9) in the
“-” direction. Thereafter, take the lower spring assembly out of the drum as
well.
When replacing the spring assembly following spring fracture, the housing,
the cable and the cable drum must be checked for damage and replaced as
well where indicated, as high dynamic forces are released when spring frac-
ture occurs and the spring fracture safeguard mechanism is activated as a
result of this.
Replace the damaged spring by a new spring assembly. If a spring of a different
strength is used, the type and load range details must be changed accordingly on
the rating plate.
(B) Reassembly/Reinstallation:
The spring assembly label must be visible when inserting the spring assembly.
After a spring fracture: Unlock the drum lock (see description under Replacing
the cable) and wind up the cable by rotating the cable drum until the cable stop
buffer comes up against the mouth of the housing. Insert the spring assembly
into the cable drum, pressing the external lever of the cable fracture safeguard
against the spring assembly.
To ensure proper functioning, the external spring suspension must engage with
the drum slot and the internal spring suspension must engage with the shaft
groove; if necessary, turn the shaft a little with the endless screw (9) to enable
the spring suspension to glide into the shaft groove. First, screw the cable drum
cover in place, then the housing cover, using new tooth lock washers. Apply the
cover disk of the worm gear and screw it in place.
Tensioning the spring: To set the maximum initial tension (preload), rotate the
shaft “X” times by turning the endless screw (worm) in the “+” direction:
8202 0782 00 = 4 1/4
8202 0782 01 = 5 1/4
8202 0782 02 = 3 1/2

WP40 EN Safety and operating instructions
© Atlas Copco Industrial Technique AB - 9836 979602 02 9
8202 0782 03 = 3 1/4
Install the balancer as described under Installation and adjust the load as de-
scribed under Adjusting the working load.
Never open the spring assembly! Defective springs must be properly dis-
posed of.
Replacing the housing
(C) Removal/Dismantling:
Release the spring tension, proceeding as follows: Apply a size-19 socket span-
ner to the endless screw (9), then turn the spanner in the direction of the “-”
symbol until the cable no longer retracts. The spring fracture safeguard now
blocks the cable drum. Do not slacken the spring too much in order to prevent
spring destruction. Unscrew the cover disk of the worm wheel and remove the
disk.
Unscrew the housing cover. Remove the circlip on the worm wheel using spe-
cial pliers. Pull the cable drum with the spring and the shaft out of the housing,
paying attention to the feather key located in the shaft. If necessary, force the
shaft through the worm wheel with a plastic-faced hammer. Put the brass
washer located between the housing and the cable drum back onto the shaft if
appropriate. Unwind the cable from the cable drum, detach it and pull it out of
the housing. Remove the suspension (see Replacing the suspension).
(D) Reassembly/Reinstallation:
Fit the suspension to the new housing (see Replacing the suspension). Insert the
worm wheel into the housing, then insert the cable drum with the shaft and the
brass washer as well, pushing the shaft through the worm wheel (thereby ensur-
ing that the feather key is correctly positioned relative to the worm wheel; ro-
tate worm wheel if necessary). The shaft’s ring groove must be visible. Insert
the circlip into the shaft’s ring groove using special pliers.
Rotate the endless screw in the “+” direction to turn the cable drum until the ca-
ble coupling is visible in the housing slot. Insert the cable through the mouth of
the housing and install it as described under Replacing the cable. Wind up the
cable via the endless screw, rotating it in the “+” direction (using a size-19
socket spanner). Be sure that the cable winds up correctly in the groove! Ten-
sion the spring and adjust the load as described under “Replacing the spring as-
sembly” – see (B).
Replacing the cable drum
Dismantle the balancer as described under “Replacing the housing” – see (C).
There is no need, however, to remove the suspension from the housing. In-
stalling a new cable drum: Unscrew the cover and insert the shaft into the cable
drum, taking care that the ball bearing is not knocked out of the drum.
Put the brass washer on the shaft and place the worm wheel into the housing.
Insert the cable drum with the shaft and the brass washer into the housing,
pushing the shaft through the worm wheel. The feather key must engage with
the groove; rotate the shaft if necessary. Secure the worm wheel with a circlip.

Safety and operating instructions EN WP40
10 © Atlas Copco Industrial Technique AB - 9836 979602 02
Insert the spring assembly into the drum as described under “Replacing the
spring assembly” (B) Reassembly/ Reinstallation. Thereafter, install the cable
as described under Replacing the housing (D) Reassembly/Reinstallation, sec-
tion 2.
Replacing the suspension
Remove the split pin, washer, bolt and tube of the suspension from the housing,
then remove the suspension as well. Insert the new suspension, push the bolt
through the housing suspension and the tube, then secure it with the washer and
a new split pin.
Useful information
Log in to Atlas Copco www.atlascopco.com
You can find information concerning our products, accessories, spare parts and
published matters on our website.
Ergonomic guidelines
Consider your workstation as you read through this list of general ergonomic
guidelines and see if you can identify areas for improvement in posture, compo-
nent placement, or work environment.
• Take frequent breaks and change work positions frequently.
• Adapt the workstation area to your needs and the work task.
• Adjust for convenient reach range by determining where parts or tools
should be located to avoid static load.
• Use workstation equipment such as tables and chairs appropriate for the
work task.
• Avoid work positions above shoulder level or with static holding during as-
sembly operations.
• When working above shoulder level, reduce the load on the static mus-
cles by reducing the weight of the tool, using for example torque arms,
hose reels or weight balancers. You can also reduce the load on the static
muscles by holding the tool close to the body.
• Make sure to take frequent breaks.
• Avoid extreme arm or wrist postures, particularly for operations requir-
ing a degree of force.
• Adjust for convenient field of vision by minimizing movement of the eyes
and head during the work task.
• Use the appropriate lighting for the work task.
• Select the appropriate tool for the work task.
• Use ear protection equipment in noisy environments.
• Use high-quality inserted tools or consumables to minimize exposure to ex-
cessive levels of vibration.
• Minimize exposure to reaction forces.
• When cutting: