Form MHD56151

PARTS, INSTALLATION AND MAINTENANCE MANUAL

for
SERIES ZA, EA AND BA
AIR BALANCERS

(Dwg. MHP2176)

READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual

contains important safety, installation, and maintenance information. Make
this manual available to all persons responsible for the installation, operation
and maintenance of these products.

This equipment is intended for industrial use only and should not be used for lifting,
supporting, or transporting people or lifting or supporting loads over people.
Always operate, inspect and maintain this balancer in accordance with applicable safety
codes and regulations.

Form MHD56151
Edition 4
April 2004
54072541
© 2004 Ingersoll-Rand Company
 TABLE OF CONTENT

This Maintenance Manual describes the correct service, disassembly, assembly and repair procedures for Balancers. Use of replacement
parts other than genuine Ingersoll-Rand original parts could result in damage to the balancer and void the warranty. Refer on page 51 for
warranty information. Be sure you read all instructions before starting work on the balancer.

Description Page No. Description Page No.

Safety Information.......................................................................3 Balancer Rebuild ....................................................................... 35
Disassembly for 6.5 and 10 inch (165 and 254 mm) 
Safe Operating Instructions........................................................4
Balancers - All Series .................................................................. 35
Warning Tag and Label...............................................................4 Disassembly of Ball Screw.......................................................... 36
Cleaning and Inspection .............................................................. 37
Typical Balancer Cross Section ..................................................5 Ball Screw and Thrust Bearing Replacement.............................. 37
Specifications................................................................................5 Ball Screw Reassembly ............................................................... 38
Reassembly.................................................................................. 38
Installation....................................................................................6 Installing Wire Rope.................................................................... 40
Series ZA ..................................................................................7-10
Series BA ................................................................................11-12 Z-Brake Adjustments and Resetting ....................................... 41
Series BA Z-Servo Control.....................................................13-16 Z-Stop Installation and Test ..................................................... 42
Series EA ................................................................................17-21
Z-Stop Assembly 200/325/500 lb.
Interlock Adjustments...............................................................24 (91/147/227 kg) Balancer........................................................... 43
Tandem Control Balancer.........................................................25 Basic 150 lb. (68 kg) Balancer................................................... 44
Load Hooks, Lash-Up and Yarding .........................................25 Z-Brake Assembly 150 lb. (68 kg) Balancer............................ 45
Load Blocks ................................................................................27 Basic 200 lb. (91 kg) Balancer................................................... 46
Suspension Kits ..........................................................................27 Basic 350 lb. (158 kg) Balancer................................................. 47
Small Balancer Suspension Kits..................................................27
Large Balancer Suspension Kit ...................................................28 Basic 500 lb. (227 kg) Balancer................................................. 48
T-Rail Suspension Kits ................................................................28 Z-Brake Assembly 200/350/500 lb.
Hook Mount Suspension Kits......................................................28
(91/158/227 kg) Balancer........................................................... 49
ZRS/ZRA/KBKII and ETA8 Suspension Kits.............................29
KBKI Suspension Kits.................................................................30 Parts Ordering Information ..................................................... 50
Tandem Tie Bar Kits....................................................................31
Preventive Maintenance Checks and Service ..............................32 Service and Maintenance .......................................................... 50

Preventive Maintenance Schedule............................................33 Warranty .................................................................................... 51

Inspection and Maintenance Report........................................34 Office Locations ......................................................................... 52

2 MHD56151 - Edition 4
 SAFETY INFORMATION

This manual provides important information for all personnel The Occupational Safety and Health Act of 1970 generally places
involved with the safe installation, operation and proper the burden of compliance with the owner/employer, not the
maintenance of this product. Even if you feel you are familiar with manufacturer. Many OSHA requirements are not concerned or
this or similar equipment, you should read this manual before connected with the manufactured product but are, rather,
operating the balancer. associated with the final installation. It is the owner’s and user’s
responsibility to determine the suitability of a product for any
particular use. It is recommended that all applicable industry, trade
Danger, Warning, Caution and Notice
association, federal, state, and local regulations be checked. Read
Throughout this manual there are steps and procedures which, if all operating instructions and warnings before operation.
not followed, may result in an injury. The following signal words
are used to identify the level of potential hazard. Rigging: It is the responsibility of the operator to exercise caution,
use common sense and be familiar with proper rigging techniques.
Refer to ASME B30.9 for rigging information, American Society
Indicates an imminently
of Mechanical Engineers, Three Park Ave, New York, NY 10016.
hazardous situation which, if not
avoided, will result in death or
serious injury. This manual has been produced by Ingersoll-Rand to provide
dealers, mechanics, operators and company personnel with the
Indicates a potentially information required to install, operate, maintain and repair the
hazardous situation which, if not products described herein. It is extremely important that
avoided, could result in death or mechanics and operators be familiar with the servicing procedures
serious injury. of these products, or like or similar products, and are physically
capable of conducting the procedures. These personnel shall have
Indicates an potentially a general working knowledge that includes:
hazardous situation which, if not 1. Proper and safe use and application of mechanics common
avoided, may result in minor or hands tools as well as special Ingersoll-Rand or
moderate injury or property recommended tools.
damage. 2. Safety procedures, precautions and work habits established
Indicates information or a by accepted industry standards.
company policy that relates
directly or indirectly to the Ingersoll-Rand cannot know of, or provide all the procedures by
safety of personnel or protection which product operations or repairs may be conducted and the
of property. hazards and/or results of each method. If operation or maintenance
procedures not specifically recommended by the manufacturer are
conducted, it must be ensured that product safety is not
endangered by the actions taken. If unsure of an operation or
maintenance procedure or step, personnel should place the product
Safety Summary in a safe condition and contact supervisors and/or the factory for
technical assistance.

• Do not use this balancer or attached equipment for lifting,

supporting, or transporting people or lifting or supporting • Balancers with capacities of 150 lbs or (68 kg) greater are
loads over people. equipped with the Z-Brake, a centrifugal brake that is
• The supporting structures and load-attaching devices used in designed to stop the uncontrolled upward travel of the wire
conjunction with these balancers must provide a safety factor rope in the event of a sudden release or loss of load, and limit
of at least three times the rated capacity of the balancer. This the excessive upward acceleration of the empty hook for the
is the customer’s responsibility. If in doubt, consult a safety of the operators. The brake must not be used as a travel
registered structural engineer. limiting stop or up stop. Failure to follow these instructions
will result in damage to the brake and the balancer.
Continuous use of the Z-Brake will cause internal damage to
the balancer and could result in damaging the balancer
• Lifting equipment is subject to different regulations in each beyond repair.
country. These regulations may not be specified in this
manual. Correct installation and operation of the balancer depends on you
reading all instructions before starting work on the balancer.
The National Safety Council, Accident Prevention Manual for
Industrial Operations, Eighth Edition and other recognized safety
sources make a common point: Employees who work near
suspended loads or assist in hooking on or arranging a load should
be instructed to keep out from under the load. From a safety Clean, dry air must be used at all times when operating
standpoint, one factor is paramount: conduct all lifting operations balancers.
in such a manner that if there were an equipment failure, no
personnel would be injured. This means keep out from under a
raised load and keep out of the line of force of any load.

MHD56151 - Edition 4 3
 SAFE OPERATING INSTRUCTIONS

The following warnings and operating instructions have been 9. Never place your hand inside the throat area of a hook.
adapted in part from American National (Safety) Standards and 10. Never use the wire rope as a sling.
are intended to avoid unsafe operating practices which might lead 11. Only operate the balancer when the wire rope is centered
to injury or property damage. over the load. Do not “side pull” or “yard”.
12. Never operate the balancer with twisted, kinked or damaged
Ingersoll-Rand recognizes that most companies who are using wire rope.
these balancers have a safety program in force at their facility. In 13. Do not force hook into place.
the event that some conflict exists between a rule set forth in this 14. Be certain the load is properly seated in the saddle of the
publication and a similar rule already set by an individual hook.
company, the more stringent of the two should take precedence. 15. Do not support the load on the tip of the hook.
16. Never run the wire rope over a sharp edge.
Safe Operating Instructions are provided to make an operator 17. Pay attention to the load at all times when operating the
aware of dangerous practices to avoid and are not necessarily balancer.
limited to the following list. Refer to specific sections in the 18. Make sure everyone is clear of the load path. Do not lift a
manual for additional safety information. load over people.
19. Never use the balancer for lifting or lowering people, and
1. Only allow personnel trained in safety and operation of this never allow anyone to stand on a suspended load.
balancer to operate this product. 20. Do not swing a suspended load.
2. Only operate the balancer if you are physically fit to do so. 21. Do not leave load suspended when the balancer is not in use.
3. When a “DO NOT OPERATE” sign is placed on the 22. Never leave a suspended load unattended.
balancer, or controls, do not operate the balancer until the 23. Never weld or cut a load suspended by the balancer.
sign has been removed by designated personnel. 24. Ensure safety wire rope is installed (where required).
4. Do not use the balancer if hook gate is sprung or broken. 25. Do not operate the balancer if wire rope is jumping, excessive
5. Check that the hook gate is closed before using. noise, jamming, overloading, or binding occurs.
6. Before each shift, check the balancer for wear and damage. 26. Shut off air supply before performing any maintenance.
Never use a balancer that inspection indicates is worn or 27. Avoid collision or bumping of the balancers.
damaged. 28. Do not continuously rotate balancer in one direction. Air line
7. Never lift a load greater than the rated capacity of the damage will occur from continuous rotation potentially
balancer. Refer to nameplate and capacity labels attached to allowing the load to lower. Reverse direction with each cycle
the balancer. of the balancer to prevent twisting and damage to air lines.
8. Do not use more than one hook on a single load.

WARNING TAG AND LABEL

Each balancer is shipped from the factory with the warning tag Balancer Label
and label shown. If the tag or label is not attached to the balancer,
order a new tag or label, and install it. Tag and label are shown
smaller than actual size.

Pendant Control Tag

(Part No. 10445) (Part No. 71148175)

4 MHD56151 - Edition 4
 TYPICAL BALANCER CROSS SECTION

(Dwg. MHP1350)

SPECIFICATIONS

If the balancer has no load attached, it may be necessary to pull

Principles of Operation
down on the load hook to lower.
Balancers contain a stationary ball screw. The ball screw is held in The 500 lb (227 kg) balancer is designed to hang at a 3 degree
position by two hex head bolts (through the end cap and end angle with the controls end lower than the end cover.
cover). Two pins in the end cover engage notches on the end of the MODEL CODE
ball screw to prevent it from rotating. The reel assembly, Example: BA - W - 020 - 120 - S - HM
consisting of reel, ball nut and thrust bearing, rides on the ball
Type of Control Kit
screw. The piston contacts the thrust bearing and travels back and
forth with the reel assembly. The piston does not rotate. Wire

Compressed air powers the balancer. It is controlled by an external Capacity

control package. Air enters or leaves the piston chamber through a
single hole in the end cap. This compressed air causes the piston to Inches of Travel
move laterally. The piston pushes against the thrust bearing Z-Stop
causing the reel to move laterally along the ball screw and winds
up the wire rope. The load or hook travels down when the air is Type of Suspension Kit
exhausted from the piston chamber through the control package to
atmosphere.

The Balancer achieves maximum capacity at 100 psi, as the line

pressure reduces so will the operating capacity of the Balancer.
For every one psi reduction in air pressure there is a 1% reduction
in overall capacity.

MHD56151 - Edition 4 5
 Capacity in Pounds at Type of Suspension
Type of Control Kit Wire or Chain Inches of Travel Options
100 psi (6.9 bar) Kit
B = Basic Unit no W = Wire Rope 005 = 50 lbs (22 kg) 040 = 40 in (102 cm) S = Z-Stop 00 = No suspension
controls C = Chain (not 015 = 150 lbs (68 kg) 060 = 60 in (152 cm) A1 = ZRA1 Rail
BA = Single Balance covered in this 020 = 200 lbs (91 kg) 080 = 80 in (203 cm) A2 = ZRA2 Rail
Control manual) 032 = 325 lbs (147 kg) 120 = 120 in (305 cm) S2 = ZRS2 Rail
EA = Hi, Low, no Z-Stop only S3 = ZRS3 Rail
load control 035 = 350 lbs (158 kg) HM= Top Hook
ZA = Pendant Control 040 = 400 lbs (181 kg) Mount
050 = 500 lbs (227 kg) TR = T-Rail/I-Beam
065 = 650 lbs (294 kg) AT = ZRAT Rail
070 = 700 lbs (317 kg) V2 = Valu-Trak
080 = 800 lbs (362 kg) K1 = KBKI Rail
100 = 1000 lbs (453 kg) K2 = KBKII Rail
130 = 1300 lbs (589 kg) E4 = ETA-4 Rail
140 = 1400 lbs (620 kg) E8 = ETA-8 Rail
200 = 2000 lbs (907 kg)

INSTALLATION

Prior to installing the balancer, carefully inspect it for possible

shipping damage. Balancers are supplied fully lubricated from the
factory.
• To avoid an unbalanced load which may damage the trolley,
the balancer must be centered under the trolley.

• Owners and users are advised to examine specific, local or Rail Mounted Balancer Installation
other regulations, including American National Standards
Institute and/or OSHA Regulations which may apply to a For proper installation of the balancer on a rail system refer to
particular type of use of this product before installing or Installation and Maintenance Manual for that rail system.
putting the balancer to use.
• A falling load can cause injury or death. Before installing,
read “SAFETY INFORMATION”. Air System
The supply air must be clean and free from water or moisture. A
Balancer minimum of 100 psi (6.9 bar/690 kPa) at the balancer is required
to provide rated capacity. Do not exceed 100 psi (6.9 bar).
Make certain the balancer is properly installed. A little extra time
and effort in so doing can contribute a lot toward preventing
accidents and helping you get the best service possible.
• Do not exceed 100 psi (6.9 bar) inlet pressure. Do not use a
Always make certain the supporting member from which the lubricator of any kind. Oil will damage internal components.
balancer is suspended is strong enough to support the weight of
the balancer plus the weight of a maximum rated load plus a Air Lines
generous factor of at least 300% of the combined weights.
The inside diameter of the balancer air supply lines must not be
Hook Mounted Balancer Installation smaller than 3/8 in. (10 mm) based on a maximum of 100 ft. (30
m) between the air supply and the balancer. Contact the factory for
The supporting member must rest completely within the saddle of recommended air line sizes for distances greater than 100 ft. (30
the hook and be centered directly above the hook shank on m). Before making final connections, all air supply lines should be
balancers suspended by a top hook. Do not use a supporting purged before connecting to balancer inlet. Supply lines should be
member that tilts the balancer to one side or the other. as short and straight as installation conditions will permit. Long
transmission lines and excessive use of fittings, elbows, tees, globe
Place hook over mounting structure. Make sure hook gate is valves, etc. cause a reduction in pressure due to restrictions and
engaged. surface friction in the lines. If quick-disconnect fittings are used at
the inlet of the balancer, they must have at least a 3/8 in. (10 mm)
Trolley Mounted Balancer Installation air passage. Use of smaller fittings will reduce performance.

When installing the balancer and trolley, make certain the balancer Air Line Filter
is centered under the rail or beam. After installation, operate the
trolley over the entire length of the rail or beam with a capacity It is recommended that an air line strainer/filter be installed as
load. Ensure rail or beam stops are installed before operating the close as practical to the balancer air inlet port. The strainer/filter
balancer. Use Grade 5 or better bolts when attaching balancer to should provide 10 micron filtration and include a moisture trap.
trolley assembly. Refer to Trolley Suspension Kit in this manual. Clean the strainer/filter monthly to maintain its operating
efficiency.

6 MHD56151 - Edition 4
To maintain dry air, the frequency for draining the filter should Item Description Qty. Part
also be based on the condition of the air supply. We suggest the No. of Part Total Number
filter be drained weekly at first. Depending on air supply 3 Mounting Screw 4 15779
condition, a proper filter drain schedule should be established.
4 Fitting, Elbow 1 10354
5 Hose (bulk) As Req’d 10555-B
Moisture in Air Lines
6 Hose (bulk) As Req’d 10555-G
Moisture that reaches the balancer through the supply lines is the 7 Fitting, Hose End 4 10560
chief factor in determining the length of time between service 8 Fitting, Adapter 4 10565
overhauls. Moisture traps can help to eliminate moisture. Other 9 Ergonomic Control Handle 1 18600
methods, such as an air receiver which collects moisture before it
reaches the balancer controls or an aftercooler at the compressor 10 Clamp 4 10548
that cools the air prior to distribution through the supply lines, are 11 ‘O’ Ring 1 15751
also helpful. 12 Warning Tag (do not remove) 1 10445

General Operating Instructions Control Kits

Part Description
Number of Part
15300-10 Control Kit 10 ft (includes items 1 to 12)
• Do not continuously rotate balancer in one direction. Air line 15300-12 Control Kit 12 ft (includes items 1 to 12)
damage will occur from continuous rotation potentially
15300-14 Control Kit 14 ft (includes items 1 to 12)
allowing the load to lower. Reverse direction with each cycle of
the balancer to prevent twisting and damage to air lines. 15300-17 Control Kit 17 ft (includes items 1 to 12)

Series ZA Basic Balancer Control Hose Installation

The control hose is pre-assembled to the control handle, but it

Manifold Installation must be attached to the manifold.
Refer to Dwg. MHP1899 on page 7. Control hose assemblies may either be gray and black straight
Place balancer on a clean, sturdy work surface with end cap hose, or yellow and black coiled tubing. The gray hose or yellow
upright. Remove ZA control kit from its package and make certain tube (6) must be connected to the down-side of the manifold. The
‘O’ Ring (11) is in place on back of manifold. Install manifold (1) black hose (5) must be connected to the up-side of the manifold.
with mounting screws and lockwashers (2 and 3).

Operational Adjustments
2&3 1
11 4

• Prior to performing operational adjustments or servicing

make sure air supply is off. Press down lever until wire rope is
8 slack.

7 1. Install manifold to end cap.

10 2. Connect black UP hose to UP port on manifold.
3. Connect gray/yellow hose (handling device applications) to
DN port on manifold.
12
6

5
• When wire rope is winding, air is entering the balancer
9 through both the up and down flow controls. Therefore, down
flow control also affects the up speed when it is set for a
minimal down speed.

4. Connect main air supply to right side port of manifold.

5. Turn on main air supply. Adjust regulator to required air
(Dwg. MHP1899) pressure.
Item Description Qty. Part 6. Rotate hook balance screw clockwise slowly until wire rope
No. of Part Total Number begins to raise, move to the full up position, ensure Z-brake
1 Manifold 1 ZHS15071 does not engage.
7. Install load hook and handling device to wire rope in required
2 Lockwasher 4 15785 position. Refer to “Lash up” instructions on page 25.

MHD56151 - Edition 4 7
8. Rotate UP flow control clockwise until snug. 4. Remove the four screws holding manifold to end cap (2 and
9. If wire rope is slack, ensure the Z-brake does not engage. 3).
10. Feather UP lever until tension is applied to wire rope, then
fully depress UP lever until load is in the full up position. Disassembly
11. Depress DN lever and check speed.
12. Adjust DN flow control on manifold counterclockwise to Refer to Dwg. MHP1904 on page 8.
increase speed, clockwise to decrease speed, until desired
speed is achieved.
13. Lower to bottom of normal travel with tension on wire rope.
14. Adjust UP flow control on manifold counterclockwise to • Use of replacement parts other than genuine Ingersoll-Rand
increase speed, clockwise to decrease speed, until desired original parts could result in damage to the balancer and void
speed is achieved. the warranty.

Series ZA Manifold 1. Remove the two adjustment screws (7). Pull out when threads
have disengaged.
2. Remove hook balance adjustment screw (11) and spring (12).
13
3. Remove piston (9) by grasping raised center with needle nose
pliers and pulling straight out.
14 4. Remove seat (5), valve (4) and spring (6). Use a No. 2
Phillips screwdriver to unscrew seat (5).
1 5. To take out ball check (2), remove down side hose fitting and
3 retainer ring (1).
15 2 6
8

9
Assembly
12
1. Thoroughly clean manifold body and all internal parts before
11 reassembly. Replace all worn parts.
2. Apply a light coat of lubricant (Lubriplate) to ‘O’ Rings (8),
U-cup (10), and threaded adjustments before reassembly.
7 4 3. Assemble manifold in reverse order of disassembly.
5
8 10 4. Use U-cup insertion tool, part number 54041777, to install
(Dwg. MHP1904) seal to prevent damage from threaded hole.

Item Description Qty. Part

No. of Part Total Number Series ZA Control Handle
• 1 Retainer Ring – ZA Manifold 1 ZHS15047
• 2 Ball, Check – ZA Manifold 1 ZHS15049
3 Body – ZA Manifold 1 15077
• 4 Valve Assembly 1 15802
• 5 Valve Seat 1 15803
• 6 Valve Spring 1 15804
7 Screw, Adjusting ZA Manifold 2 15080
• 8 ‘O’ Ring 3 15751
9 Piston – ZA Manifold 1 ZHS15083
• 10 U-cup – ZA Manifold 1 15086
11 Screw, Adjusting ZA Manifold 1 15081
12 Spring – ZA Manifold 1 15084
13 Nameplate, Series ZA Manifold 1 10297
14 Mounting Screw 4 15779
15 Lockwasher 4 15785
Recommended Spare Available in Kit 15099 –
•
ZA Manifold Repair Kit

Removal From Balancer (Dwg. MHP1906)

1. Lower suspended load to floor. Turn off air supply to Item Description Qty. Part
balancer. No. of Part Total Number
2. Press down lever until wire rope is slack and all air is Ergonomic Control Handle
exhausted from balancer. --- 1 18600
Assembly
3. Remove air supply (4) and hoses (5 and 6) from manifold (1).

8 MHD56151 - Edition 4
 Item Description Qty. Part Series ZA Control Handle (Ergonomic)
No. of Part Total Number
1 Valve Body 1 18601
• 2 Cartridge Valve 2 18602
Up Lever 1 18609
• 3
Up Lever Stainless Steel 1 18609S
Down Lever 1 18607
• 4
Down Lever Stainless Steel 1 18607S
5 ZA Ergonomic Handle 1 18604
• 6 Pin 1 10550200
7 Pin 1 Y178-64
• 8 Button Head Screw 1 70422
9 Guard 1 18622
10* Spring 2 18613
11* ‘O’ Ring 1 18633
12* Quad Ring 1 18632
• Recommended Spare

Recommended spare parts are available in kit

18575 - Ergo Control Handle Repair Kit (Dwg. MHP1907)
18575S - Ergo Control Handle with Steel Lever Repair/Upgrade
Kit Item Description Qty. Part
*18570 - Cartridge Valve Repair Kit No. of Part Total Number
• 1 Pin 1 18421
Removal From Balancer • 2 Screw 1 18422
• 3 Insert Valve Assemblies 2 18412
Refer to Dwg. MHP1899 on page 7.
1. Lower suspended load to floor. Turn off air supply to • 4* Spring 2 18418
balancer. 5 ZA Handle Bracket 1 18446
2. Press down lever until wire rope is slack and all air is
exhausted from balancer. 6 ZA Handle Grip 1 18447
3. Disconnect twin hose (5 and 6) at handle (9). 7 Mounting Block 1 1826
8 Control Valve Assembly 1 ZHS18410
Disassembly
9 Button Head Screw 2 18451
Refer to Dwg. MHP1906 on page 8. • 10* Seal 1 18417
• 11* ‘O’ Ring 2 ZHS18415
• 12* V-Seal 1 18423
• Use of replacement parts other than genuine Ingersoll-Rand
original parts could result in damage to the balancer and void • 13* ‘O’ Ring 1 15759
the warranty. • 14 Lever (Up) 1 18419
• 15 Lever (Down) 1 ZHS18420
1. Remove pins (6) and UP and DOWN levers.
2. Remove screw (8). 16 Setscrew 1 16093
3. Remove the two insert valve cartridges (2) by grasping with 17 Screw 2 ZHS70427
needle nose pliers and pulling straight out.
4. Remove two springs (10). Check valve springs for breakage • Recommended Spare
or loss of tension. Replace springs, if necessary. Examine the
rubber seat on the end of the valve stem. Examine ‘O’ Rings Suggested spare parts available in kit
for signs of wear or deterioration. Clean valve body (1). 18475 - ZA Control Handle Repair Kit
5. Replace all worn parts. *18470 - Insert Valve Repair Kit

Reassembly Removal From Balancer

1. Control handle is assembled in the reverse order of Refer to Dwg. MHP1899 on page 7.
disassembly. 1. Lower suspended load to floor. Turn off air supply to
2. Apply a light coat of lubricant (10886) to ‘O’ rings and balancer.
threaded connections before reassembly. 2. Press down lever until wire rope is slack and all air is
exhausted from balancer.

MHD56151 - Edition 4 9
3. Disconnect twin hose (5 and 6) at handle (9). 4. Remove two springs (4). Clean valve body. Check valve
springs for breakage or loss of tension. Replace springs, if
Disassembly necessary. Examine rubber seat on end of valve stem.
Examine ‘O’ Rings for signs of wear or deterioration.
Refer to Dwg. MHP1907 on page 9. 5. Replace all worn parts.

Reassembly

• Use of replacement parts other than genuine Ingersoll-Rand 1. Control handle is assembled in reverse order of disassembly.
original parts could result in damage to the balancer and void 2. Apply a light coat of lubricant (10886) to ‘O’ Rings and
the warranty. threaded connections before reassembly.

1. Remove pin (1) from UP and DOWN levers.

2. Remove screw (2).
3. Remove two insert valve assemblies (3) by pulling them
straight out.

Series ZA Troubleshooting Guide

• Before doing any disassembly, lower load until wire rope is slack. Prior to performing operational adjustments or servicing make
sure air supply is off.

Basic Balancer - Refer to Applicable Breakdown for Parts

SYMPTOM POSSIBLE CAUSE SOLUTION
Balancer will not lift or hold load. End cap ‘O’ Ring leaking. Replace ‘O’ Ring.
Air leaking from inside housing. Ball screw cap, seal leaking air. Tighten hex head bolt in center of end cap. Remove if leak
continues and replace seal.
Air leak around piston. Replace piston.
Cap (ball screw) may be damaged. Replace cap (ball screw).
Balancer will not lift load. No air Z-Brake engaged. Lower load, refer to “Z-BRAKE ADJUSTMENT AND
leaking from the balancer. RESETTING” section on page 41.
Balancer lifts but will not lower. Control hoses installed backwards. Reverse hoses. Refer to Dwg. MHP1899 on page 7.

ZA Basic Control
SYMPTOM POSSIBLE CAUSE SOLUTION
Balancer will lift, but will not hold Air leak between manifold and  Replace ‘O’ Ring (15751).
load. balancer end cap.
Air leak around up/down adjustment Replace ‘O’ Ring (15751).
screws on manifold.
Air leak around hook balance Replace U-cup (15086) or replace ball (ZHS15049).
adjustment screw on manifold.
Worn or cut control air lines. Replace control air line.
Improper assembly of hose fittings Check and tighten fittings. Apply pipe sealant if necessary.
(leakage).
Air leaks around or through “down” Clean and inspect assembly. Replace worn parts.
valve assembly in control handle.
Balancer lifts load without up lever Hook balance adjustment set too Turn adjusting screw (15081) counterclockwise until screw
being actuated. high. head is flush with top of manifold. If problem continues
rebuild manifold. Refer to Dwg. MHP1904 on page 8.
Air leak around or through “up” Clean and inspect assembly. Replace worn parts.
valve assembly in control handle.

10 MHD56151 - Edition 4
 4. Rotate adjustment knob clockwise slowly until wire rope
Series BA Balancer
begins to raise, move to the full up position. (Ensure the
150 lb (68 kg) Capacity Z-brake does not engage - 150 lb (68 kg) units only).
5. Install load hook and tooling or fixture to wire rope in the
required position. Refer to “Lash up” instructions on page 25.
6. Rotate adjustment knob clockwise until load is suspended.
7. The correct setting will require equal effort to lift and lower
the load.
8. If unit is required to raise the load out of the way, turn
adjustment knob clockwise until desired speed is achieved.
9. Tighten jam nut just above adjustment knob to maintain
proper setting.

Series BA Regulator

*Control
(Dwg. MHP1908) Note: Diaphram
Air Passage
Item Description Qty. Part Bulge On
No. of Part Total Number Regulator
1 Regulator Assembly 1 13825 Segments
Must Be
2 Tandem Manifold 1 15093
Aligned
3 ‘O’ Ring 1 15751 *Diaphram

4 Mounting Screw 4 15779

5 Lockwasher 4 15785

Manifold Installation
*Bleed
Refer to Dwg. MHP1908 on page 11.
Screw
Place balancer on a clean, sturdy work surface with end cap
upright. Remove BA control kit from its package. Check to be sure *Gasket
‘O’ Ring (3) is in place on the back side of the manifold (2). Install
manifold to end cap by using the 4 mounting screws and
lockwashers (4 and 5) provided. Regulator is supplied with a hex
nipple and a check valve. The hex nipple should be threaded into
the hole on the manifold as shown in Dwg. MHP1259 on page 12.
Connect air supply to check valve.

• Arrow on check valve must be pointing toward balancer. If

installed backwards balancer will not function.

Operational Adjustments

• Prior to performing operational adjustments or servicing

make sure air supply is off and wire rope is slack.
4
1. Connect regulator to balancer. (Dwg. MHP1258)
2. Rotate regulator adjustment knob counterclockwise until it
stops.
3. Turn on main air supply. Adjust regulator to required air
pressure.

MHD56151 - Edition 4 11
 Item Description Qty. Part
No. of Part Total Number
--- Regulator Assembly 1 13825
1 Check Valve 1 13270
2 Regulator 1 13830
3 Plug 2 10764
4 Control knob 1 13832
5 Setscrew 1 13833
6 Fitting, Nipple 1 13840

(Dwg. MHP1259)

Series BA Troubleshooting Guide

• Before doing any disassembly, lower load and turn control knob (counterclockwise) until wire rope is slack. Prior to performing
additional adjustments or servicing make sure air supply is off

SYMPTOM POSSIBLE CAUSE SOLUTION

Balancer will not lift load. Check valve installed backwards. Install check valve properly, arrow toward regulator.
Regulator adjustment set low. Turn adjustment clockwise until load rises.
Make sure load does not exceed
capacity of balancer. Insufficient air pressure. Increase pressure to 100 psi (6.9 bar).
Excessive leakage around piston, ‘O’ Check for damaged piston, seal or ‘O’ Ring. Replace worn
Ring or seal on end cap. parts.
Binding of ball screw assembly, or Clean and lubricate ball screw assembly and thrust bearing,
thrust bearing. or replace if excessively worn.
Load rises but is hard to pull down. Regulator adjustment set too high. Back off adjustment (counterclockwise) until load is
balanced.
Exhaust hole in regulator bleed screw Clean exhaust hole using fine wire, or replace bleed screw.
plugged.
Air constantly blowing out of Ruptured diaphragm in regulator. Replace diaphragm.
exhaust ports on regulator.
Erratic, jerky operation. Fluctuating air supply pressure. Clean parts thoroughly.
Dirt or oil clogging inlet valve or Clean thoroughly and lubricate.
bleed screw orifice.
Ball screw and thrust bearing dirty. Install line regulator set at highest maintainable pressure. Do
not exceed 100 psi (6.9 bar).

12 MHD56151 - Edition 4
 Series BA Z-Servo Control Regulator Installation
200, 350 and 500 lb (90, 158 and 227 kg) Capacity Place balancer on a clean, sturdy work surface with end cap
upright. Pull out wire rope until reel bottoms out. Remove BA
S Control Kit control kit from package, check to ensure that ‘O’ Ring is in
254 mm (10 in.) Balancer correct position on back of EA regulator (2). Install regulator on
end cap with four mounting screws and lockwashers (3, 4 and 5).

Control kit is supplied with a coil hose assembly (6). Connect coil
hose to “A” port of regulator.

Operational Adjustments
Refer to Dwg. MHP1909 on page 13.

• Prior to performing operational adjustment or servicing

make sure air supply is off and wire rope is slack.

• A minimum of 70 psi (4.8 bar) is required to operate the

regulator.

1. Install regulator to balancer.

2. Install Z-Servo as close to but below the ball stop. Refer to 
Z-Servo Installation instructions on page 13.
3. Rotate regulator adjustment knob counterclockwise until 1/2
inch (13 mm) of thread is visible.
4. Rotate trim valve clockwise until snug, then
counterclockwise 2 full turns.
5. Rotate auxiliary flow valve clockwise until snug.
6. Turn on main air supply. Adjust regulator to required air
pressure.
7. Rotate adjustment knob clockwise slowly until wire rope
begins to raise, move to the full up position, ensure Z-brake
does not engage.

(Dwg. MHP1909)
Item Description Qty. Part • Auxiliary flow valve is fully open when 1/8 in. (3.2 mm) of
No. of Part Total Number screw head protrudes from regulator body. Do not open
beyond this point.
1 Z-Servo Control 1 10602
2 Integral Regulator Series EA 1 15601
3 Screw 2 15781 • Up and down speed should be the same for ease of
4 Screw 2 15782 adjustment.
5 Lockwasher 4 15785 8. Install load hook and tooling or fixture to wire rope in the
6 Coiled Poly Black Tube 1 93948 required position. Refer to “Lash-up” instructions on page
25.
7 Fitting, Elbow 1 ZHS93969
9. Rotate regular adjustment knob clockwise until load raises to
8 Connector 1 ZHS93963 the full up position. The speed should be relatively slow. Pull
9 Warning Tag (do not remove) 1 10445 down and release the load and check the speed.
10. Connect black tube to the “A” port on the regulator.
11. Rotate auxiliary flow valve counterclockwise until lowering
Z-Servo Installation speed is the same as the lifting speed. “Pinching” off the
black tube will pressurize regulator to raise the load.
Mount balancer on overhead suspension, with wire rope fully 12. Raise and lower load two or three times to verify speeds are
extended. Determine proper wire rope location for Z-Servo, refer the same. If speed in one direction is much faster than the
to the “Load Hook Lash Up” section on page 23. Attach  opposite direction the load will be difficult to move and may
Z-Servo valve to wire rope as shown on page 14, Dwg. MHP1354. provide erratic operation.
13. Pinch off black tube and connect free end to the Z-Servo
fitting.

MHD56151 - Edition 4 13
14. Turn knurled nut at the top of the servo until load is balanced. Z-Servo Control
Rotating nut clockwise will increase balance setting or raise
6 14
the load. Counterclockwise rotation of the nut will reduce 9
balance setting and lower the load. 12
15. Lift and lower the load several times. Equal effort should be
required to raise and lower the load. If load is hard to pull
down turn trim valve clockwise 1/2 turn and check. If load is
hard to raise turn trim valve counterclockwise 1/2 turn and
check. 8
5
7

• A small volume of air will exhaust at the Z-Servo while in

operation.

Z-Servo Wire Rope Installation

11 3
15 2
13 10 4
1
(Dwg. MHP1910)
g

Item Description Qty. Part

No. of Part Total Number
Z-Servo Control
--- 1 1602
(includes items 1-15)
1 Valve 1 10626
2 Valve Stem 1 10631
• 3 Seal 1 ZHS10632
• 4 ‘O’ Ring 1 10635
5 Guide Washer 1 10613
6 Load Washer 1 ZHS10614
(Dwg. MHP1354)
7 Spring 1 ZHS10642
1. Mount balancer on overhead suspension.
2. Position Z-Servo below travel range of wire rope. 8 Housing 1 10645
3. Insert wire rope through top hole in Z-Servo. Install two 9 Plunger 1 10651
clamps on wire rope 1-1/2 in. (38 mm) above top of Z-Servo
and 1-1/2 in. (38 mm) apart. Leave 16 in. (40.64 cm) of wire 10 Adjusting Nut 1 10620
rope free for Z-Servo to operate properly. 11 Cap 1 ZHS10628
4. Insert wire rope through bottom hole in the Z-Servo. Install 2
clamps on wire rope 1-1/2 in. (38 mm) apart. 12 Nut 1 10662
5. Install load hook. • 13 Spring Pin 1 10616
• 14 Spring Pin 1 10617
• 15 Setscrew 1 10619
• You must leave enough slack in the wire rope to allow proper
• Recommended Spare
operation of the Z-Servo balancer.
Recommended Spare Parts Available In Kit 10600 - Z-Servo
Repair Kit.

The regulator is the primary control for the BA system. The 

Z-Servo bleeds off air. Therefore it works like an amplifier. If the
pilot regulator must be readjusted for any reason, the auxiliary
flow, trim valve and Z-Servo must be readjusted.

Removal From Balancer

1. Place suitable stand or platform under the suspended load.

The stand or platform should be high enough for the load to
rest on when the balancer is at the bottom of its travel.
2. Slowly turn pilot regulator screw counterclockwise until wire
rope is slack. Remove the load, and load hook from wire
rope.

14 MHD56151 - Edition 4
3. Turn off air supply. 5. Remove pin (14) and nut (12). This permits removal of
4. Disconnect control hose from Z-Servo control. Remove wire plunger (9) and spring (7).
rope clamps at top and bottom of Z-Servo control to complete
removal of control. Refer to page 22 to repair EA regulator. Assembly

Disassembly 1. Slide washer (6) (flat side up) onto plunger (9). Slide spring
(7) and washer (5) onto plunger (9). Insert this assembly into
Refer to Dwg. MHP1910 on page 14. housing (8).
2. Apply a light coat of lubricant (10886) to ‘O’ Ring (4) and
insert in valve groove (1).
3. Install seal (3) on valve stem (2), with flat side of seal against
• Use of replacement parts other than genuine Ingersoll-Rand shoulder of stem. Insert it into valve (1). Slide this assembly
original parts could result in damage to the balancer and void onto plunger (9).
the warranty. 4. Thread adjusting nut (10) onto plunger (9), grooved side first.
Tighten to allow cap (11) to be started. Install pin (13).
1. Remove spring pin (13). 5. Tighten nut (12). Align hole in nut with hole in housing.
2. Remove cap (11). 6. Insert roll pin (14).
3. Loosen setscrew (15) and remove knurled adjusting nut (10). 7. Tighten adjusting nut (10). Control is now ready for
4. Slide valve (2) and body (1) from bolt. Remove valve from installation to balancer. Refer to ‘Z-Servo Installation’
body and check seal (3) and ‘O’ Ring (4) for deforming or section on page 13.
wear.

Series BA Z-Servo Troubleshooting Guide

• Before doing any disassembly, lower load, turn control knob (counterclockwise) until wire rope is slack. Prior to performing
additional adjustments or servicing make sure air supply is off.

SYMPTOM POSSIBLE CAUSE SOLUTION

Balancer will not balance or lift No air supply to balancer. Turn on air. Set line regulator between 70 psi (4.8 bar)
load - no air bleeding from Z-Servo minimum and maximum 100 psi (6.9 bar).
control.
Air supply check valve holding. Low air pressure (should be 70 psi (4.8 bar) minimum).
Pilot regulator pressure set low. Adjust until load rises or is in balance.
Load over capacity of balancer. Check weight of load. 100 psi (6.9 bar) is required to
operate balancer at maximum capacity.
Trim valve closed. Adjust to manual specification. Refer to ‘BA Z-Servo
Operational Adjustments’ section on page 13.
Filter assembly plugged. Remove and clean or replace.
Pilot regulator contaminated with oil, Remove, replace or clean. Check all parts for wear.
water or dirt.
Air blowing from inside of balancer. Piston leaking - install new piston. Clean and lubricate
cylinder bore.
Leakage in control line. Replace hose, fittings as require.
Air leaking around end bolt. Replace seal (10061) and tighten end bolt to 100 ft. lb.
(13.83 kg/m).
Air leaking around O.D. of end cap. Replace ‘O’ Ring (15020).
Thrust bearing, worn or tight. Will not Remove ball screw and reel assembly. Replace or free up
rotate. bearing as required. Lubricate with #10886.
Reel and nut assembly do not turn. Check for rust, dirt, wear, or the lack of lubrication.
Clean and lubricate as required.

MHD56151 - Edition 4 15
 Series BA Z-Servo Troubleshooting Guide Continued

SYMPTOM POSSIBLE CAUSE SOLUTION

Balancer will not balance or lower Air supply check valve holding. Low air pressure - adjust to 70 psi (4.8 bar), minimum
the load. and 100 psi (6.9 bar) maximum.
Excessive air flow through trim valve. Close trim valve (clockwise) slowly until load floats
down.
Air does not bleed from control line Auxiliary flow control valve closed.
fitting at port “A” of regulator.
Foreign matter in fittings at regulator or Remove and check for blockage.
Z-Servo.
Control line pinched or has air flow Make sure control line is unobstructed so air can flow.
restriction.
Erratic operation. Z-Servo not adjusted properly at Adjust - tighten adjusting nut (10620).
adjustment ring.
Worn seal on Z-Servo. Replace seal.
Worn ‘O’ Ring on Z-Servo. Replace ‘O’ Ring.
Damaged regulator. Replace regulator - return to shop for repair.
Fluctuating air supply pressure. Install pressure regulator in supply line. Set at 70 psi (4.8
bar) minimum. Do not exceed 100 psi (6.9 bar).
Air contaminated with water, oil, dirt, Install 5 micron self-straining type filter.
etc.
Trim valve not open enough. Rotate trim valve counterclockwise in 1/4 turn
increments until operation is smooth.
Damaged regulator. Replace regulator repair as necessary. Refer to EA
Regulator disassembly.
Load hard to pull down. Z-Servo adjustment ring too tight. Loosen ring until air flow is evident.
Trim valve open too much. Rotate trim valve clockwise in 1/4 turn increments until
load is easy to pull down.
Wire rope does not have enough Perform Z-Servo removal. Loosen bottom wire rope
slack - holding Z-Servo closed. clamp and pull wire rope up. Retighten clamp.
Auxiliary flow control valve closed too Rotate auxiliary flow control counterclockwise in 1/4
much. turn increment until load is easy to pull down.

16 MHD56151 - Edition 4
 Series EA Balancer Operational Adjustments

• The auxiliary flow valve is fully open when 1/8 in. (3.2 mm) of • Prior to performing operational adjustments or servicing
screw head protrudes from regulator body. Do not open make sure air supply is off.
beyond this point. • Balancer may not support weight of empty handling device,
or may raise device at a potentially hazardous rate. Extreme
care must be used until control adjustments are complete.

• A minimum of 70 psi (4.8 bar) is required to operate the

regulator. Do not use an air line lubricator.

EA Basic

1. Install regulator to balancer.

• Auxiliary flow valve is fully open when 1/8 in. (3.2 mm) of
screw head protrudes from regulator body. Do not open
beyond this point.

2. Install EA pendant to “A” port of regulator.

3. Rotate control handle to HI-LOAD position.
4. Rotate regulator adjustment knob counterclockwise until 1/2
inch (13 mm) of thread is visible.
(Dwg. MHP1911) 5. Rotate trim valve clockwise until snug, then
counterclockwise 2 full turns.
Item Description Qty. Part
No. of Part Total Number 6. Rotate auxiliary flow valve clockwise until snug.
7. Turn on main air supply. Adjust regulator to required air
1 Integral Regulator Series EA 1 15601 pressure.
2 Mounting Screw 2 15781 8. Rotate adjustment knob clockwise slowly until the wire rope
begins to raise, move to the full up position, ensure Z-brake
3 Mounting Screw 2 15782 does not engage.
4 Lockwasher 4 15785 9. Install load hook and tooling or handling device to wire rope
in the required position. Refer to “Lash-up” instructions on
5 Control Hose, Black 10 10249
page 25.
6 Fitting, Swivel 2 10261 10. Rotate both LO-LOAD and UN-LOAD flow controls
Safety EA Control Handle clockwise until snug.
7 1 ZHS01810 11. Apply the heaviest load to the tooling or handling device.
Assembly
12. Rotate auxiliary flow valve clockwise until snug, then
Optional EA Control Handle counterclockwise until 1/8 inch (3.2 mm) of screw head
7A 2 ZHS01800
Assembly protrudes from side of regulator body.
8 Warning Tag (do not remove) 1 10445 13. Rotate regulator adjustment knob clockwise until load is
balanced.
14. Lift and lower load several times. Equal effort should be
Series EA Regulator Installation required to raise and lower load. If load is hard to pull down
turn trim valve clockwise 1/2 turn and check. If load is hard
Refer to Dwg. MHP1911 on page 17. to raise turn trim valve counterclockwise 1/2 turn and check.
Place balancer on a clean, sturdy work surface with end cap 15. Rotate pendant to LO-LOAD position.
upright. Pull out load wire rope until reel bottoms out. Remove EA 16. Slowly rotate LO-LOAD flow control counterclockwise until
control kit from package. Check to ensure that ‘O’ Ring is in port load drifts to the floor or full down position. The wire rope
on back of regulator (1). Install regulator on end cap with four should go slack.
mounting screws and lockwashers (2, 3 and 4). Connect control 17. Remove heaviest load from tooling or handling device.
hose to port A on regulator and port on control handle. 18. Apply medium weight load to tooling or handling device.
19. Rotate LO-LOAD flow control clockwise until load is
balanced.
20. Tighten jam nut to maintain proper setting.
21. Lift load to full up position.
22. Rotate pendant to UN-LOAD position.

MHD56151 - Edition 4 17
23. Slowly rotate UN-LOAD flow control counterclockwise until
Item Description Qty. Part
load drifts to the floor or full down position. Allow wire rope No. of Part Total Number
to go slack.
24. Remove medium weight load from tooling or handling 1 Integral Regulator-Series EA 1 15601
device. 2 Mounting Screw 2 15781
25. Rotate UN-LOAD flow control clockwise until tooling or
handling device is balanced. 3 Mounting Screw 2 15782
26. Maneuver tooling or handling device to heaviest load and 4 Lock Washer 4 15785
engage load.
Two Position Vacuum Sensor 99075
27. Rotate pendant to HI-LOAD position. 5 1
28. The load should be in balance. Two Position Pressure Sensor 99080
29. Set down the heaviest load and rotate pendant to UN-LOAD *6 Bleed Valve 1 13419
position.
30. Maneuver tooling or handling device to medium weight load 7 Fitting, Nipple 1 10730
and engage load. 8 Fitting, Elbow 2 01973
31. Rotate pendant to LO-LOAD position.
32. The load should be in balance. 9 Fitting, Tube 1 93965
33. Set down medium load and rotate pendant to UN-LOAD 10 Fitting, Elbow 1 93969
position.
11 Fitting, Reducer Bushing 1 13501
12 Pipe Plug 3 13835
* Included in Two Position Sensor
• If, for any reason, the pilot regulator must be readjusted, the
needle valves will have to be adjusted also.

EA 2PS
• The balancer may not support the weight of the empty
handling device, or may raise device at a potentially hazardous
Trim Valve 1
rate. Extreme care must be used until control adjustments are
complete.
Auxiliary Flow
Control Valve
Refer to Dwg. MHP1915 on page 18.
1. Install regulator and 2PS valve to balancer.
8 2. Rotate regulator adjustment knob counterclockwise until 1/2
inch (13 mm) of thread is visible.
7 9 3. Rotate trim valve clockwise until snug, then
counterclockwise 2 full turns.
12
4. Rotate auxiliary flow valve clockwise until snug, then
2 counterclockwise until 1/8 inch (3.2 mm) of screw head
10
3 protrudes from side of regulator body.
11 5. Rotate 2PS-flow control clockwise until snug, then
4
counterclockwise 1 turn.
Pilot 6. Ensure tube is connected at the 2PS valve and handling
Regulator device.
Screw 7. Turn on main air supply. Adjust regulator to required air
Pressure to pressure.
Handling Device 8. Rotate adjustment knob clockwise slowly until wire rope
5 Controls begins to raise, move to the full up position, ensure the
Z-brake does not engage.
9. Install load hook and tooling or handling device to wire rope
in required position. Refer to “Lash- up” instructions on page
*6
25.
2PS Bleed 10. Engage load with tooling or handling device.
Signal from Part/ Valve
Present Switch 11. Rotate regulator adjustment knob clockwise until load is
balanced.
(Dwg. MHP1915)
12. Lift and lower load several times. Equal effort should be
required to raise and lower load. If load is hard to pull down
turn trim valve clockwise 1/2 turn and check. If load is hard
to raise turn trim valve counterclockwise 1/2 turn and check.
13. Lower part to set down position. Rotate 2PS-flow control
counterclockwise one full turn. Tooling or handling device
may raise or lower unexpectedly when part is released.
Ensure you are clear of the vertical path at all times during
adjustments.

18 MHD56151 - Edition 4
14. Release part from tooling or handling device. Rotate 
Series EA Control Handle
2PS-flow control counterclockwise if tooling or handling
device raises or counterclockwise if it lowers until tooling or
handling device is balanced. 6 10
15. Lift and lower load several times. Equal effort should be 16 2A 15
required to raise and lower load. If load is hard to pull down, 2
turn 2PS-flow control counterclockwise 1/2 turn and check. 7 9 1
8 10
If load is hard to raise turn trim valve clockwise 1/2 turn and
check.
16. Engage and disengage the part checking the balance 3
12
condition of both the loaded and unloaded tooling or 5 13 11 AL 0185
0 ASS
EMBLY

handling device. 14 4 TY 0185

1/ OPTION
SAFE

18
Removal From Balancer 19
17
Refer to Dwg. MHP1911 on page 17.
1. Place suitable stand or platform under suspended load. Stand
or platform should be high enough for load to rest on when
balancer is at bottom of its travel.
2. Slowly turn pilot regulator screw counterclockwise. This will 21
release tension on wire rope for load removal.
3. Turn off air supply. 20
4. Disconnect control hose (5) from EA Handle. Refer to page
(Dwg. MHP1912)
22 to repair EA regulator.
Item Description Qty. Part
No. of Part Total Number
Disassembly
Safety EA Control Handle
Refer to Dwg. MHP1912 on page 19. --- 1 ZHS01810
Assembly
Optional EA Control Handle
--- 1 ZHS01800
Assembly (Incl’s items 1 to 21)
• Use of replacement parts other than genuine Ingersoll-Rand • 1 Spring Pin, Control Valve 1 1807
original parts could result in damage to the balancer and void
2 Valve Rotor, Optional EA 1 1862
the warranty.
2A Valve Rotor, Safety EA 1 1863
1. Remove two screws (17). Remove rotor control valve • 3 Needle Valve Assembly 2 1838
assembly (01851) or (01850) from bracket (18).
2. Drive out spring pin (16). 4 Valve Body Option & Safety 1 1860
3. Remove screw (15), be cautious these are spring loaded parts. • 5 Brass Washer 1 1886
4. Remove and replace any worn or broken parts in rotor valve
(2) or (2A). • 6 Thumb Well Locator 1 1804
5. Remove floating seal assembly (11), spring (13), ball detent 7 Setscrew 1 1803
(9) and spring (10).
8 Setscrew 1 1834
6. Inspect seal (11) and ‘O’ Ring (12) for wear. The face of the
seal should be smooth. If it is not, polish seal on crocus cloth. • 9 Detent Ball 1 1805
‘O’ Ring (12) must be free of nicks and cuts. Replace all • 10 Detent Spring 2 ZHS1806
worn parts.
7. Remove and inspect two needle valves (3) for damage to their • 11 Floating Seal 1 1880
tapered tips. Replace damaged valves. • 12 ‘O’ Ring 1 1882
• 13 Seal Spring 1 1884
14 Setscrew 1 1801
15 Flt. Hd. Screw 1 1817
• 16 Spring Pin 1 1814
17 Button Head Screw 2 10070
18 Handle Bracket 1 1840
19 Hex Head Screw 2 ZHS1833
20 Mounting Block 1 1826
21 Handle Grip 1 18447
• Recommended Spare

Recommended Spare Parts Available In Kit 01813 - EA Control

Handle Repair Kit

MHD56151 - Edition 4 19
 Assembly 5. Insert screw (15) through rotor. Mate this assembly with
valve body assembly. Tighten screw until hole in screw is
1. If pin (1) has been removed, reinstall it into 1/8 in. (3.2 mm) aligned with hole in body.
hole in the rotor (2) or (2A). Pin must protrude 3/32 in. 6. Insert pin (16).
(2.4 mm) above surface. 7. Thread two needle valves (3) into rotor body.
2. Install setscrew (7), spring (10) and ball detent (9) in small 8. Adjust setscrew (7) to give proper detent feel to rotor.
hole in valve body (4). 9. Install and tighten setscrew (8).
3. Insert washer (5), spring (13) and floating seal (11) with 10. Install and tighten setscrew (14).
‘O’ Ring (12) into large hole in valve body (4). Apply a small 11. Attach rotor control valve assembly (2) or (2A) to handle
amount of lubricant to ‘O’ Ring (12). bracket (18).
4. For rotor (2A) only, insert spring (10) and locator (6) in slot 12. Reinstall to control hose. Refer to EA Basic Installation on
in rotor valve. Locator should slide in and out freely. Apply page 17.
small amount of light grease in slot if necessary. 13. Perform EA Basic Operational Adjustments.

• If new screw (15) is installed, it must be drilled to accept pin

(16).

Series EA Troubleshooting Guide

• Before doing any disassembly, lower load, turn control knob (counterclockwise) until wire rope is slack. Prior to performing
additional adjustments or servicing make sure air supply is off.

SYMPTOM POSSIBLE CAUSE SOLUTION

Balancer will not lift load. Control No air supply to balancer. Turn on air. Set line regulator at maximum maintainable
handle in hi-load position. pressure not to exceed 100 psi (6.9 bar).
Air supply check valve holding. Low air pressure (should be 70 psi (4.8 bar) minimum).
Pilot regulator pressure set low. Adjust until load rises.
Load over capacity of balancer. Check weight of load including handling device. 100 psi (6.9
bar) is required to operate balancer at maximum capacity.
Trim valve closed. Adjust to manual specification. Refer to page 17.
Filter assembly plugged. Remove and clean or replace.
Pilot regulator full of oil, water or Remove, replace or clean. Check all parts for wear. Replace
dirt. worn items.
Air blowing from inside of balancer. Piston leaking - install new piston. Clean and lubricate
cylinder bore.
Leakage in control line or handle. Replace hose, fittings or handle parts as required.
Air leaking around end cap bolt. Replace seal (10061) and tighten end cap bolt to 100 ft. lb.
(13.83 kg/m).
Air leaking around outside diameter Replace ‘O’ Ring (15020) or (15520).
of end cap.
Thrust bearing, worn or tight, will Remove ball screw and reel assembly. Replace or free up
not rotate. bearing as required. Lubricate with P/N 10886.
Reel and ball nut assembly do not Check for rust, dirt, wear, or the lack of lubrication. Clean and
turn. lubricate as required.

20 MHD56151 - Edition 4
 Series EA Troubleshooting Guide Continued
SYMPTOM POSSIBLE CAUSE SOLUTION
Balancer will not Lo-load needle valve closed. Refer to EA Basic Operational Adjustments.
balance or lower the
Air supply check valve holding. Low air pressure - should be 70 psi (4.8 bar), minimum.
load. Control handle in
lo-load position. Excessive air flow through trim valve. Close trim valve (clockwise) slowly.
Air does not bleed from control line fitting at Refer to EA Basic Operational Adjustments, Trim Valve and
“A” port of EA regulator. Auxiliary Flow Valve Settings.
Control line pinched or has air flow Make sure control line is unobstructed so air can flow.
restriction.
Foreign matter in fittings at EA regulator, Make sure air passages are open for air flow.
handle, or bleed parts in handle.
Balancer will not un- Air supply check valve holding. Check for sufficient air supply pressure, 70 psi (4.8 bar)
load. Control handle in minimum.
un-load position. Un-load needle valve closed. Open needle valve slowly.
Excessive air flow through trim valve. Close trim valve (clockwise) slowly until empty hook is
balanced.
Foreign matter in fittings at EA regulator, Make sure air passages are open for air flow.
handle, or bleed parts in handle.
Erratic Operation Fluctuating air supply pressure. Install pressure regulator in supply line. Set at low end of
pressure fluctuation. Do not exceed 100 psi (6.9 bar).
Air contaminated with water, oil, dirt, etc. Install 5 micron self-draining type filters.
Damaged EA regulator. Replace regulator or repair as necessary. Refer to EA Regulator
disassembly, on page 22.

21 MHD56151 - Edition 4
 SERIES EA, BA Z-SERVO REGULATOR

2
12 4
15
13
3
2 14
6
10
8
11
34
9
16
36
17

20
7

27
18
5
19
26 23 21
22
33 31
28 24
32
25
30

29
(Dwg. MHP1914) 1

Item Description Qty. Part Item Description Qty. Part

No. of Part Total Number No. of Part Total Number
1 Guide Assembly - EA Regulator 1 15692 • 20 Valve Spring 1 15804
• 2 ‘O’ Ring 3 15750 21 Pipe Plug 1 ZHS13500
• 3 ‘O’ Ring 1 15754 • 22 Pilot Piston Assembly 1 15800
• 4 ‘O’ Ring 1 15755 • 23 U-Cup Seal 1 15801
5 Valve Seat - EA Regulator 1 ZHS15670 • 24 ‘O’ Ring 1 15757
6 Intake Filter Assembly 1 13062 25 Pilot Bonnet - EA Regulator 1 15821
7 Body Assembly - EA Regulator 1 15605 26 Self Tap Screw 4 15777
• 8 ‘O’ Ring 1 15758 27 Set Screw 1 10619
• 9 ‘O’ Ring 1 15759 28 Pilot Spring 1 15810
10 Piston - EA Regulator 1 15730 29 Regulator Screw Assy. - EA Reg. 1 15841
• 11 Seal - Integral Check 1 15740 30 Bonnet - EA Regulator 1 15620
12 Plug - EA Regulator 1 15710 • 31 Main Diaphragm Assy - EA Reg. 1 15630
13 Spring - EA Regulator 1 15720 • 32 ‘O’ Ring 1 15752
• 14 Valve Stem - EA Regulator 1 15680 • 33 ‘O’ Ring 1 15751
15 Stem Spring - EA Regulator 1 15700 34 Screw 2 15782
• 16 ‘O’ Ring 2 15748 35 Screw 2 15781
17 Needle Valve - EA Regulator 2 15760 36 Lockwasher 4 15785
• 18 Valve Assembly 1 15802 • Recommended Spare
• 19 Valve Seat 1 15803 Recommended Spare Parts Available In Kit 15900 - EA Regulator
Repair Kit

22 MHD56151 - Edition 4
 Removal From Balancer 10. Remove trim valve (17) and ‘O’ Ring (16). Check ‘O’ Ring
for wear and trim valve tip for possible damage.
1. Place suitable stand or platform under suspended load. Stand 11. Remove auxiliary flow control valve (17) and ‘O’ Ring (16).
or platform should be high enough for load to rest on when Check ‘O’ Ring for wear and valve tip for possible damage.
balancer is at bottom of its travel. 12. Clean regulator body (7) and components thoroughly.
2. Slowly turn pilot regulator screw counterclockwise until wire Replace all worn parts.
rope is slack. Remove load from hook.
3. Turn off air supply.
4. Disconnect all hose connections from EA regulator.
• If more than 2 or 3 items require replacement, it is generally
5. Remove mounting screws.
advisable to thoroughly clean regulator and install a P/N
15900 repair kit.
Disassembly

Refer to Dwg. MHP1914 on page 22. Assembly

1. Apply a very light coat of lubricant (10886) to all ‘O’ Rings

during reassembly.
• Use of replacement parts other than genuine Ingersoll-Rand 2. Install auxiliary flow control valve (17) and ‘O’ Ring (16).
original parts could result in damage to the balancer and void Turn until head of valve protrudes 1/16 in. to 1/8 in. (1.6 to
the warranty. 3.2 mm) from regulator body.
3. Install trim valve (17) and ‘O’ Ring (16). Turn clockwise
1. Remove filter assembly (6). Check for dirt or loose filter until closed.
media. 4. Install pilot regulator components. Insert spring (20) into
2. Remove check valve assembly by removing plug (12) and hole. Position valve (18) in place. Make sure rubber insert of
pushing piston (10) out from opposite side with a blunt valve faces away from spring.
punch. Assembly consists of the hexagon plug (12), spring 5. Insert valve seat (19) and carefully tighten.
(13) and piston (10), ‘O’ Rings (2), (9) and seal (11). Inspect 6. Insert ‘O’ Rings (4) and (3) into guide. Apply a light coat of
check valve ‘O’ Ring (2), seal (11), and piston ‘O’ Ring (9) lubricant (10886) on outside diameter of valve stem (14).
for wear. Slide spring (15) over small end of valve stem. Insert this
3. Remove guide assembly (1). This consists of three different assembly into guide assembly (1). Place completed guide and
size ‘O’ Rings (2), (3) and (4), a valve stem (14) and spring valve assembly into center hole of regulator body (7) and
(15). Two ‘O’ Rings (2) are located inside guide assembly. tighten.
Check ‘O’ Rings and valve stem for wear. Check inside valve 7. Insert filter assembly (6) into hole above port B and tighten.
for possible clogging of small pressure balance hole. 8. Insert stem of check valve assembly (10) seal end first into
4. To remove bonnet (30) and diaphragm (31), push on brass hole above port A. Insert spring (13) and hexagon plug (12).
ball, visible through hole in valve seat (5), with an instrument 9. Place ‘O’ Ring (24) into groove in regulator body between
softer than brass. ports A and B. Insert spring (28) into regulator screw (29).
5. Check rubber diaphragm for cracks or cuts. Replace it if Lubricate U-cup (23) with lubricant (10886). Insert it with
necessary. Make sure brass ball pin is free to rotate. piston assembly (22) into pilot regulator bonnet (25). Make
sure brass stem goes through center of valve seat (19).
10. Insert and tighten four screws (26). This completes the pilot
regulator assembly.
• Brass ball pin must not have end play. If end play is found, 11. Connect air supply to regulator and turn on.
adjust setscrew on opposite side of diaphragm. Apply a light 12. Check pilot regulator operation by turning regulator screw
coat of thread-locking compound to prevent screw from (29) clockwise until air pressure flows through small hole
turning. End play in pin will cause slow exhaust or erratic located on back of regulator body, at edge of bonnet (30)
operation. opening.

6. Remove four screws (26) from pilot regulator bonnet (25).

7. Remove pilot piston assembly (22). Check U-cup (23) and
‘O’ Ring (24) for wear. • After checking for air flow, turn adjustment knob
8. Check opening in brass tube of piston assembly (22) to make counterclockwise until air flow stops. Disconnect air supply.
sure it is clear.
9. To inspect valve assembly (18), valve seat (19) and spring 13. Insert diaphragm assembly (31), bonnet (30) and ‘O’ Ring
(20), remove seat with a #2 Phillips screwdriver or 3/8 in. (33).
(10 mm) socket wrench. Check rubber insert on valve (18)
for wear. Replace if necessary. (Dwg. MHP1920)

MHD56151 - Edition 4 23
 INTERLOCK ADJUSTMENTS

Refer to Dwg. MHP1920 on page 24.

1. Raise handling device/fixture to a mid travel position, so
balancer is supporting the entire weight. The Interlock screw
threads into the aluminum housing that will rotate with the
screw. Hold aluminum housing while turning the screw.
2. Turn screw counterclockwise until Interlock light illuminates
(green light) or until 1-1/2 inch (38 mm) of thread is visible.
3. Depress and release (repeatedly) the clamp/vacuum release
button while rotating Interlock screw clockwise until clamp
opens or blow off air is heard at vacuum cups or Interlock
indicator extinguishes.
4. Raise and lower handling device/fixture several times. Check
for proper operation of clamp and vacuum controls.
5. Raise handling device/fixture to the full up position.
6. Depress and hold up lever of the “ZA” control for three
seconds. This will simulate an additional load on the
balancer.
7. Depress and release clamp/vacuum release button. Clamp
should remain closed or not blow off air to vacuum cups.
8. Check that Interlock indicator has illuminated (green light).
9. Lower handling device/fixture and engage a part with the end
effector.
10. Raise load 1 inch (26 mm) above pick up point.
11. Depress and release clamp/vacuum release button. Part
should remain attached to end effector.
12. Lower handling device/fixture and release part at the pick up
point.
13. Hold aluminum housing and tighten jam nut on Interlock
screw to prevent setting from changing.

(Dwg. MHP1920)
Item Description Qty. Part
No. of Part Total Number
Quad-Coil Hose Assembly with
--- 1 *10813
Fittings
1 Quad Coil Hose 1 93949
2 Warning Tag (do not remove) 1 10445
3 Interlock 1 99064
Push on Elbow Fitting, 5/32 tube 1
4 93970

5 Push on Fitting, 3/8 tube 5 93947

6 Push on Fitting, 5/32 tube 1 93963
7 Street Tee, 3/8 NPT 1 10708
8 Reducer Bushing 1 13503

24 MHD56151 - Edition 4
 TANDEM CONTROL BALANCER

Item Description Qty. Part

No. of Part Total Number
Master Tandem Manifold
1 1 10549780
Assembly (includes item 8)
Slave Tandem Manifold
2 1 10549814
Assembly (includes item 8)
3 Mounting Screw 4 15778
4 Mounting Screw 4 15779
5 Mounting Screw 2 15786
6 Mounting Screw 2 15787
7 Lockwasher 8 15785
8 ‘O’ Ring 2 15751
(Dwg. MHP1923) 9 Street Elbow 90° 3 10375
10 Black Control Hose 2.5 ft. 10555-B
Tandem Control Installation 11 Swivel-F Hose Fitting 2 10560
1. Install master manifold (1) behind EA, ZA or BA control kit. 12 Male Adapter 2 10565
Refer to Dwg. MHP1923 on page 25. Street Tee
2. Install slave manifold (2) to 2nd balancer. 13 1 1964
Used with Zimmerman Interlock
3. Install tandem hose assembly (10) between master (1) and
slave (2) manifolds as shown in Dwg. MHP1923 on page 25.

LOAD HOOKS, LASH-UP AND YARDING

Lash-Up
To properly install load hook to wire rope you must determine the
following:
1. Highest point which load must clear from floor. Refer Dwg.
MHP1358 on page 25.
2. Distance from hook throat to bottom of load. Refer Dwg.
MHP1924 on page 25.
3. Add number 1 dimension to number 2 dimension, then add 3-
1/2 in. (89 mm).
4. Measuring from the floor with the wire rope fully retracted,
install hook using the dimension from number 3 to the floor.

Load #2

(Dwg. MHP1924)

• Do not operate balancer if load is not centered under wire

rope. Yarding of the wire rope will cause premature wire rope
(Dwg. MHP1358) failure and undue wear of internal balancer parts and may
void warranty.
5. Verify coverage is correct. Use wire cutter part number 01942 • Do not continuously rotate balancer in one direction. Air line
to remove excess wire rope. damage will occur from continuous rotation potentially
allowing the load to lower. Reverse direction with each cycle of
the balancer to prevent twisting and damage to air lines.

MHD56151 - Edition 4 25
 Yarding Wire Rope to Hook Assembly
Wire rope should not be yarded more than 10 degrees from
vertical center line of wire rope guide.
Excessive Yarding will cause increased wear on balancer and
decrease working life of components.

Wire Rope Guide

Wire Rope
Guide

10˚
Maximum Incorrect
Incorrect
Angle

Correct
Correct (Dwg. MHP1362)

(Dwg. MHP1925)

Hook Assembly

(Dwg. MHP1926)
Item Description Qty. Part
No. of Part Total Number
1 Hook Assy., Spring Lock 1 10223
1A Hook Assy., Pin Lock 1 10227
2 Thimble 1 10210
3 Clamp 1 10237
4 Wire Rope, 30 ft. length 1 10084-30

Spread and insert thimble (2) to clamp loop. Thread wire rope
around thimble.

• Allow at least 1 in. (26 mm) of excess wire rope and cap end
of wire rope. Join live wire rope strand to excess and install
clamp as shown in Dwg. MHP1362 on page 26.
26 MHD56151 - Edition 4
 LOAD BLOCKS

Load Block Installation

1. Thread wire rope through and around pulley(s) in Load
Block.
2. Bring excess wire rope back up to bottom eye pad of
balancer.
3. Install thimble on eye pad.
4. Loop wire rope around thimble.
5. Tighten wire rope and install clamps.

(Dwg. MHP1363) (Dwg. MHP1364)

• Balancers using load blocks should not have ball stops on
wire rope.

SUSPENSION KITS

Small Balancer Suspension Kits

• Severe injury and/or property damage can occur if 5

suspension kit is not installed correctly, or if installed on a rail
flange other than specified. Rail stops must not contact
balancer housing.

Part Refer To Page

Number Balancer Suspension Kit Dwg: No.
6
16300 ZRS2/3 Small Balancer MHP1931 29
16305 ZRA1 Small Balancer
MHP1927 27 8 4
16307 ZRV2 Small Balancer
2
16310 ZRA2 Small Balancer
MHP1931 29
16315 KBK II Small Balancer
16320 T-Rail Small Balancer MHP1928 28 1

16325 KBK I Small Balancer MHP1932 30

16344 ETA4 Small Balancer MHP1927 27 7
3
16345 ETA 8 Small Balancer MHP1931 29
(Dwg. MHP1927)
16355 ZRAT Small Balancer MHP1927 27
Part Number
16360 Hook Mount Small Balancer MHP1930 28 Item Description Qty.
No. of Part Total 16305 16355 16344 16307
16380 Opt. Small Balancer ZRA1 ZRAT ETA4 ZRV2
MHP1931 29 1 Bushing 2 17025
16400 ZRS2/3 Large Balancer
2 Screw 2 17047
16405 ZRA1 Large Balancer
MHP1929 28 3 Nut 2 17060
16407 ZRV2 Large Balancer Trolley
4 2 17125
16410 ZRA2 Large Balancer Bracket
MHP1931 29 5 Trolley 1 30279 31056 30743 31525
16415 KBK II Large Balancer
6 Screw 2 ZHS72005
16420 T-Rail Large Balancer MHP1928 28 7 Nut 2 75563
16425 KBK I Large Balancer MHP1932 30 8 Spacer 4 30073-500
16444 ETA4 Large Balancer MHP1929 28
16445 ETA8 Large Balancer MHP1931 29
16455 ZRAT Large Balancer MHP1929 28
16460 Hook Mount Large Balancer MHP1930 28
16480 Opt. Mount Large Balancer MHP1931 29

MHD56151 - Edition 4 27
 Large Balancer Suspension Kits Part Part
Number Number
Item Description Qty. 16320 Qty. 16420
No. of Part Total T-Rail Total T-Rail
Small Large
Balancer Balancer
5
2 Rail Safety 1 01925 2 01925
3 Trolley Half 2 16006 2 16013
6
4 Axle 2 16043 2 16043
5 Spring Pin 4 16060 4 16060
6 Bushing 2 17045 2 17045
7 Bushing Clip 4 ZHS17046 4 ZHS17046
2
8 Setscrew 2 ZHS70438 2 ZHS70438
4 3
8 Hook Mount Suspension Kits
1
7 3
2 1
(Dwg. MHP1929)
Part Number
Item Description Qty.
No. of Part Total 16405 16455 16444 16407 4
ZRA1 ZRAT ETA4 ZRV2
1 Bushing 2 17025 5
2 Screw 2 17047 6
3 Nut 2 17060
Trolley
4 2 17220
Bracket
5 Trolley 2 30279 31056 30743 31525
6 Screw 2 ZHS72005 8
7 Nut 2 75563 7
8 Spacer 4 30073-500 (Dwg. MHP1930)
Part Number
16360 16460
Item Description Qty. Hook Hook
T-Rail Suspension Kits No. of Part Total Mount Mount
Small Large
Balancer Balancer
1 Safety Cable 3 ft. 10096-3
2 Thimble 2 10210
3 Clamp 4 10230
1 4 Top Hook 1 17010
5 Bushing 2 17025
6 Screw 2 17047
7 Nut 2 17060
4
3 6 8 Bracket Top Hook 2 17505 17012
7
8
5 2

(Dwg. MHP1928)
Part Part
Number Number
Item Description Qty. 16320 Qty. 16420
No. of Part Total T-Rail Total T-Rail
Small Large
Balancer Balancer
1 Spring Pin 1 01902 2 01902

28 MHD56151 - Edition 4
 ZRS/ZRA2/KBKII and ETA8 Suspension Kits

(Dwg. MHP2931)
Part Number
Item Description Qty.
No. of Part Total 16300 16310 16315 16345
ZRS2/3 Sm. Balancer ZRA2 Sm. Balancer KBKII Sm. Balancer ETA 8 Sm. Balancer
1 Bushing 2 17025
2 Screw 2 17047
3 Nut 2 17060
4 Trolley Bracket 2 17110
5 Trolley 1 ZHS30510 30015 30030 30929
6 Screw 2 72626
7 Nut 2 75566
8 Spacer 4 30073-312

Part Number
Item Description Qty.
No. of Part Total 16400 16410 16415 16445
ZRS2/3 Lg. Balancer ZRA2 Lg. Balancer KBKII Lg. Balancer ETA 8 Lg. Balancer
1 Bushing 2 17025
2 Screw 2 17047
3 Nut 2 17060
4 Trolley Bracket 2 17215
5 Trolley 1 ZHS30510 30015 30030 30929
6 Screw 2 72626
7 Nut 2 75566
8 Spacer 4 30073-312

Item Description Qty. Part Number

No. of Part Total 16380 - Opt. Sm. Balancer 16480 - Opt. Lg. Balancer
1 Bushing 2 17025
2 Screw 2 17047
3 Nut 2 17060
4 Suspension Bracket 2 95488-S 95486-S

MHD56151 - Edition 4 29
 KBKI Suspension Kits

2
4
8

7
3
(Dwg. MHP2932)

Part Number
Item Description Qty.
No. of Part Total 16325 - KBKI 16425 - KBKI
Small Balancer Large Balancer
1 Bushing 2 17025
2 Screw 2 17047
3 Nut 2 17060
4 Trolley Bracket 2 17120 17220
5 Trolley 2 ZHS30603
6 Screw 2 ZHS72005
7 Nut 2 75563
8 Spacer 4 30073-594

30 MHD56151 - Edition 4
 Tandem Tie Bar Kits

5
6 3

4
(Dwg. MHP1933)
Item Description Qty.
Part Number
No. of Part Total
1 Tandem Tie-Bar 1 16200
2 Capscrew 2 17047
3 Locknut 2 17060
4 Tandem Reeve Eyebolt 1 16155
5 Nut 1 75512
6 Lockwasher 1 74513

8 9 3

5
4
6

1 Axles Are Not

Included in Kit
2

7
(Dwg. MHP1934)
Item Description Qty.
Part Number
No. of Part Total
1 Tie-Bar Clip 1 16047
2 Steel Axle Bushing 2 16052
3 Setscrew 2 16093
4 Socket Head Screw 2 16098
5 Lockwasher 2 16099
6 T-Rail Tie-Bar 1 16112
7 Tandem Reeve Eyebolt 1 16155
8 Lockwasher 1 74513
9 Nut 1 75512

MHD56151 - Edition 4 31
 PREVENTIVE MAINTENANCE CHECKS AND SERVICE

Lubrication can be accomplished by partial disassembly of

balancer while still on the overhead rail as follows:
1. On series EA and BA balancers, turn pilot regulator screw
• Clean, dry air must be used at all times when operating (counterclockwise) until wire rope is slack. On series ZA
balancers. balancers, depress down lever until wire rope is slack.
2. Remove load from balancer.
Preventive Maintenance 3. Turn off air supply.
4. Remove wire rope guide, end cap and piston. Refer to
Preventive maintenance recommendations are designed to prevent Balancer Rebuild Disassembly steps 4 - 7 on page 35 for
unexpected breakdowns and problems through periodic inspection removal of end cap.
and maintenance. Maintenance intervals should be based on 5. Using a paint brush (or a similar object) reach through the
frequency of usage and operating environment. Frequent usage, or wire rope window in the housing and apply approximately a
dirty operating conditions require more frequent servicing. A tablespoon of lubricant (10886) to ball screw.
clean, dry air supply will help keep the equipment functioning
properly. Refer to “INSPECTION AND MAINTENANCE
REPORT” on page 34. Using this report will aid in tracking
component failures or faults. We recommend the use of this report • Lubricant (10885) must be used in 500 lb. (227 kg) Balancer.
as a preventive maintenance tool.
6. Using a clean rag, wipe off piston, cylinder bore of housing
and ball screw cap.
Wire Rope and Load Hooks
7. Apply lubricant (10885) to cylinder bore and outside
diameter of ball screw cap. To reassemble refer to Balancer
Wire rope, load hooks and clamps should be inspected on a daily
Rebuild Assembly steps 6 - 14 on page 40.
basis. Time intervals should be based on the frequency of usage
8. Attach control package to end cap. Turn on air.
and in accordance with standard wire rope manufacturers
9. Readjust balancer, per Control Operational Adjustments.
specifications. Refer to “PREVENTIVE MAINTENANCE
SCHEDULE” on page 33.
Air Supply
Wire Rope Inspection
Be sure that air supply is free of rust, dirt, water and oil. Use of a
good air filter and in line regulator is highly recommended. 100
1. Depress the down lever to lower the load to the bottom of
psi (6.9 bar) is required to operate balancer at its maximum
balancer travel.
capacity. Lower pressure reduces balancer capacity accordingly.
2. Use a gloved hand to carefully slide up the rope, if the glove
Do not use an air in-line oiler. Oil will damage balancer and
snags on the wire rope refer to Preventive Maintenance
controls.
Schedule.
3. Check entire length of rope up to the wire rope guide.
4. Replace wire rope if found faulty. Balancers Not in Regular Use

1. Balancers which have been idle for a period of one month or

Load Hook Inspection
more, but less than one year, should be given an inspection
conforming with the requirements of “Frequent Inspection”
1. Top bail of hook swivels freely.
prior to being placed into service.
2. Tip of hook aligns with the self-closing gate.
2. Balancers which have been idle for a period of more than one
3. No more than 10% wear is allowed at the base of the hook.
year should be given an inspection conforming with the
4. No more than 5% wear in all other areas.
requirements of “Periodic Inspection” prior to being placed
5. Quic-Check“ marks must align with a half-inch increment.
into service.
3. Standby balancers should be inspected at least semiannually
Balancer Lubrication in accordance with the requirements of “Frequent
Inspection.” In abnormal operating conditions balancers
Basic Balancer: There are only 3 moving parts (ball nut, thrust should be inspected at shorter intervals.
bearing and piston) inside the balancer that require periodic
cleaning and lubrication. Cleaning usually requires complete
disassembly of the balancer and a thorough washing in a solution,
such as mineral spirits.

• Special lubricants mentioned in the reassembly instructions

are recommended for balancers and are available through
Ingersoll-Rand.

32 MHD56151 - Edition 4
 PREVENTIVE MAINTENANCE SCHEDULE

Daily Frequent Periodic

Component Inspection Criteria for Operation (1st Operation (Less than 6 (More than 6
of Shift) months/semiannual) months/annual)
Wire Rope Kinks No visible kinks on entire length. X X X
Fraying No visible fraying on entire length. X X X
Bird caging No visible separations on entire length. X X X
Clamps Tightness Clamps do not slide on wire rope. X X
Clamps are tight. X Torque check clamps Torque check clamps
at 7.5 ft. lbs at 7.5 ft. lbs
(1.04 kg/m) (1.04 kg/m)
Cracks No visible cracks. X X X
Load Hook Cracks No visible cracks. X X
Swivel Smooth operation and free rotation. X X
Hook Latch Positive locking of latch X X
Reeve Block Cracks No visible cracks X X
Swivel Smooth operation and free rotation. X X
Hook Latch Positive locking of latch. X X
Hardware Center pulley bolt for full engagement. X X X
Pulley Smooth operation when in motion. X X
Suspension Hardware No loose or missing hardware. X X X
Kit Trolley Body Aluminum–no visible cracks.
X X
Steel–no visible broken welds.
Trolley Wheels Smooth operation with no binding. X X
Hook Mount (Optional) Positive locking of latch. X X
Safety Cable (Optional) No loose clamps. No damage or wear X X
to wire rope. X Torque check clamps Torque check clamps
at 4.3 ft. lbs at 4.3 ft. lbs
(0.6 kg/m) (0.6 kg/m)
Balancer Smooth operation No binding or resistance in motion. X X X
Lubrication Piston and ball screw for grease. X
Wear Internal parts for excessive wear.
Refer to Balancer ‘Cleaning and X
Inspection’ section on page 37.
Controls Fittings No visible cracks, leaks or looseness X X
Tubing No visible bulges, cracks, kinks X X
Handles No visible cracks, leaks, looseness, or
X X
sticking of buttons
Manifold/Regulator No visible cracks, leaks or looseness of
X X
hardware
Z-Brake Brake Rods Secured and straight X
Bearing Smooth rotation X
Brake Ring No gouges-Burrs removed X
Brake Spring Security. No deformation X
Z-Stop Engagement Pin Fully engages plate-past notch in pin X
Engagement Plate Secured to brake rods.
X
Flat surface-no warping
Housing Secured to end cover. No air leakage X
Fittings Secured. No air leakage X

MHD56151 - Edition 4 33
 INSPECTION AND MAINTENANCE REPORT

Ingersoll-Rand Air Balancers

Model Number: Date:

Serial Number: Inspected by:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspection (___ Monthly ___ Yearly)
Operating Environment:
2. Discrepancy(s) noted during Frequent Inspection
3. Discrepancy(s) noted during maintenance Normal ___ Heavy ___ Severe ___
4. Other: ___________________________
Refer to the Parts, Operation and Maintenance Manual “INSPECTION” section for general inspection criteria. Also, refer to appropriate
National Standards and Codes of practice. If in doubt about an existing condition contact the nearest Ingersoll-Rand Distributor or the
factory for technical assistance.
CONDITION CORRECTIVE
COMPONENT NOTES
Pass Fail Repair Replace
Fasteners
Shafts
Bearings ---
Spool
Wire Rope Guide ---
Cover
Controls
Hooks ---
Gate acts as gauge when visually inspecting for stretched, twisted or bent hooks.
Top Damage ---
Hook Crack Test Method Used: Dye Penetrant ____ Magnetic Particle ____ Other: __________________________
Gate acts as gauge when visually inspecting for stretched, twisted or bent hooks.
Bottom Damage ---
Hook Crack Test Method Used: Dye Penetrant ____ Magnetic Particle ____ Other: __________________________
Hook Gate ---
Wire Rope
Working length(s) maximum stretch: ______ inches / ______ mm
Support Structure
Rail System Refer to Rail System Manual
Labels and Tags ---
Other Components (list in
NOTES section)

This page may be copied and used as an inspection / maintenance record.

34 MHD56151 - Edition 4
 BALANCER REBUILD

8. Remove ball screw cap by slipping it off the ball screw. Refer
Disassembly for 6.5 and 10 inch Balancers - All Series
to Dwg. MHP1936 on page 35.

• Turn off air supply to balancer and be sure wire rope is slack
before attempting any disassembly operations. Refer to
(exploded view of balancers) Dwgs. MHP1962 - 1965 on pages
44 - 48 for your specific balancer.

• Use of replacement parts other than genuine Ingersoll-Rand

original parts could result in damage to the balancer and void
the warranty.

• The balancer shown in the following instructions has 120 in. (Dwg. MHP1936)
(305 cm) travel with all controls removed.

1. Place balancer on a bench or suitable clean work area.

2. Remove Z-Stop if installed. Refer to section “Z-STOP
INSTALLATION AND TEST” on page 42.
3. Cut load wire rope above ball stop (if used). Refer to Dwg.
MHP1935 on page 35.
4. Remove load hook and wire rope guide.
5. Loosen center bolt in end cap and end cover. Do not remove.

(Dwg. MHP1368)

• Wire rope anchor hole in reel should be visible at this time. If

not, rotate reel slightly, winding up wire rope, until hole is
visible. Swaged fitting on the end of wire rope has a shank
which fits into anchor hole. The fit should not be tight. If fit is
tight, be careful not to damage reel assembly when removing
wire rope. Refer to Dwg. MHP1368 on page 35 and Dwg.
(Dwg. MHP1935) MHP1937 on page 36.

6. Remove screws (if applicable) around outside diameter of 9. Push wire rope into balancer until swaged fitting is exposed.
end cap. Remove hex head bolt in center of end cap. Pull on swaged fitting to remove wire rope. Refer to Dwg.
7. To remove end cap pull on wire rope. This will force piston MHP1938 on page 36.
against end cap and push end cap and piston out of housing.

• DO NOT run reel off end of ball screw or ball bearings will
drop out.
• Most balancers are equipped with thin metal shims inside the
ball screw cap to assure an air tight fit of seal (10061). Do not
lose shims.

MHD56151 - Edition 4 35
 Disassembly of Ball Screw

• Use of replacement parts other than genuine Ingersoll-Rand

original parts could result in damage to the balancer and void
the warranty.

• If ball screw or ball nut do not show signs of excessive wear,

disassembly of ball screw is not required.

1. Place ball screw and reel assembly on a shop towel, with

(Dwg. MHP1937) thrust bearing facing upwards.

10. Remove all screws around outside diameter of end cover.

11. Remove end cover and ball screw-reel assembly by pushing
on piston end of ball screw. Refer to Dwg. MHP1938 on page
36.

(Dwg. MHP1940)

(Dwg. MHP1938) 2. Rotate ball screw counterclockwise, removing it from reel

assembly. Refer to Dwg. MHP1940 on page 36.

• Use suitable marking pen to index ball screw notch with end
cover spring pin to prevent misalignment of reel.

12. Remove end cover and brake from ball screw and reel
assembly, by removing center bolt from end cover.

(Dwg. MHP1941)

3. Grasp reel with both hands and gently lift up. Ball bearings
will fall on shop towel. There are 64 ball bearings for models
150, 200 and 350. There are 84 ball bearings for model 500.
Lightly tap reel to remove any remaining ball bearings. If all
(Dwg. MHP1939) balls do not fall out, it may be necessary to insert a wire
through the ball return tubes to push out any balls which may
13. If balancer has a housing liner, remove it at this time. Refer to be lodged inside. Refer to Dwg. MHP1941 on page 36.
Dwg. MHP1939 on page 36.

36 MHD56151 - Edition 4
 Cleaning and Inspection Metal Slug

Now that the basic balancer is completely disassembled, the

components should be thoroughly cleaned and inspected.

1. Examine cylinder bore surface for excessive wear. Some

small scuff marks may be removed with fine emery cloth. If
wear is too excessive, housing must be replaced. If balancer
has a liner, it should also be inspected for wear or possible
cracking.
2. Check piston for cracks and wear of flexible sealing lips.
Check steel backing plate for cracks and wear.
3. Inspect ball screw and thrust bearing for excessive wear,
pitting, rusting and security in reel assembly.
4. Check wire rope guide for wear. Excessively worn or grooved
wire rope guides should be replaced.
5. Inspect reel assembly for cracks and wear of “V” grooves, (Dwg. MHP1943)
and anchor hole for deformation.
3. Installing New Ball Screw Nut - To install ball screw nut,
position washer over small diameter of nut. Place pin in
Ball Screw and Thrust Bearing Replacement position. Align pin with groove in reel and press in nut.
Refer to Dwgs. MHP1944 and MHP1945 on page 37.
1. Removing Thrust Bearing - Thrust bearing is attached to
reel with a retainer pressed into the hub of the reel
approximately 1/4 in. (6.4 mm). To remove, use a bearing
puller to engage under-cut at bottom of retainer inside
diameter. Refer to Dwg. MHP1942 on page 37.

(Dwg. MHP1944)

Metal
Slug

(Dwg. MHP1942)

2. Removing Ball Screw Nut - Ball screw nut can be pressed

out of reel using a cylindrical metal slug 2 inches (50.8 mm)
in diameter. Support reel along outer portion to allow ball nut
to be removed. Press out ball screw nut, being careful not to
damage reel. Refer to Dwg. MHP1943 on page 37.

(Dwg. MHP1945)

4. Installing New Thrust Bearing - To install thrust bearing,

place ground inside diameter side of bearing race against
reel, place retainer through thrust bearing and press it into
reel. After retainer is pressed in, check outer bearing race to
be sure it rotates freely. Thrust bearing retainer should be
0.008 to 0.012 in. (0.2 to 0.3 mm) below surface of outer
bearing race. Refer to Dwg. MHP1946 on page 38.

MHD56151 - Edition 4 37
 Metal
Slug

(Dwg. MHP1948)
(Dwg. MHP1946)
7. Repeat steps 4, 5 and 6 until all ball bearings are reinstalled
Ball Screw Reassembly into ball nut.

1. Plug hole on slotted end of ball screw with a small piece of

paper towel, to prevent ball bearings from dropping into
threaded hole.
2. Insert plugged end of ball screw into ball nut from thrust
bearing side.
3. Turn ball screw clockwise to thread into ball nut. Thread ball
screw to within 1-1/2 in. (38 mm) of ball nut end.
4. Stand assembly on ball screw and drop in approximately half
of ball bearings. Refer to Dwg. MHP1947 on page 38.

(Dwg. MHP1949)

8. Remove paper plug from end of ball screw.

Z-Brake Inspection

1. Remove balancer from service.

2. Remove end cover of balancer.
(Dwg. MHP1947) 3. Perform Z-Brake Preventive Maintenance. Refer to
Preventive Maintenance Schedule on page 33.
5. With one hand holding ball screw, rotate reel down and up 4. Check engagement.
until all ball bearings have rolled into the tubes of the ball 5. Grasp brake rods and rotate clockwise with a rapid motion.
nut. Refer to Dwg. MHP1948 on page 38. The brake shoe should engage the end cover and stop
6. Lay reel down on its side with ball screw in a horizontal rotation. Refer to Z-Brake Adjustment if unable to engage
position. Rotate ball screw three or four times to seat ball brake.
bearings in proper location. Refer to Dwg. MHP1949 on page
38. Reassembly

• Before reassembly, make sure all internal parts are clean,

properly lubricated and all worn parts have been replaced.

38 MHD56151 - Edition 4
 (Dwg. MHP1953)
(Dwg. MHP1950)
3. Position housing as shown. Insert liner, if so equipped. Be
sure to align round hole in liner at top of cut out with wire
rope guide bolt hole in housing. Refer to Dwg. MHP1953 on
page 39.

(Dwg. MHP1951)

1. Align and insert brake rods into holes in reel. Refer to Dwg.
MHP1950 on page 39. Anti-rotation pins in end cover must (Dwg. MHP1954)
line up with slots in ball screw (refer to Dwg. MHP1951 on
page 39) and protrude 1/8 to 5/32 in. (3.2 to 4 mm) from 4. Slide reel and end cover assembly into housing. Align screw
inside surface of end cover. Insert shorter bolt through end holes in end cover with holes in housing. Check to see that
cover and thread it into ball screw. Hand tighten bolt until bottom of reel ‘V’ groove is aligned with tapped hole or stud
ball screw is held firmly against end cover. at top of wire rope guide opening. If it is not in line refer to
2. Lubricate ball screw and thrust bearing with lubricant Dwg. MHP1954 on page 39, rotate end cover in either
(10886). direction until groove is aligned and bolt holes on outside
diameter of end cover are in line with bolt holes in housing.
Dwg. MHP1952, Figure ‘B’ on page 39 illustrates reel and end Insert two screws on opposite sides of housing. Check reel
cover assembly inserted into housing. alignment did not change when screws were inserted. If
alignment is correct, insert remaining end cover screws.
Fig. A Fig. B

Reel Reel
(Dwg. MHP1952)

(Dwg. MHP1955)

MHD56151 - Edition 4 39
• Most balancers have metal shims inside the ball screw cap,
between end of ball screw and ball screw cap, to obtain air
tight fit. If balancer is so equipped, be sure shims are in place.

5. Stand balancer on end. Place shims on end of ball screw.

Place ball screw cap over ball screw. Refer to Dwg.
MHP1955 on page 39.
6. Apply a very light, even coat of Lubricant (10885) to housing
cylinder bore and outside diameter of ball screw cap.

(Dwg. MHP1958)

• Be careful not to damage ‘O’ ring during this operation.

10. Install end cap. Tapped holes for screws around outside
diameter of end cap must be aligned with corresponding
holes in housing. Make sure control kit mounting holes are at
top of balancer. When end cap is properly aligned, use a soft
(Dwg. MHP1956)
hammer to tap it into housing. Refer to Dwg. MHP1958 on
page 40.
7. Insert piston into housing, steel side first and push it down
11. Make sure seal (10061) has not moved during installation of
until it contacts thrust bearing. Refer to Dwg. MHP1956 on
end cap. Inside diameter of seal should not be visible through
page 40.
hole in center of end cap.
8. Apply a light coat of Lubricant (10886) to end cap ‘O’ Ring
12. Insert bolt into center of end cap and hand tighten.
and insert it in groove of end cap.
13. Insert screws around outside diameter of end cap.
14. Tighten end cap and cover center bolts to 90-100 ft./lbs
(12.4-13.8 k/m).

Installing Wire Rope

• Use of wire rope other than Ingersoll-Rand wire rope

assembly should be avoided. Internal damage to the balancer
may result.

1. Install new wire rope assembly, by first rotating reel down

(direction of arrow in Dwg. MHP1366 on page 41) until
anchor hole in reel is visible.
(Dwg. MHP1957)

9. Apply a coat of lubricant (10885) to one side of seal (10061).

Press lubricated side onto end of ball screw cap. Refer to • Wire rope must be wrapped by hand twice around reel for
Dwg. MHP1957 on page 40. Lubrication helps hold seal in proper operation.
place while end cap is positioned.
2. End of wire rope is inserted down through anchor hole in reel
and into groove. Continue pushing wire rope into groove
until end appears at top of reel. Grasp this end and pull until
swaged fitting on end of wire rope is pulled into anchor hole
in reel. Refer to Dwg. MHP1366 on page 41.
3. Wrap wire rope around reel one more time, as described in
step 2. Wire rope should be centered in opening of housing.
Refer to Dwg. MHP1367 on page 41.

40 MHD56151 - Edition 4
 Swaged Tapped Hole
Fitting or Stud

Wire Rope
Aligned
With Hole
Or Stud

(Dwg. MHP1366)

(Dwg. MHP1367)

Installing Ball Stop

1. To install ball stop, the control package must be installed.
2. Turn on air to balancer and slowly wind as much wire rope as
possible into balancer.
3. Slide ball stop (10165) and wire rope stop (10200) onto wire
rope and up to balancer. Correct clearance between the wire
rope guide and ball stop is 1/8 to 1/4 in. (3.2 to 6.4 mm).
4. Use swage tool, part number 01927 to secure stop in position.

Z-BRAKE ADJUSTMENTS AND RESETTING

5. Follow appropriate control adjustments to ensure proper

operation of balancer.
6. Resume operation.
• Balancers with capacities of 150 lbs (68 kgs) or greater are 7. If brake engages when a load is attached or it interferes with
equipped with the Z-Brake, a centrifugal brake that is standard operation brake must be adjusted. Refer to
designed to stop uncontrolled upward travel of wire rope in Z-Brake ‘Adjustment Procedure’ section on page 42 for
the event of a sudden release or loss of load, and limit excessive further instructions.
upward acceleration of empty hook. Brake MUST NOT be
used as a travel limiting stop or up stop. Failure to follow these 91, 158, 227 kg (200, 300, 500 lb.) Balancer
instructions will result in damage to brake and the balancer.
Continuous use of brake will cause internal damage to
balancer and could result in damaging balancer beyond
repair.

Z-Brake Reset Procedure

ZA Controls

1. Ensure vertical path of load is clear.

2. Press down lever and release air in balancer until load begins
to lower.
3. Resume operation.
4. If brake engages when a load is attached or it interferes with Spring
standard operation, brake must be adjusted. Refer to Z-Brake Hole #2 Brake Shoe
‘Adjustment Procedure’ section on page 42 for further
instructions. (Dwg. MHP1369)

BA and EA Controls
1. Ensure vertical path of load is clear.
2. Grasp load hook at lifting eye pad and pull down on wire
rope. Carefully and slowly release load hook.
3. Attempt to resume operation.
4. If brake is still engaged rotate pilot regulator screw of
regulator until load begins to lower. This will change settings
on control.

MHD56151 - Edition 4 41
 68 kg (150 lb.) Balancer

• Note position of bearing retainer between end cover and ball

screw. Bearing retainer not required for 200 lb. (90 kg)
balancer.

9. Place end cover on work bench so that rods are pointing up.
10. With needle nose pliers remove end of spring on brake shoe
and place in desired hole. The farther from the center of
balancer spring is set, the less sensitive it will become.

Reassembly
1. Place balancer on its side so wire rope guide is facing you.
Hole #1 2. With your fingers rotate reel so it moves toward end cover.
Wire rope will retract.
(Dwg. MHP1370) 3. Hold end cover and align rods with holes in reel. The 150 lb.
(68 kg) balancer has only one rod.

• Be sure air supply is off and wire rope has slack.

• Be sure bearing retainer is in place between ball screw and
Adjustment Procedure brake assembly.

1. Remove balancer from overhead suspension. 4. Slide rod(s) and end cover assembly into hole(s) in reel until
2. Place balancer on a clean, dry work bench. the 9/32 in. (7.14 mm) diameter holes in housing and anti-
3. Remove control regulator from balancer. rotation notches on ball screw line up with pins in end cover.
4. Stand balancer on end cap (control end). 5. Install bolts on end cover outside diameter.
5. Loosen hex bolt in center of end cover. 6. Install end cover center bolt and torque to 90-100 ft/lb.
6. Remove bolts around the diameter of housing. (12.45-13.83 kg/m).
7. Remove center bolt from end cover. 7. Install controls and perform operational adjustments as
8. Remove end cover Z-Brake assembly. necessary.

Z-STOP INSTALLATION AND TEST

Refer to Dwg. MHP2178 on page 43. 4. Stand balancer on end cap (control end).
1. Lower the load completely. 5. Remove wire rope guide.
2. Disconnect/shut off air supply. 6. Disconnect red and yellow (7 and 8) tubes at fittings (4).
7. Remove screws (1 and 2) from Z-Stop housing (3).
If installing as a retrofit kit: 8. Remove spring (18).
a. Remove end cover from balancer. 9. Grasp engagement pin (17) with needle nose pliers and pull
b. Install new end cover. Ensure brake shafts align with straight out. If the pin is engaged in the plate, rotate the reel
corresponding holes in reel assembly. SLOWLY in either direction through the wire rope guide
c. Align end cover with outer housing holes, and install opening to release.
four each bolts. 10. Install in reverse order.
d. Tighten the end cover center bolt to 100 ft. lbs. (14 11. Lubricate ‘O’ rings (14, 15 and 16) with part number 10885.
kg/m) of torque.
3. Connect air supply to air fitting (4) on end cover using yellow
Testing
5/32 in. tubing.
4. Connect red 5/32 in. tubing to balancer interlock port to air 1. Run balancer through range of motion in work cell to ensure
fitting (4) on Z-Stop. proper operation.
5. Connect/turn on air supply. 2. With handling device/fixture in mid-point of travel
6. Check for leakage at all air fitting connections. Repair any disconnect/shut off air supply to balancer.
leaks found. 3. Balancer should be locked out of operation, the handling
device/fixture may drift down a small amount until Z-Stop
Removal locks out.
4. Attempt to raise or lower the handling device/fixture. No
Refer to Dwg. MHP2178 on page 43. movement should be detected.
1. Remove balancer from overhead suspension. 5. Connect/turn on air supply to balancer.
2. Place balancer on a clean, dry work bench. 6. Slowly move handling device fixture up and down. The
3. Remove control regulator from balancer. handling device/fixture should respond to inputs from
controls.

42 MHD56151 - Edition 4
 Z-STOP ASSEMBLY - 200/325/500 LB. (91/147/227 KG) BALANCER

9
10

11

9
8

19

4 15

3 12
2
13
14
1 16
18 16 17
(Dwg. MHP2178)
Part Number
Item Description Qty.
No. of Part Total 13301 – Z-Stop Assembly 13321 – Z-Stop Assembly
200 lb. (91 kg) and 325 lb. (147 kg) Balancer 500 lb. (227 kg) Balancer
1 Capscrew 2 ZHS70255
2 Capscrew 2 ZHS70254
3 ‘Z’ Stop Housing 1 13335
4 Fitting, Elbow 2 ZHS93969
5 Tube, Bulk As Req’d Tri Coil Assembly 93953/Quad Coil Assembly 93949
6 Interlock 1 99064
7 Tube, 5/32 in. Red 2 ft. 93960-R
8 Tube, 5/32 in. Yellow 2 ft. 93960-Y
9 Fitting, Elbow 2 93970**
10 Fitting, Reducer 1 13502
11 Fitting, Tee 1 ZHS10708
12 Retaining Ring 2 99126 99127
*13 Engagement Plate 1 ZHSEA0035 ZHSEA0036
*14 ‘O’ Ring 1 13342
*15 ‘O’ Ring 1 13343
*16 Quad Ring 2 13344
*17 Engagement Pin 1 13338
*18 Spring 1 ZHS76522
19 Screw 2 ZHSEA0029
* Refer to Dwg. MHP1960 on page 49 for breakdown.
** Use part number 93983 with handling device.

MHD56151 - Edition 4 43
 BASIC 150 LB. (68 KG) BALANCER

18
15
16
19
29 26
30

24 14
12B 2
17 12A
23 12 13
21
30
22 7 31 27
4
8
3 28

1 6

9
10
25

8 7

20 11
5
(Dwg. MHP1962)
Item Description Qty. Part Item Description Qty. Part
No. of Part Total Number No. of Part Total Number
1 Ball Screw Bolt (End Cover) 1 ZHS10017 19 Real Assy. 1 11514
2 Ball Screw Bolt (End Cap) 1 ZHS10013 20 Housing Assy. 1 12911
3 Ball Screw Cap 1 ZHS10046 21 Retainer (Z- Brake) 1 13039
• 4 Ball Screw Seal 1 10061 22 Z-Brake Assy.* 1 ZHSEA0034
5 Screw 8 10071 23 Anti-Rotation Pin 2 13440
6 Wire Rope Guide 1 ZHS10116 24 End Cover Assy. 1 13805
7 Nut 2 10124 25 Piston Assy. 1 14502
8 Wire Rope Guide Plate 2 10125 26 End Cap Spring Pin 1 ZHS15037
9 Ball Stop Assy. 1 10165 27 End Cap Assy. 1 15515
• 10 Swaged Stop 1 10200 • 28 ‘O’ Ring 1 15520
11 Accessory Kit 1 10208 29 Ball Nut Dowel Pin 1 16058
12 0.005 in. (0.127 mm) Shim As Req’d 10415 30 Washer 2 74516
12A 0.010 in. (0.254 mm) Shim As Req’d 10416 • 31 Wire Rope 20 ft. (6 m) 1 10084-20
12B 0.025 in. (0.635 mm) Shim As Req’d 10417 41 Capacity Label ** 1 10402
13 Pipe Plug 1/4 NPT 1 10764 42 I-R Label ** 1 ZHS54033030
14 Ball Nut Washer 1 HSPPS-2 • Recommended Spare Parts Available in Kit 10590
15 Thrust Bearing Retainer 1 ZHS11081 * Refer to Dwg. MHP1959 on page 45 for Z-Brake Assembly
16 Thrust Bearing 1 ZHS11091 ** Not Shown
17 Ball Screw Assy. *** 1 11112 *** Set of 64 Ball Bearings - Part Number 11012
18 Ball Screw and Reel Assy. 1 11514

44 MHD56151 - Edition 4
 Z-BRAKE ASSEMBLY - 150 LB. (68 KG) BALANCER

Refer to unit breakdown for

applicable end cover assembly

6 9

Note: Apply Loctite® 242 on screw threads

and shaft (2) end during assembly. Tighten
screw to 60 - 72 in.lbs (0.7-0.83 kg.m)
(Dwg. MHP1959)
Item Description Qty. Part
No. of Part Total Number
--- Brake Assembly - 150 lb. (68 kg) Balancer 1 ZHSEA0034
2 Shaft 1 13112
3 Pivot Shaft 1 13113
4 Brake Rotor 1 ZHSEA0033
5 Brake Shoe 1 13116
6 Bushing 1 65054
7 Radial Bearing 1 65074
8 Screw 1 ZHS70427
9 Heavy Spring 1 76517

MHD56151 - Edition 4 45
 BASIC 200 LB. (91 KG) BALANCER

18
16
17
20 14
30

23 15
13B 1
19 13A 31
26 13
24
31
25 8 32 28
4
9
3 29
2 5 7

10
22 11
27

9 8
21 12

(Dwg. MHP1963)
Item Description Qty. Part Item Description Qty. Part
No. of Part Total Number No. of Part Total Number
1 Ball Screw Bolt (End Cap) 1 ZHS10017 20 Real Assy. 1 11125
2 Ball Screw Bolt (End Cover) 1 ZHS10013 21 Housing Assy. 1 ZHS12204
3 Ball Screw Cap 1 ZHS10044 22 Housing Liner 1 12225
• 4 Ball Screw Seal 1 10061 23 End Cover Assy. 1 13035
5 Screw 8 10072 24 Retainer (Z-Brake) 1 13036
7 Wire Rope Guide 1 ZHS10114 25 Z-Brake Assy.* 1 ZHSEA0032
8 Screw 2 10120 26 Anti-Rotation Pin 2 13440
9 Wire Rope Guide Plate 1 10125 27 Piston Assy. 1 14005
10 Ball Stop Assy. 1 10165 28 End Cap 1 15016
• 11 Swaged Stop 1 10200 • 29 ‘O’ Ring 1 15020
12 Accessory Kit 1 10208 30 Ball Nut Dowel Pin 1 16058
13 0.005 in. (0.127 mm) Shim As Req’d. 10415 31 Washer 2 74516
13A 0.010 in. (0.254 mm) Shim As Req’d. 10416 • 32 Wire Rope 30 ft. (91.1m) 1 10084-30
13B 0.025 in. (0.635 mm) Shim As Req’d. 10417 41 Capacity Label ** 1 10403
14 Pipe Plug 1/4 NPT 1 HSPPS-2 42 I-R Label ** 1 ZHS54033030
15 Ball Nut Washer 1 11076 • Recommended Spare Parts Available in Kit 10591
16 Thrust Bearing Retainer 1 ZHS11081 Refer to Dwg. MHP1960 on page 49 for Z-Brake
*
17 Thrust Bearing 1 ZHS11091 Assembly
18 Ball Screw & Reel Assy. 1 11102 ** Not Shown
19 Ball Screw Assy. *** 1 11112 *** Set of 64 Ball Bearings - Part Number 11012

46 MHD56151 - Edition 4
 BASIC 350 LB. (158 KG) BALANCER

20
15 2
17 39
22
18 14B
34 14A 31
14
27 16
5 32
19 8 31
4
3 33
28 9
30
29 7

10
11
37
1

8
24
12

25 5
(Dwg. MHP1964)
Item Description Qty. Part Item Description Qty. Part
No. of Part Total Number No. of Part Total Number
1 Ball Screw Bolt (End Cover) 1 ZHS10012 22 Reel Assy. 1 11544
2 Ball Screw Bolt (End Cap) 1 ZHS10017 24 Housing Assy. 1. ZHS12204
3 Ball Screw Cap 1 ZHS10048 25 Liner Assy. 1 12240
• 4 Ball Screw Seal 1 10061 27 End Cover Assy. 1 13038
5 Screw 8 10072 28 Retainer (Z-Brake) 1 13039
7 Wire Rope Guide 1 10115 29 Z-Brake Assy. * 1 ZHSEA0032
8 Screw 2 1012 0 30 Anti-Rotation Pin 2 13440
9 Wire Rope Guide Plate 1 10125 31 Piston Assy. 1 14005
10 Ball Stop Assy. 1 10165 32 End Cap 1 15016
• 11 Swaged Stop 1 10200 • 33 ‘O’ Ring 1 15020
12 Accessory Kit 1 10208 34 Ball Nut Dowel Pin 1 16058
14 0.005 in. (0.127 mm) Shim As Req’d 10415 37 Washer 2 74516
14A 0.010 in. (0.254 mm) Shim As Req’d 10416 • 39 Wire Rope 30 ft. (9.1 m) 1 10084-30
14B 0.025 in. (0.635 mm) Shim As Req’d 10417 41 Capacity Label ** 1
15 Pipe Plug 1/4 NPT 1 HSPPS-2 42 I-R Label ** 1 ZHS54033030
16 Ball Nut Washer 1 11076 • Recommended Spare Parts Available in Kit 10951
17 Thrust Bearing Retainer 1 ZHS11081 * Refer to Dwg. MHP1960 on page 49 or Z-Brake Assembly
18 Thrust Bearing 1 ZHS11091 ** Not Shown
19 Ball Screw Assy. *** 1 11112 *** Set of 64 Ball Bearings - Part Number 11012
20 Ball Screw & Reel Assy. 1 11514

MHD56151 - Edition 4 47
 BASIC 500 LB. (227 KG) BALANCER

21
19 15
16 33
17
37
2
35 14B 36
18 14A
14
28
5
32 4
29 8 34
3
31 9
36 30 6
10
11
1 26

8
25 12

5
(Dwg. MHP1965)
Item Description Qty. Part Item Description Qty. Part
No. of Part Total Number No. of Part Total Number
1 Ball Screw Bolt (End Cover) 1 ZHS10017 21 Reel Assy. 1 11564
2 Ball Screw Bolt (End Cap) 1 ZHS10018 25 Housing Assy. 1 12208
3 Ball Screw Cap 1 ZHS10047 26 Liner Assy. 1 12245
4 Ball Screw Seal 1 10061 28 End Cover Assy. 1 13038
5 Screw 12 10072 29 Bearing Retainer (Z-Brake) 1 13039
6 Wire Rope Guide 1 ZHS10118 30 Z-Brake Assy. * 1 ZHSEA0038
8 Screw 2 10120 31 Anti-Rotation Pin 2 ZHS13440
9 Wire Rope Guide Plate 1 10125 32 Piston Assy. 1 14005
10 Ball Stop Assy. 1 10165 33 End Cap 1 15016
• 11 Swaged Stop 1 10200 • 34 ‘O’ Ring 1 15020
12 Accessory Kit 1 10208 35 Ball Nut Dowel Pin 1 16058
14 0.005 in. (0.127 mm) Shim As Req’d 10415 36 Washer 2 74516
14A 0.010 in. (0.254 mm) Shim As Req’d 10416 • 37 Wire Rope 30 ft. (9.1) 1 10084-30
14B 0.025 in. (0.635 mm) Shim As Req’d 10417 41 Capacity Label ** 1 10398
15 Pipe Plug 1/4 NPT 1 HSPPS-2 42 I-R Label ** 1 ZHS54033055
16 Thrust Bearing Retainer 1 ZHS11081 • Recommended Spare Parts Available in Kit 10591
17 Thrust Bearing 1 ZHS11091 * Refer to Dwg. MHP1960 on page 49 for Z-Brake Assembly
18 Ball Screw Assy. *** 1 11115 ** Not Shown
19 Ball Screw & Reel Assy. 1 11515 *** Set of 64 Ball Bearings - Part Number 11012 (2 sets
required for 500 lb. (227 kg) model)

48 MHD56151 - Edition 4
 Z-BRAKE ASSEMBLY – 200/350/500 LB. (91/158/227 KG) BALANCER

Refer to unit breakdown for

applicable end cover and bearing
retainer parts.

12
8 12A

11 2
5

4 3
10
Note: Apply Loctite 242 on screw threads
and shaft (2) ends during assembly. Tighten
screws (10) and (11) to 60-72 in. lbs (0.7-0.83 kg.m)

(Dwg. MHP1960)
Part Number
Item Description Qty. ZHSEA0032 – ZHSEA0032 – ZHSEA0038 –
No. of Part Total Z-Brake Assembly Z-Brake Assembly Z-Brake Assembly
200 lb. (91 kg) 350 lb. (158 kg) 500 lb. (227 kg)
Balancer Balancer Balancer
2 Shaft 2 13112 13142
3 Shaft Retainer 1 ZHS13122
4 Pivot Shaft 1 ZHS13123
5 Brake Rotor 1 ZHSEA0020 ZHSEA0037
6 Brake Shoe 1 13125
7 Thrust Washer 2 65063
8 Bushing 1 65073
9 Radial Bearing 1 65074
10 Screw 2 ZHS70257
11 Screw 2 ZHS70515
12 Spring 76517
1
12A Heavy Spring 76520*
* Replaces 76517 Brake Spring

MHD56151 - Edition 4 49
 PARTS ORDERING INFORMATION

Balancers are designed and constructed to provide long, trouble- For your convenience and future reference it is recommended that
free service. In time it may become necessary to order and install the following information be recorded.
new parts to replace those that have been subjected to wear.
Model Number _______________________________________
The use of other than Ingersoll-Rand replacement parts may
result in decreased performance, and may invalidate the warranty. Serial Number ________________________________________
For prompt service and genuine Ingersoll-Rand parts, provide
your nearest Distributor with the following: Date Purchased _______________________________________

1. Complete model number and serial number as it appears on

Return Goods Policy
the nameplate.
2. Part number and part description as shown in this manual. If it becomes necessary to return the complete balancer or certain
3. Quantity required. parts to the factory, contact the Distributor from whom you
purchased the balancer, or the nearest Ingersoll-Rand Distributor
in your locality, Ingersoll-Rand will not accept any returned
goods for warranty or service work unless prior arrangements have
been made and written authorization has been provided from the
location where the goods were purchased.

• Continuing improvement and advancement of design may

cause changes to this balancer which are not included in this
manual. Manuals are periodically revised to incorporate
changes. Always check the manual edition number on the
front cover for the latest issue.
The model and serial number label is located on the housing.
Disposal
When the life of the balancer has expired, it is recommended that
the balancer be disassembled, degreased and parts separated as to
materials so that they may be recycled.

SERVICE AND MAINTENANCE

For additional information contact:

Ingersoll-Rand
U.S. and International Sales
1872 Enterprise Drive
Rochester Hills, MI 48309
Phone: (248) 293-5700
Fax: (248) 293-5800

For additional information on related products order publication by the referenced Part/Document Number listed:
Product Part/Document Number Product Part/Document Number
Z Rail Manual MHD56159 Valu-Trak Rail Manual MHD56161
Manipulator Arm Manual MHD56162 Jib Crane Manual MHD56209
Balancer Electric Controls Manual MHD56222

50 MHD56151 - Edition 4
 WARRANTY

LIMITED WARRANTY
Ingersoll-Rand Company (I-R) warrants to the original user its I-R makes no other warranty, and all implied warranties
Products to be free of defects in material and workmanship for a including any warranty of merchantability or fitness for a
period of one year from the date of purchase. I-R will repair, particular purpose are limited to the duration of the expressed
without cost, any Product found to be defective, including parts warranty period as set forth above. I-R’s maximum liability is
and labor charges, or at its option, will replace such Products or limited to the purchase price of the Product and in no event
refund the purchase price less a reasonable allowance for shall I-R be liable for any consequential, indirect, incidental,
depreciation, in exchange for the Product. Repairs or replacements or special damages of any nature rising from the sale or use of
are warranted for the remainder of the original warranty period. the Product, whether based on contract, tort, or otherwise.

If any Product proves defective within its original one year Note: Some states do not allow limitations on incidental or
warranty period, it should be returned to any Authorized I-R consequential damages or how long an implied warranty lasts so
Material Handling Service Distributor, transportation prepaid with that the above limitations may not apply to you.
proof of purchase or warranty card.
This warranty gives you specific legal rights and you may also
This warranty does not apply to Products which I-R has have other rights which may vary from state to state.
determined to have been misused or abused, improperly
maintained by the user, or where the malfunction or defect can be
attributed to the use of non-genuine I-R parts.

IMPORTANT NOTICE
It is our policy to promote safe delivery of all orders. Damage Claims
You must file claims for damage with the carrier. It is the
This shipment has been thoroughly checked, packed and inspected transportation company’s responsibility to reimburse you for
before leaving our plant and receipt for it in good condition has repair or replacement of goods damaged in shipment. Claims for
been received from the carrier. Any loss or damage which occurs loss or damage in shipment must not be deducted from the
to this shipment while en route is not due to any action or conduct Ingersoll-Rand invoice, nor should payment of Ingersoll-Rand
of the manufacturer. invoice be withheld awaiting adjustment of such claims as the
carrier guarantees safe delivery.
Visible Loss or Damage
If any of the goods called for on the bill of lading or express You may return products damaged in shipment to us for repair,
receipt are damaged or the quantity is short, do not accept them which services will be for your account and form your basis for
until the freight or express agent makes an appropriate notation on claim against the carrier.
your freight bill or express receipt.

Concealed Loss or Damage

When a shipment has been delivered to you in apparent good
condition, but upon opening the crate or container, loss or damage
has taken place while in transit, notify the carrier’s agent
immediately.

MHD56151 - Edition 4 51
 United States Office Locations International Office Locations

Technical Support Regional Sales Offices Offices and distributors in Asia Pacific Operations
principal cities throughout the Ingersoll-Rand Ltd.
Ingersoll-Rand Annandale, NJ world. Contact the nearest 42 Benoi Road
Zimmerman Handling P.O. Box 970 Ingersoll-Rand office for the Jurong, Singapore
Systems 1467 Route 31 South name and address of the 629903
1872 Enterprise Drive Annandale, NJ 08801 distributor in your country or Phone: 65-861-1555
Rochester Hills, MI Phone: (908) 238-7000 write/fax to: Fax: 65-861-0317
48309 Fax: (908) 238-7048
Phone: (248) 293-5700 Canada Russia
Fax: (248) 293-5800 National Sales Office Ingersoll-Rand
Regional Warehouse Presnensky Val
For Order Entry,  Toronto, Ontario 19, Moscow, Russia 123557
Order Status 51 Worcester Road Phone: (7) 095-933-03-24
Ingersoll-Rand Rexdale, Ontario Fax: (7) 095-737-01-48
Global Logistics M9W 4K2
P.O. Box 618 Phone: (416) 213-4500 Australia
510 Hester Drive Fax: (416) 213-4510 Ingersoll-RandLtd.
White House, TN 37188 Order Desk Landmark Corporate Center
Phone: (615) 474-8665 Fax: (416) 213-4506 Level 2
Fax: (615) 672-0854 454-472 Nepean Highway
Europe, Middle East and Frankston, Vic 3199
Web Site: Africa Australia
www.irco.com Ingersoll-Rand Phone: 613 8781 1600
Douai Operations Fax: 613 8781 1611
111, Avenue Roger Salengro
59450 Sin Le Noble, France
Phone: (33) 3-27-93-08-08
Fax: (33) 3-27-93-08-00

Printed in USA