Ingersoll-Rand Zimmerman 600 User manual

Form MHD56162
PARTS, OPERATION, AND MAINTENANCE MANUAL
for
MANIPULATOR ARM
MODELS
600 700C 701C 713 720
(Dwg. MHP1568) (Dwg. MHP2468)
Form MHD56162
Edition 2
December 2002
71341481
© 2002 Ingersoll-Rand Company
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.
WARNING
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 unit in accordance with applicable safety
codes and regulations.

2MHD56162 - Edition 2
TABLE OF CONTENTS
Description Page No.
Safety Information
Danger, Warning, Caution, and Notice .......................................................................................................................................................... 3
Safety Summary.............................................................................................................................................................................................. 3
Safe Operating Instructions ........................................................................................................................................................................... 4
Specifications .............................................................................................................................................................................................. 4
Warning Label ........................................................................................................................................................................................... 8
Installation
Mounting ........................................................................................................................................................................................................ 8
Air System ...................................................................................................................................................................................................... 8
Operation
Description of Operation ................................................................................................................................................................................ 10
Balancer Operation ......................................................................................................................................................................................... 10
Control Operation ........................................................................................................................................................................................... 10
Manipulator Arm Operation ........................................................................................................................................................................... 10
Operation Adjustments ................................................................................................................................................................................... 11
Lash-Up .......................................................................................................................................................................................................... 12
Yarding ........................................................................................................................................................................................................... 12
Inspection
Records and Reports ....................................................................................................................................................................................... 13
Wire Rope Reports.......................................................................................................................................................................................... 13
Frequent Inspections ....................................................................................................................................................................................... 13
Periodic Inspection ......................................................................................................................................................................................... 13
Wire Rope Inspection Procedure .................................................................................................................................................................... 14
Units Not in Regular Use................................................................................................................................................................................ 14
Lubrication.................................................................................................................................................................................................. 15
Troubleshooting ......................................................................................................................................................................................... 15
Inspection and Maintenance Report .................................................................................................................................................... 16
Maintenance
Maintenance Intervals..................................................................................................................................................................................... 17
Wire Rope Replacement ................................................................................................................................................................................. 17
Disassembly .................................................................................................................................................................................................... 17
Cleaning, Inspection and Repair..................................................................................................................................................................... 18
Assembly ........................................................................................................................................................................................................ 18
Testing ............................................................................................................................................................................................................ 19
Series 600 Drawing and Parts List............................................................................................................................................................. 20-24
Manipulator Arm 700C Assembly Drawing and Parts List....................................................................................................................... 26-28
Pivot Column Mount Assembly Drawing and Parts List ............................................................................................................................... 29
Manipulator Arm 713 and 720 Assembly Drawing and Parts List............................................................................................................ 30-31
Carriage Assembly Drawing and Parts List ............................................................................................................................................. 32-33
Parts Ordering Information
Return Goods Policy....................................................................................................................................................................................... 34
Warranty ..................................................................................................................................................................................................... 35
Office Locations ............................................................................................................................................................................................ 36

MHD56162 - Edition 2 3
SAFETY INFORMATION
This manual provides important information for all personnel
involved with the safe installation, operation, and proper
maintenance of this product. Even if you feel you are familiar
with this or similar equipment, you should read this manual
before operating the product.
Danger, Warning, Caution, and Notice
Throughout this manual there are steps and procedures which, if
not followed, may result in a hazard. The following signal words
Danger is used to indicate the presence of
a hazard which will cause severe injury,
death, or substantial property damage if
the warning is ignored.
Warning is used to indicate the presence
of a hazard which can cause severe injury,
death, or substantial property damage if
the warning is ignored.
Caution is used to indicate the presence of
a hazard which will or can cause injury or
property damage if the warning is
ignored.
Notice is used to notify people of
installation, operation, or maintenance
information which is important but not
hazard-related.
DANGER
W
W
A
A
R
R
N
N
I
I
N
N
G
G
C
C
A
A
U
U
T
T
I
I
O
O
N
N
N
N
O
O
T
T
I
I
C
C
E
E
are used to identify the level of potential hazard.
Safety Summary
Personal protective and safety equipment required by the
operator’s surrounding environment must be used and maintained
in accordance with manufacturer’s instructions.
WARNING
• Do not use this unit or attached equipment for lifting,
supporting, or transporting people or lifting or supporting
loads over people.
• The supporting structures and load-attaching devices used in
conjunction with these units must provide a safety factor of at
least three times the rated capacity of the unit. This is the
customer’s responsibility. If in doubt, consult a registered
structural engineer.
• If system air pressure is lost, lower the load immediately. The
operator must stay out of the vertical path of the load.
NOTICE
• Lifting equipment is subject to different regulations in each
country. These regulations may not be specified in this
manual.
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 standpoint, one factor is paramount: conduct all operations
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.
The Occupational Safety and Health Act of 1970 generally places
the burden of compliance with the owner/employer, not the
manufacturer. Many OSHA requirements are not concerned or
connected with the manufactured product but are, rather,
connected 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 association, federal, state and local regulations be checked.
Read all operating instructions and warnings before operation.
This manual has been produced by Ingersoll-Rand to provide
dealers, mechanics, operators and company personnel with the
information required to install, operate, maintain and repair the
products described herein.
It is extremely important that mechanics and operators be familiar
with the servicing procedures of these products, or like or similar
products, and are physically capable of conducting the
procedures. These personnel shall have a general working
knowledge that includes:
1. Proper and safe use and application of mechanics common
hand tools as well as special Ingersoll-Rand or
recommended tools.
2. Safety procedures, precautions and work habits established
by accepted industry standards.
Ingersoll-Rand cannot know of, or provide all the procedures by
which product operations or repairs may be conducted and the
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 in a safe condition and contact supervisors and/
or the factory for technical assistance.

4MHD56162 - Edition 2
** T00 = Ceiling mount
B00 = Column mount
Series 700C Arm - Column/Ceiling Mounted
Part No. Arm Length Capacity Weight
ft mlbskg lbs kg
70015A**Z0613 6 1.83
150 65
218 99
70015A**Z0713 7 2.13 237 108
70015A**Z0813 8 2.44 248 113
70015A**Z0913 9 2.74 263 120
70015A**Z1013 10 3.05 275 125
70020A**Z0613 6 1.83
200 90
248 113
70020A**Z0713 7 2.13 267 121
70020A**Z0813 8 2.44 278 126
70020A**Z0913 9 2.74 278 126
70020A**Z1013 10 3.05 304 138
70035A**Z0613 6 1.83
350 155
257 117
70035A**Z0713 7 2.13 279 127
70035A**Z0813 8 2.44 290 132
70035A**Z0913 9 2.74 290 132
70035A**Z1013 10 3.05 316 144
70050A**Z0613 6 1.83
500 225
271 123
70050A**Z0713 7 2.13 290 132
70050A**Z0813 8 2.44 328 149
70050A**Z0913 9 2.74 350 159
70050A**Z1013 10 3.05 367 167
** CA1 = Carriage A1 (A1 only in 6, 7, 8 ft [1.83, 2.13, 2.44 m]
lengths / 150 and 200 lbs [65 and 90 kg] capacity)
CA2 = Carriage A2 CS2 = Carriage S2
CS3 = Carriage S3 CTR = Carriage T-Rail
CE8 = Carriage ETA8
Series 700C Arm - Carriage Mounted
Part No. Arm Length Capacity Weight
ft mlbskg lbs kg
70015A**Z0600 6 1.83
150 65
218 99
70015A**Z0700 7 2.13 237 108
70015A**Z0800 8 2.44 248 113
70015A**Z0900 9 2.74 263 120
70015A**Z1000 10 3.05 275 125
70020A**Z0600 6 1.83
200 90
248 113
70020A**Z0700 7 2.13 267 121
70020A**Z0800 8 2.44 278 126
70020A**Z0900 9 2.74 278 126
70020A**Z1000 10 3.05 304 138
70035A**Z0600 6 1.83
350 155
257 117
70035A**Z0700 7 2.13 279 127
70035A**Z0800 8 2.44 290 132
70035A**Z0900 9 2.74 290 132
70035A**Z1000 10 3.05 316 144
70050A**Z0600 6 1.83
500 225
271 123
70050A**Z0700 7 2.13 290 132
70050A**Z0800 8 2.44 328 149
70050A**Z0900 9 2.74 350 159
70050A**Z1000 10 3.05 367 167
SPECIFICATIONS
700 Series Manipulator arms consist of a connecting linkage type boom that folds within itself to offer a large coverage area, these arms
utilize the Balance Air® lifting and balancing unit as the lifting power.
SAFE OPERATING INSTRUCTIONS
The following warnings and operating instructions are intended to
avoid unsafe operating practices which might lead to injury or
property damage.
Ingersoll-Rand recognizes that most companies who use material
handling equipment have a safety program in force at their facility.
If you are aware that some conflict exists between a rule set forth
in this publication and a similar rule already set by an individual
company, the more stringent of the two should take precedence.
The manual supports a fully installed system. Operators should be
familiar with the operation of the controls before using the system.
Safe Operating Instructions are provided to make an operator
aware of dangerous practices to avoid and are not necessarily
limited to the following list. Refer to specific sections in the
manual for additional safety information.
1. Only allow personnel trained in, safety and operation on this
product to operate and maintain the balancer.
2. Only operate a balancer if you are physically fit to do so.
3. When a “DO NOT OPERATE” sign is placed on the
balancer controls, do not operate unit until sign has been
removed by designated personnel.
4. Do not use unit if hook latch has been sprung or broken.
5. Before each shift, check unit for wear and damage. Never
use a unit that inspection indicates is worn or damaged.
6. Never lift a load greater than rated capacity of unit. Refer to
capacity labels attached to the unit.
7. Only operate the unit when the wire rope is centered over the
load. Do not “side pull” or “yard”.
8. Never operate unit with twisted, kinked or damaged wire
rope.
9. Never run wire rope over a sharp edge.
10. Pay attention to the load at all times when operating the unit.
11. Make sure everyone is clear of the load path. Do not lift a
load over people.
12. Never use the unit for lifting or lowering people, and never
allow anyone to stand on a suspended load.
13. Never weld or cut a load suspended by the unit.
14. Do not operate the unit if wire rope is jumping, or if
excessive noise, jamming, overloading, or binding occurs.
15. Shut off air supply before performing any maintenance.
16. Avoid collision or bumping of the units.
17. Do not turn continuously in one direction when using the
arm.
18. Do use good posture when operating the system.
19. Do check air connections for leakage.

MHD56162 - Edition 2 5
Series 600 Arm - Mast Configurations
Part No. Capacity Max. Travel Notes
lbs kg in. mm
Single Mast Configuration
60015*A1**Z** 150 68.2 80 2032
1x Balancer
60020*A1**Z** 200 90.9 120 3048
60035*A1**Z** 350 159.1 80 2032
60050*A1**Z** 500 227.3
6007R*A1**Z**
700 318.2 40 1016 1x Bal. (reeved)
6007T*A1**Z** 80 2032 2x Balancer
6001R*A1**Z**
1000 454.5 40 1016 1x Bal. (reeved)
6001T*A1**Z** 80 2032 2x Balancer
Dual Mast Configuration
60015*A2**Z** 150 68.2 80 2032
1x Balancer
60020*A2**Z** 200 90.9 120 3048
60035*A2**Z** 350 159.1 80 2032
60050*A2**Z** 500 227.3
6007R*A2**Z**
700 318.2 40 1016 1x Bal. (reeved)
6007T*A2**Z** 80 2032 2x Balancer
6001R*A2**Z**
1000 454.5 40 1016 1x Bal. (reeved)
6001T*A2**Z** 80 2032 2x Balancer
Series 701C Arm
Part No. Arm Length Capacity Weight
ft mlbskg lbs kg
70115A**Z0613 6 1.83
150 65
218 99
70115A**Z0713 7 2.13 237 108
70115A**Z0813 8 2.44 248 113
70115A**Z0913 9 2.74 263 120
70115A**Z1013 10 3.05 275 125
Series 713 Arm - Column/Ceiling Mounted
Part No. Arm Length Capacity Weight
ft mlbskg lbs kg
71315A**Z0613 6 1.83
150 65
151 69
71315A**Z0713 7 2.13 166 75
71315A**Z0813 8 2.44 175 80
71315A**Z0913 9 2.74 184 84
71315A**Z1013 10 3.05 228 104
71320A**Z0613 6 1.83
200 90
197 90
71320A**Z0713 7 2.13 213 97
71320A**Z0813 8 2.44 224 102
71320A**Z0913 9 2.74 235 107
71320A**Z1013 10 3.05 281 128
71335A**Z0613 6 1.83
350 155
233 106
71335A**Z0713 7 2.13 246 112
71335A**Z0813 8 2.44 261 119
71335A**Z0913 9 2.74 258 117
71335A**Z1013 10 3.05 271 123
71350A**Z0613 6 1.83
500 225
261 119
71350A**Z0713 7 2.13 275 125
71350A**Z0813 8 2.44 276 125
71350A**Z0913 9 2.74 335 152
71350A**Z1013 10 3.05 351 160
** T00 = Ceiling mount
B00 = Column mount
** CA1 = Carriage A1 (A1 only in 6, 7, 8 ft
[1.83, 2.13, 2.44 m] lengths / 150 lbs [65 kg] capacity)
CA2 = Carriage A2
CS3 = Carriage S3
CE8 = Carriage ETA8
CS2 = Carriage S2
CTR = Carriage T-Rail
Series 713 Arm - Carriage Mounted
Part No. Arm Length Capacity Weight
ft mlbskg lbs kg
71315A**Z0600 6 1.83
150 65
151 69
71315A**Z0713 7 2.13 166 75
71315A**Z0800 8 2.44 175 80
71315A**Z0900 9 2.74 184 84
71315A**Z1000 10 3.05 228 104
71320A**Z0600 6 1.83
200 90
197 90
71320A**Z0713 7 2.13 213 97
71320A**Z0800 8 2.44 224 102
71320A**Z0900 9 2.74 235 107
71320A**Z1000 10 3.05 281 128
71335A**Z0600 6 1.83
350 155
233 106
71335A**Z0713 7 2.13 246 112
71335A**Z0800 8 2.44 261 119
71335A**Z0900 9 2.74 258 117
71335A**Z1000 10 3.05 271 123
71350A**Z0600 6 1.83
500 225
261 119
71350A**Z0713 7 2.13 275 125
71350A**Z0800 8 2.44 276 125
71350A**Z0900 9 2.74 335 152
71350A**Z1000 10 3.05 351 160
Series 720 Arm - Column/Ceiling Mounted
Part No. Arm Length Capacity Weight
ft mlbskg lbs kg
72015A**Z0613 6 1.83
150 65
218 99
72015A**Z0713 7 2.13 237 108
72015A**Z0813 8 2.44 248 113
72015A**Z0913 9 2.74 263 120
72015A**Z1013 10 3.05 275 125
Series 720 Arm - Carriage Mounted
Part No. Arm Length Capacity Weight
ft mlbskg lbs kg
72015A**Z0600 6 1.83
150 65
xx xx
72015A**Z0700 7 2.13 xx xx
72015A**Z0800 8 2.44 xx xx
72015A**Z0900 9 2.74 xx xx
72015A**Z1000 10 3.05 xx xx

6MHD56162 - Edition 2
Series 600 Model Code Explanation
Example: 60015IA1A2ZPG 600 15 I A 1 A2 Z P G
Style
600
Capacity - Vertical Travel
15 = 150 lbs (68.2 kg) - 80 in. (2032 mm)
20 = 200 lbs (90.9 kg) - 120 in. (3048 mm)
35 = 350 lbs (159.1 kg) - 80 in. (2032 mm)
50 = 500 lbs (227.3 kg) - 80 in. (2032 mm)
7R = 700 lbs (318.2 kg) - 40 in. (1016 mm)
7T = 700 lbs (318.2 kg) - 80 in. (2032 mm)
1R = 1000 lbs (454.5 kg) - 40 in. (1016 mm)
1T = 1000 lbs (454.5 kg) - 80 in. (2032 mm)
Intelift Options
S = Standard Balancer
I = Intelift Balancer
A = Arm
Single or Dual Mast
1 = Single Mast
2 = Dual Mast
Carriage Options
A1 = ZRA1
A2 = ZRA2
S2 = ZRS2
S3 = ZRS3
TR= T-Rail
E8 = ETA-8
K2 = KBK2
Note: All Zimmerman 600 Arms use a Low Profile Carriage Assembly
Controls
Z = ZA (Zim-Air) Control (Includes dummy handle)
Brake Options
0=NoBrake
P = Pin-lock Brake (hard stops every 45°)
B = Bumper Friction Brake (soft stop at any point on 360°rotation)
C = Caliper Brake
Mast Length
A = 4 ft (1.22 m) G = 7 ft (2.13 m) P = 10 ft (3.05 m)
B = 4 ft 6 in. (1.37 m) H = 7 ft 6 in. (2.29 m) Q = 10 ft 6 in. (3.20 m)
C = 5 ft (1.52 m) J = 8 ft (2.44 m) R = 11 ft (3.35 m)
D = 5 ft 6 in. (1.68 m) K = 8 ft 6 in. (2.59 m) S = 11 ft 6 in. (3.51 m)
E = 6 ft (1.83 m) M = 9 ft (2.75 m) T = 12 ft (3.66 m)
F = 6 ft 6 in. (1.98 m) N = 9 ft 6 in. (2.90 m)

MHD56162 - Edition 2 7
Series 700 Model Code Explanation
Example: 70015SATT0ZP06A 700 15 S A TT 0 ZP 06 A
Style
700
701 (150 lb (68.2 kg) capacity only)
713
720 (150 lb (68.2 kg) capacity only)
Capacity - Vertical Travel
15 = 150 lbs (68.2 kg) - 80 in. (2032 mm)
20 = 200 lbs (90.9 kg) - 120 in. (3048 mm)
35 = 350 lbs (159.1 kg) - 80 in. (2032 mm)
50 = 500 lbs (227.3 kg) - 80 in. (2032 mm)
Intelift Options
S = Standard Balancer
I = Intelift Balancer
A = Arm
Mounting Options
TT = Top Mount (Ceiling mount) S2 = ZRS2 Carriage Mount
BB = Bottom Mount (Column mount) TR = T-Rail Carriage Mount
A1 = ZRA1 Carriage Mount* E8 = ETA-8 Carriage Mount
A2 = ZRA2 Carriage Mount K2 = KBK2 Carriage Mount
* Note: A1 Carriage Mount Option is only available for arms with 150 and 200 lbs (65 and 90 kg)
capacity / 6, 7, and 8 ft (1.83, 2.13 and 2.44 m) length.
Carriage Options
0 = No Carriage
H = High-Profile Carriage
L = Low-Profile Carriage
Controls
ZP = ZA (Zim-Air) Pendant Control EP = EA (Equi-Air) 2PS Pressure
ZQ = ZA (Zim-Air) Quad-Coil EV = EA (Equi-Air) 2PS Vacuum
ZT = ZA (Zim-Air) Tri-Coil
BA = BA (Balance-Air) Standard
BZ = BA (Balance-Air) Z-Servo
Arm Length
06 = 6 ft (1.83 m) Arm
07 = 7 ft (2.13 m) Arm
08 = 8 ft (2.44 m) Arm
09 = 9 ft (2.74 m) Arm
10 = 10 ft (3.05 m) Arm
Mounting Accessories
0 = No Mounting Accessories D = 9 ft (2.74 m) Column Mount
A = 13 in. (0.33 m) Ceiling Mount E = 10 ft (3.05 m) Column Mount
B = 8 ft (2.44 m) Column Mount F = 11 ft (3.35 m) Column Mount
C = 8 ft 6 in. (2.59 m) Column Mount G = 12 ft (3.66 m) Column Mount

8MHD56162 - Edition 2
WARNING LABELS
Each Manipulator Arm is supplied from the factory with the
warning labels shown. If the warning labels are not attached to
your Manipulator Arm, order new labels and install them. Refer
to parts list for part number. Read and obey all warnings and other
safety information attached to the Manipulator Arm. Warning
labels may not be shown actual size. The warning labels must be
clearly visible at all times.
INSTALLATION
Prior to installing unit, carefully inspect it for possible shipping
damage. Units are supplied fully lubricated from the factory.
CAUTION
• Owners and users are advised to examine specific, local or
other regulations, including American National Standards
Institute and/or OSHA Regulations which may apply to a
particular type of use of this product before installing or
putting the unit into use.
• A falling load can cause injury or death. Before installing,
read “SAFETY INFORMATION”.
Mounting
Make certain unit is properly installed. A little extra time and
effort in doing so can contribute a lot toward preventing accidents
and helping you get the best service possible.
Always make certain supporting member from which unit is
suspended is strong enough to support the weight of the unit plus
the weight of a maximum rated load plus a generous factor of at
least 300% of the combined weights. If in doubt, contact a
registered structural engineer.
Securely mount unit to support using six or fourteen 1/2-13 grade
8 capscrews and torque to 76 ft lb (103 Nm) dry or 57 ft lb (77
Nm) lubricated.
Air System
The air supply system should be purged for a minimum of 30
seconds prior to connection of the balancer and controls. This will
remove any debris from air lines and help prevent damage to
controls at start up.
WARNING
• Do not exceed 100 psig (6.9 bar/690 kPa) inlet pressure. Do
not use a lubricator of any kind. Oil will damage internal
components.
• The air supply must be clean and free from water and water
vapor.
Air Lines
The inside diameter of the unit air supply lines must not be
smaller than 3/8 inch (10 mm) based on a maximum of 100 feet
(30 m) between the air supply and the unit. Contact the factory for
recommended air line sizes for distances greater than 100 feet
(30 m). Before making final connections, all air supply lines
should be purged before connecting to unit inlet. Supply lines
should be as short and straight as installation conditions will
permit. Long transmission lines and excessive use of fittings,
elbows, tees, globe valves, etc. cause a reduction in pressure due
to restrictions and surface friction in the lines. If quick-disconnect
fittings are used at the inlet of the unit, they must have at least a
3/16 inch (10 mm) air passage. Use of smaller fittings will reduce
performance.
(Part number
54116009)
(Part number
54115993)

MHD56162 - Edition 2 9
Connection of Air Lines
(Dwg. MHP1902)
ZA Control
The control hose is pre-assembled to the Manipulator Arm.
Control hoses are black, yellow and white precoiled hose
assemblies. The yellow hose must be connected to the down port
of the ZA manifold. The black hose must be attached to the up
port of the ZA manifold. The white hose must be installed in the
pilot port of the balancer.
2PS Control (2 Position Sensor)
The control tubing is a tri-coil assembly. A black 3/8 inch (9.5
mm) tube supplies air to the handling device. A 5/32 inch (3.9
mm) tube supplies the pilot signal to the 2PS valve. Manipulator
Arms with a hi-lo circuit utilize a yellow 3/8 inch (9.5 mm) tube.
Air Line Filter
It is recommended that an air line strainer/filter be installed as
close as practical to the unit air inlet port. The strainer/filter
should provide 5 micron filtration and include a moisture trap.
Clean strainer/filter monthly to maintain its operating efficiency.
To maintain dry air, the frequency for draining the filter should
also be based on the condition of the air supply. We suggest the
filter be drained weekly at first. Depending on air supply
condition, a proper filter drain schedule should be established.
Moisture in Air Lines
Moisture that reaches the unit through supply lines is the chief
factor in determining the length of time between service
overhauls. Moisture traps can help to eliminate moisture. Other
methods, such as an air receiver which collects moisture before it
reaches the unit controls or an aftercooler at the compressor that
cools the air prior to distribution through the supply lines, are also
helpful.
Wire Rope
Retract wire rope completely into Balancer. Ensure wire rope is
correctly reeved through Manipulator Arm pulleys. Ensure hook
wire rope clamp does not contact pulley. Ensure wire rope end is
not frayed, use plastic cap to prevent snagging and damage to air
hoses. Refer to “Maintenance” section for wire rope replacement
instruction.
(Dwg. MHP2026)
Air Supply
Up
(Black)
Down
(Yellow)
Interlock (White)
Plug if not required.

10 MHD56162 - Edition 2
OPERATION
Description Of Operation
The Manipulator Arm is an integrated group of components
designed to maximize the interaction of man and machine. The
Manipulator Arm mounts to an overhead beam or rail system and
incorporates a Zimmerman balancer. The balancer has a wire
rope with load hook which is fed through the Manipulator Arm to
the work area. The operator controls the system by use of the
Zimmerman ZA (Zim-Air) up and down control or the
Zimmerman 2PS (2 Position Sensor) zero gravity control.
The system renders the load virtually weightless through the
balancer’s compressed air operation. When the Manipulator Arm
is mounted to a rail system it provides for ease of horizontal
movement. This combination requires little physical strength to
operate and reduces operator fatigue.
Balancer Operation
Energy used to power the balancer is compressed air, a minimum
of 70 psig (4.8 bar/480 kPa) is required. Air is controlled by an
external control package. Compressed air pushes against the
piston, causing it to move laterally.
The piston pushes the reel assembly causing the reel to move
laterally as well as rotate which winds the wire rope into the
balancer, raising the hook or handling device. Compressed air is
released through the controls to atmosphere and the reel rotates in
the opposite direction lowering the hook or handling device.
The balancer reaches maximum capacity when 100 psig (6.9 bar/
690 kPa) is applied. As air pressure decreases the unit capacity
decreased proportionally. If 80 psig (5.5 bar/552 kPa) is applied to
the balancer, maximum balancer operational capacity is 80% of
rated capacity.
Control Operation
The Manipulator Arm uses the Zimmerman ZA (Zim-Air) or
2PS (2 Position Sensor) control package.
ZA Control
The Zim-Air control package utilizes an up/down control
pendant, connected to the manifold mounted to the balancer. The
top of the manifold has two flow control valves, labeled “UP” and
“DN”. They control the speed with which a load will raise and
lower. The center screw control is for “hook balance adjustment”
to maintain the hook in a floating condition when it does not have
a load on it.
Air is supplied through the manifold to the control pendant. When
the “UP” lever is depressed, air passes through a passage in the
pendant and into the balancer piston chamber resulting in the
balancer raising the load. Lowering the load is accomplished by
depressing the “DN” lever, which releases air in the balancer to
atmosphere through the block, and lowers the load.
2PS (2 Position Sensor)
This style control utilizes the EA Regulator and Two Position
Sensor Valve.
The EA Regulator provides a control circuit and a work circuit
through the regulator for balancer operation. The trim valve is an
adjustable flow control providing a (control circuit) regulated low
volume of air to the main regulator. The main regulator provides a
higher volume of air to the piston chamber of the balancer. The
auxiliary flow control allows air to be bled to atmosphere to
support a lighter load.
The Two Position Sensor Valve is a pilot operated, four way, spring
return valve. Pilot signal is sent to the valve by a switch mounted
on the handling device, or by a pilot line from the clamp circuit.
The EA Regulator controls operation of the balancer when the
handling device has a load attached to it.
The Two Position Sensor Valve controls balancer operation when
the handling device is empty by bleeding air pressure from the
EA Regulator to atmosphere.
The pilot signal shifts the 2PS valve to a blocked port giving the
EA Regulator full balancing control of the handling device and
load. Once the load is placed and released, the spring return will
over come the pilot signal shifting the valve back to a bleed
condition balancing the empty handling device.
Manipulator Arm Operation
WARNING
• If system air pressure is lost, lower the load immediately. The
operator must stay out of the path of the load. Clamp may lose
force required to hold load resulting in injury.
The “UP” and “DN” levers allow adjustable speed control. As
lever is depressed further, operational speed increases. Use lever
to ‘throttle’ speed to ensure controlled movement of the hook or
handling device.
CAUTION
• Do not wrap control hoses around the wire rope. Damage to
hoses and failure of unit may result.
Raising and lowering of the load is dependent on the type of
control circuit on the handling device. The Zim-Air (ZA) type
control requires manual lever operation to raise and lower the
device. If the handling device has a 2PS (2 Position Sensor)
control, the device is in zero gravity with or without a load and
requires the operator to push up or down to raise and lower the
device.
1. Move Manipulator Arm to the pick up point, and position it
over the load for pick up.
2. Slowly lower balancer and engage load until completely
seated.
3. Raise load and maneuver to the set down point.
4. At the set down point lower the load.
5. Maneuver the Manipulator Arm back to the pick up point
and repeat steps.
Positioning of the load is best accomplished by the operator, when
moving away from the manipulator arm pivot point. Manipulator
arm will freely follow.

MHD56162 - Edition 2 11
Operation Adjustments
WARNING
• Air supply pressure must be a minimum of 70 psig (4.8 bar/
480 kPa) and a maximum of 100 psig (6.9 bar/690 kPa).
Excessive air pressure may damage the balancer or controls.
• Prior to adjustment of the controls, ensure air is off and wire
rope is slack.
• Interlock should not be adjusted until all control adjustments
have been completed. Interlock may not function properly if it
is set before the controls.
• Screw type flow control and hook balance adjustment screws
on the ZA manifold should never extend above manifold body.
Thread engagement will be minimal and could result in screw
being discharged from manifold.
• The 2PS control may not support the weight of the empty
handling device, or may raise device at a potentially hazardous
rate. Extreme care must be used until all control adjustments
are complete.
ZA Control
1. On top of the ZA manifold are two screw type flow controls.
Turn “UP” and “DOWN” flow control screws clockwise until
fully closed. Then turn each flow control screw
counterclockwise one full turn.
2. The center screw is for hook balance adjustment. Screw head
should be flush with top of manifold body.
3. Turn on air supply. Adjust supply pressure; do not exceed
100 psig (6.9 bar/690 kPa).
4. Raise load to “UP” stop.
5. Depress “DOWN” lever on ZA control pendant. Adjust
“DOWN” flow control screw, by turning counterclockwise,
until desired down speed is reached.
6. Depress “UP” lever on ZA control pendant. Adjust “UP”
flow control screw, by turning counterclockwise, until
desired speed is achieved.
7. To set hook balance point, adjust hook balance adjustment
screw, by turning clockwise, until empty handling device
begins to rise. Slowly adjust screw, by turning
counterclockwise, until handling device stops moving.
2PS Control
1. Set pilot regulator screw with 1/2 inch (12 mm) of thread
visible.
2. On the left side of the regulator (farthest from the balancer as
the control is installed) locate trim valve screw and adjust, by
turning clockwise, until closed. Turn screw counterclockwise
one and a half turns.
3. Locate auxiliary flow control (closest to the balancer as the
control is installed) screw and adjust, by turning screw
counterclockwise, until screw head protrudes from regulator
body 1/8 inch (3 mm).
4. Adjust 2PS bleed valve screw, by turning clockwise, until
closed, then turn counterclockwise two turns.
5. Turn on air supply to system. Adjust supply pressure to 70
psig (4.8 bar/480 kPa) minimum, but do not exceed 100 psig
(6.9 bar/690 kPa).
6. Turn on air supply to handling device.
7. Engage part with handling device.
8. Adjust pilot regulator to balance (support) handling device
and part. Adjust pilot regulator screw, by turning clockwise,
to increase balancing capacity. Turn screw counterclockwise
to reduce balancing capacity. When balanced, equal effort
will be required to raise and lower the handling device and
part together.
9. Disengage part at place point.
10. Adjust bleed valve screw at 2PS valve to balance empty
handling device. Turn bleed valve screw clockwise to
increase balancing capacity. Turn bleed valve screw
counterclockwise to decrease balancing capacity. When
empty handling device is properly balanced, it will require
equal effort to raise and lower.
Interlock (Safety Circuit)
CAUTION
• Interlock should not be adjusted until all control adjustments
have been completed.
NOTICE
• It may be necessary to actuate clamp/unclamp or vacuum/
blowoff button several times to obtain correct interlock
setting.
• Interlock is available only on ZA controlled handling devices.
1. With the empty handling device suspended by the balancer,
adjust interlock adjustment screw, by turning
counterclockwise, until 3/4 inch (38 mm) of thread is visible.
2. While cycling clamp/unclamp or vacuum/blowoff functions,
turn interlock adjustment screw clockwise until both clamp/
unclamp or vacuum/blowoff circuits function.
3. Cycle clamp/unclamp or vacuum/blowoff buttons several
times to ensure smooth operation and that interlock valve is
shifting completely.
4. Raise empty handling device to its “UP” stop. Depress “UP”
lever for 3 to 4 seconds to simulate a load on the balancer.
5. Actuate clamp/unclamp or vacuum/blowoff circuits. Clamp/
blowoff should not function. Air may be heard discharging to
atmosphere.
6. If clamp/blowoff does function, repeat this adjustment
procedure until clamp/blowoff does not open with handling
device at the “UP” stop.
7. Once interlock valve is adjusted correctly, hold interlock
stem with a suitable pair of pliers and tighten the 3/8 inch
jam nut on interlock adjustment screw to prevent setting
from changing.

12 MHD56162 - Edition 2
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 to
Dwg. MHP1358 on page 12.
(Dwg. MHP1358)
2. Distance from hook throat to bottom of load. Refer to Dwg.
MHP1896 on page 12.
3. Add dimension #1 to dimension #2, then add 3-1/2 inches
(89 mm).
4. Measuring from the floor with the wire rope fully retracted,
install hook using the dimension from instruction #3 to the
floor.
(Dwg. MHP1896)
Yarding
CAUTION
• Do not operate the unit if load is not centered under wire
rope. Yarding of the wire rope will cause premature wire rope
failure and undue wear of unit parts.
Wire rope should not be yarded more than 10 degrees in any
direction from the center line of the wire rope guide or pulley.
Excessive yarding will cause increased wear on the unit and may
decrease the working life of the components.
(Dwg. MHP1897)
Obstruction
#1
Load #2
Incorrect
Correct
10 Degree
Maximum
angle in
any direction

MHD56162 - Edition 2 13
INSPECTION
WARNING
• All new, altered or modified equipment should be inspected
and tested by personnel instructed in safety, operation and
maintenance of this equipment to ensure safe operation at
rated specifications before placing equipment is service.
• Never use a unit that inspection indicates is defective.
Frequent and periodic inspections should be performed on
equipment in regular service. Frequent inspections are visual
examinations performed by operators or personnel trained in
safety and operation of this equipment and include observations
made during routine equipment operation. Periodic inspections
are thorough inspections conducted by personnel trained in the
safety, operation and maintenance of this equipment. Inspection
intervals depend upon the nature of the critical components of the
equipment and the severity of usage.
Careful inspection on a regular basis will reveal potentially
dangerous conditions while still in the early stages, allowing
corrective action to be taken before the condition becomes
dangerous.
Deficiencies revealed through inspection, or noted during
operation, must be reported to designated personnel instructed in
safety, operation and maintenance of this equipment. A
determination as to whether a condition constitutes a safety
hazard must be decided, and the correction of noted safety
hazards accomplished and documented by written report before
placing the equipment in service.
Records and Reports
Inspection records, listing all points requiring periodic inspection
should be maintained for all load bearing equipment. Written
reports, based on severity of service, should be made on the
condition of critical parts as a method of documenting periodic
inspections. These reports should be dated, signed by the person
who performed the inspection, and kept on file where they are
readily available for authorized review.
Wire Rope Reports
Records should be maintained as part of a long-range wire rope
inspection program. Records should include the condition of wire
rope removed from service. Accurate records will establish a
relationship between visual observations noted during frequent
inspections and the actual condition of wire rope as determined by
periodic inspections.
Frequent Inspections
For equipment in continuous service, frequent inspections should
be made by operators at the beginning of each shift.
1. OPERATION. Check manipulator arm for full range of
motion, smooth operation and ease of movement. Locate the
source of any binding or rough operation and repair. Make
sure all controls function properly.
2. WIRE ROPE. Lower load and visually inspect all wire rope.
Refer to “Wire Rope Inspection Procedure” on page 14.
Inspect for wear and damage indicated by distortion of wire
rope such as kinking, “birdcaging,” core protrusion, main
strand displacement, corrosion, broken, or cut strands. If
damage is evident, do not operate unit until the discrepancies
have been reviewed and inspected further by personnel
instructed in the operation, safety, and maintenance of this
unit.
WARNING
• The full extent of wire rope cannot be determined by visual
inspection. At any indication of wear inspect the wire rope in
accordance with instructions in “Periodic Inspection.”
3. WIRE ROPE CLAMP. Inspect wire rope clamp at handling
device lifting eye for tightness of clamp, security of thimble,
and load hook for proper latching. Ensure wire rope free end
is capped.
4. THREADED CONNECTIONS. Check all threaded
connections for tightness. Tighten or replace if necessary.
5. OVERHEAD MOUNTING. If any loose or missing
hardware is detected, tighten or replace.
6. TUBING. Inspect tubing and fittings for cracks, cuts or
leaks. Replace if any are detected.
7. PULLEY SYSTEM. Inspect pulleys for cracks, nicks, wear
or damage. Replace if necessary.
8. INTERLOCK (Safety Circuit). Test operation with no load.
Raise empty handling device to the “UP” stop. With “UP”
lever depressed for 3 to 4 seconds (to simulate load), actuate
clamp/unclamp or vacuum/blowoff circuit. Clamp or blowoff
should not function. Refer to “OPERATION” section,
‘Interlock’ for adjustment instructions.
9. AIR SYSTEM. Visually inspect all connections, fitting,
hoses and components for indication of air leaks. Repair any
leaks found.
Periodic Inspection
Frequency of periodic inspection depends on the severity of
usage:
Disassembly may be required for HEAVY or SEVERE usage.
Keep accumulative written records of periodic inspections to
provide a basis for continuing evaluation.
Inspect all the items in “Frequent Inspection”. Also inspect the
following:
1. FASTENERS. Check all rivets, split pins, capscrews and
nuts. Replace if missing or tighten if loose.
2. ALL COMPONENTS. Inspect for wear, damage,
deterioration, deformation and cleanliness. If external
evidence indicates the need, disassemble. Check bearings,
pulleys, and plates. Replace worn or damaged parts. Clean,
lubricate and reassemble.
NORMAL HEAVY SEVERE
yearly semiannually quarterly

14 MHD56162 - Edition 2
3. WIRE ROPE. In addition to Frequent Inspection
requirements, also inspect for the following:
a. Build-up of dirt and corrosion. Clean with steam or a
stiff wire brush to remove dirt and corrosion if
necessary.
b. Loose or damaged end connection. Replace if loose or
damaged.
c. Check wire rope anchor is secure in drum.
d. Verify wire rope diameter. Measure the diameter of the
wire rope from crown-to-crown throughout the life of
the wire rope. Recording of the actual diameter should
only be done with the wire rope under equivalent
loading and in the same operating section as
accomplished during previous inspections. If the actual
diameter of the wire rope has decreased more than 1/64
inch (0.4 mm) a thorough examination of the wire rope
should be conducted by an experienced inspector to
determine the suitability of the wire rope to remain in
service. Refer to Dwg. MHP0056 on page 14.
(Dwg. MHP0056)
4. PULLEYS. Inspect pulleys for wear or damage. Replace if
necessary.
5. PIVOT ASSEMBLY. Inspect pivoting connections for
looseness, bearing wear, and smooth operation. Repair or
replace any loose or worn components.
6. AIR SYSTEM. Inspect valves, controls, connections for
leakage and wear. Repair or replace components if leaks are
found or if operation is rough. Inspect all tubing, air lines,
and fittings for cuts, damage, or leakage. Repair or replace
tubing and fittings as necessary.
7. SUPPORTING STRUCTURE. Check for distortion, wear
and continued ability to support load.
8. CARRIAGE TROLLEYS. Check trolley assemblies for ease
of movement, loose or missing hardware. Check for cracks
in or damage to wheels. Repair or replace trolley and/or
wheels as necessary.
9. LABELS AND TAGS. Check for presence and legibility of
labels. Replace if damaged or missing.
10. BALANCER. Inspect Balancer in accordance with
recommendations in Balancer Parts, Operation and
Maintenance manual.
11. CARRIAGE (optional feature). Inspect for cracks or
damage. Replace if either are found.
Wire Rope Inspection Procedure
To properly inspect the wire rope:
1. Lower the load until all wire rope has played out of the
balancer.
2. Use a gloved hand to run the length of wire rope exposed
below the end of arm pulley. IF THE GLOVE SNAGS ON
THE ROPE CHECK FOR FRAYING AND REPLACE AS
NECESSARY WITH APPROVED INGERSOLL-RAND
REPLACEMENT PART. Part number 10084-30 (galvanized)
10084-30SS (stainless).
3. Use a permanent marker to mark the wire rope at the end of
arm pulley.
4. Model 700C Arm
Place a rag over the wire rope at the balancer cable guide
opening.
Model 713 Arm
a. Ensure wire rope is slack.
b. Support the balancer.
c. Remove top balancer mount bolt.
d. Allow balancer to rotate down.
e. Continue with step 5 below.
5. Using the controls slowly raise the wire rope checking for
frays in the same manner as the end of arm. IF THE RAG
SNAGS ON THE ROPE CHECK FOR FRAYING AND
REPLACE AS NECESSARY WITH APPROVED
INGERSOLL-RAND REPLACEMENT PART.
6. Ensure the mark placed on the rope passes across the rag to
verify the entire length has been inspected.
IF THE MARK ON THE ROPE DOES NOT PASS THE
RAG.
7. Use a flashlight and inspection mirror to access the wire rope
throught the centerlink openings at the pulleys. IF THE
ROPE APPEARS TO BE FRAYED OR DAMAGED IN
ANYWAY; REPLACE AS NECESSARY WITH
APPROVED INGERSOLL-RAND REPLACEMENT PART.
The wire rope should inspected daily to ensure the maximum
safety.
If one strand of wire is broken on any given bundle replace the
wire rope.
Units Not in Regular Use
1. Units which have been idle for a period of one month or
more, but less than one year, should be given an inspection
conforming with the requirements of “Frequent Inspection”
prior to being placed into service.
2. Units which have been idle for a period of more than one
year should be given an inspection conforming with the
requirements of “Periodic Inspection” prior to being placed
into service.
3. Standby units should be inspected at least semiannually in
accordance with the requirements of “Frequent Inspection”.
In abnormal operating conditions, units should be inspected
at shorter intervals.

MHD56162 - Edition 2 15
LUBRICATION
Pivot assemblies are pre-packed with grease at the factory and
should not require any additional lubrication.
If after time it becomes necessary to disassemble the pivot
assembly, all parts should be cleaned with a mineral spirit
solution and the bearings repacked with grease. Recommended
lubricant (10885) is available through Ingersoll-Rand.
Wire Rope
Follow wire rope manufacturer’s instructions. At a minimum,
observe the following guidelines.
1. Clean with a brush or steam to remove dirt, rock dust or other
foreign material on surface of wire rope.
CAUTION
• Do not use an acid-based solvent. Only use cleaning fluids
specified by wire rope manufacturer.
2. Apply Ingersoll-Rand LUBRI-LINK-GREEN or ISO VG
100 (SAE 30W) oil as a wire rope lubricant.
3. Brush, drip or spray lubricant weekly, or more frequently,
depending on severity of service.
TROUBLESHOOTING
The following table is for Manipulator Arm specific problems. This section provides basic troubleshooting information. Determination of
specific causes to problems are best identified by thorough inspections performed by personnel instructed in safety, operation and
maintenance of this equipment. The chart below provides a brief guide to common problems, probable causes and remedies. Refer to the
Balancer Service Manual for Balancer/Control specific problems.
Symptom Possible Cause Remedy
Hook does not balance or raise and lower. Balancer controls may need adjustment. Refer to Balancer manual for adjustment of
controls.
Air lines or connections may be leaking. Check air system for leaks and repair if leaks
are found.
Air line connections incorrect. Reconnect air lines as described in ‘Connec-
tion of Air Lines’ in “INSTALLATION”
section.
Hook up and down is erratic. Cable guide wheels or bearings are damaged. Inspect guide wheels and bearing sleeves for
damage or tightness. Repair or replace as
required.
Cable may be damaged. Inspect cable and replace if damaged or
worn.
Arm movement is stiff. Swivel assembly bearings require
lubrication.
Check locknut adjustment and lubricate
bearings.

16 MHD56162 - Edition 2
INSPECTION AND MAINTENANCE REPORT
Ingersoll Rand Manipulator Arm
This page may be photocopied and used as an Inspection/Maintenance record.
Model Number: Date:
Serial Number: Inspected By:
Reason for Inspection: (Check Applicable Box)
1. Scheduled Periodic Inspection
( ______ Quarterly ______ Semiannually ______ Yearly)
Operating Environment:
Normal _______ Heavy _______ Severe _______
2. Discrepancies noted during Frequent Inspection
3. Discrepancies noted during Maintenance
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.
COMPONENT
CONDITION CORRECTIVE
NOTES
Pass Fail Repair Replace
Arm or Mast
Fasteners
Shafts and Pulleys
Bearings ---
Balancer Refer to Balancer Parts, Operation and Maintenance Manual.
Wire Rope Guide ---
Covers
Controls and Hoses
Air Manifold
Bottom
Hook
Measure hook and check for increased throat opening.
Damage ---
Hook Crack Test Method Used: Dye Penetrant ______ Magnetic Particle ______ Other: ________________________________
Hook Latch ---
Wire Rope Working length(s) maximum stretch: _________ inches/ _________ mm
Supporting Structure
Labels and Tags ---
Other Components
(list in NOTES section)

MHD56162 - Edition 2 17
MAINTENANCE
CAUTION
• Use of other than genuine Ingersoll-Rand replacement parts
could result in damage to the unit and void the warranty.
WARNING
• Never perform maintenance on the Manipulator Arm while
it is supporting a load.
• Before performing maintenance, tag controls:
WARNING - DO NOT OPERATE -
EQUIPMENT BEING REPAIRED.
• Only allow service personnel trained in safety and
maintenance on this unit to perform maintenance.
• After performing any maintenance on the unit, adjust and
test unit in specified application before returning to service.
• Turn off air supply to unit and be sure wire rope is slack
before attempting any disassembly operations.
Maintenance Intervals
The Maintenance Interval chart is based on intermittent operation
of the unit eight hours each day, five days per week. If unit
operation exceeds eight hours per day, or use is under HEAVY or
SEVERE conditions, more frequent maintenance should be
performed. Refer to ‘Periodic Inspection’ in the “INSPECTION”
section for interval guidance.
Wire Rope Replacement
WARNING
• Improper routing of the wire rope can cause severe injury or
death. Wire rope must run through all of the pulleys in the arm.
1. Lower load until wire rope is slack and all air pressure has
been bled from balancer.
2. Turn off air supply.
3. Remove load from hook.
4. Remove hook from wire rope.
5. Remove capscrew (17) and nut (15) from upper mounting
bracket of balancer.
6. Allow balancer to rotate down towards the floor. The lower
mounting bolt will support weight of balancer.
7. Pull wire rope from balancer until it stops at bottom of travel.
8. Cut wire rope at the balancer.
9. Secure wire rope inside of manipulator arm until new wire
rope has been installed in balancer.
10. Remove wire rope from balancer. Refer to the balancer
Service Manual.
11. Install new wire rope to balancer reel.
12. Two full wraps around reel are required for balancer to
function properly. Ensure second full wrap of wire rope is in
the center of the cable guide opening.
13. Make a butt joint splice with old wire rope and free end of
new wire rope.
14. From load end of manipulator arm, pull old wire rope from
manipulator arm until new wire rope comes out of last pulley.
15. Disconnect butt splice.
16. Discard old wire rope.
17. Rotate balancer toward upper mount bracket and install
capscrew (17) and nut (15).
18. Pull all slack wire rope from manipulator arm.
19. Lash hook to wire rope.
20. Apply load and turn on air supply.
Disassembly
NOTICE
• Air lines are connected to the balancer end cap. Use care
when removing end cap.
700C Manipulator Arm
Refer to Dwg. MHP1567 on page 26.
1. Shut off air supply and disconnect air lines. Remove
capscrews (10), washers (9), nuts (20) and manipulator arm
from carriage or support.
2. Remove capscrews (11), washers (19), nuts (20) and pivot
assembly (7) from rear mast (3).
3. Remove hook assembly from end of wire rope.
4. Remove wire rope, refer to ‘Wire Rope Replacement.’
Remove capscrews (17), nuts (15) and bushings (16) which
secure the Balancer. Remove the Balancer and pull
remaining wire rope from arm.
5. Remove capscrews (13) and washers (14) from connector
plates (4).
6. Tap out pins (8) and (35) and separate connector plates from
masts (2) or (3) and center link (1).
7. Note shim pack (22) thickness and position, then remove
from center link. Tap bearing cups (24) from connector
plates and bearing cones (23) from center link (1).
8. Remove capscrew (29) and separate spacer (25), thrust
washers (26) and pulley (27) from center link.
9. Remove screws (42) and drive out pins (41) from cable guide
(43). Remove cable guide.
10. Remove capscrew (40) and nut (45) from front mast (2).
Separate bearings (38) and cable sheave (39) from front
mast.
11. Loosen setscrew (44) and slide air manifold (5) from front
mast (2).
INTERVAL MAINTENANCE CHECK
Start of each shift
(Operator or
Maintenance
Personnel)
Make a thorough visual inspection of the
Manipulator Arm and attached compo-
nents for damage. Do not operate the
unit, or components, if damaged.
Operate the unit through the normal
range of movements. Unit must operate
smoothly without sticking, binding or
abnormal noises.
3 months
(Maintenance
Personnel)
Check operation of balancer. Refer to
balancer manual for maintenance
information.
Yearly
(Maintenance
Personnel)
Inspect pivot assembly.
Check all the supporting members,
including the clamps, fasteners, nuts,
etc. for indications of damage or wear.
Repair or replace as required.

18 MHD56162 - Edition 2
713 Manipulator Arm
Refer to Dwg. MHP1888 on page 30.
1. Shut off air supply and disconnect air lines. Remove
capscrews (10), washers (9), nuts (20) and manipulator arm
from carriage or support.
2. Remove capscrews (11), washers (19), nuts (20) and pivot
assembly (7) from rear mast (3).
3. Remove hook assembly from end of wire rope.
4. Remove wire rope, refer to ‘Wire Rope Replacement.’
Remove capscrews (17), nuts (15) and bushings (16) which
secure the Balancer. Remove the Balancer and pull
remaining wire rope from arm.
5. Bend lockwasher (52) tab free from locknut (51). Remove
locknut, lockwasher and washer (53).
6. Separate front arm (2) from rear arm (3). Remove bearing
cups (24) and bearing cones (23).
7. Remove capscrew (40) and nut (45) from front mast (2).
Separate bearings (38) and cable sheave (39) from front
mast.
8. Loosen setscrew (44) and slide air manifold (5) from front
mast (2).
Pivot Removal and Disassembly
Refer to Dwg. MHP1567 on page 26 and MHP1888 on page 30.
1. Remove pivot assembly (7) from arm and mounting carriage/
column.
2. Reference Pivot Assembly drawings MHP1566 and
MHP1873 on page 29 for component identification.
3. Bend locking tang on lockwasher (65) away from nut (66).
4. Use a 3-5/8 in. spanner with a 0.360 /0.365 in. (9.1/9.3 mm)
slot and remove spanner nut (66).
5. Remove lockwasher (65).
6. Remove bearing hub (64) from bearing post (61). Removal
may require the use of a hammer and brass or non-marring
punch to lightly tap bearing and hub from bearing post.
7. Remove bearing (62) from bearing hub (64).
8. Remove bearing (68) from bearing post (61).
9. Inspect bearing assemblies (62) and (68) for smooth rotation,
binding, rust, and corrosion. None should be present or
visible.
Cleaning, Inspection and Repair
Examine disassembled components and fasteners for wear or
damage. If worn or damaged, do not reuse. During reassembly all
damaged and worn components should be replaced to prevent
component failure which may result in injury or property damage.
It is recommended that lockwashers be discarded and replaced
with new ones after each use.
Use the following procedures to clean, inspect and repair the
Manipulator Arm and associated components.
Cleaning
Thoroughly clean all Manipulator Arm components in solvent.
The use of a stiff bristle brush will facilitate the removal of
accumulated dirt and sediments on the columns. Wipe off each
part after cleaning. Remove all old Loctite® residue.
Inspection
All disassembled parts should be inspected to determine their
fitness for continued use. Pay particular attention to the following:
1. Inspect all threaded items and replace those having damaged
threads.
2. Inspect all bearings for freeness of rotation and wear.
Replace bearings if rotation is rough or bearings are worn.
3. Inspect wire rope pulleys. Replace worn bushings and
pulleys.
4. Inspect stop pins, stop plates and bumpers for damage.
Replace if worn or deformed.
5. Inspect all pivot pins for wear. Replace pins that are scored
or worn.
6. Inspect air lines for cracks, cuts and leakage.
7. Inspect air fittings for cracks, leakage and security.
Repair
Actual repairs are limited to the removal of small burrs and other
minor surface imperfections. Use a fine stone or emery cloth for
this work.
1. Worn or damaged parts must be replaced. Refer to the parts
section for specific replacement parts information.
2. Inspect all remaining parts for evidence of wear or damage.
Replace or repair any part which is in questionable
condition. The cost of the part is often minor in comparison
with the cost of redoing the job.
3. When fastening components, always use Loctite® 243 on
capscrew threads.
Assembly
700C Manipulator Arm
Refer to Dwg. MHP1567 on page 26.
1. Install bearings (38) in cable sheave (39). Position sheave
assembly in front mast (2) and secure with capscrew (40) and
nut (45).
2. Install pulleys (27) in center link (1) with spacer (25), thrust
washers (26) and capscrew (29).
3. Install shim sets (22) and bearing cones (23) on center link
(1) pivot posts. Use positions noted during disassembly.
4. Install bearing cups (24) in connector plates (4).
5. Install connector plates (4) on center link (1) and position on
rear mast (3). Secure connector plates in position with
capscrews (13) and washers (14). Do not tighten capscrews.
6. Drive pins (8) into connector plates and mast until flush.
Torque capscrews.
7. Repeat steps 4 and 5 to mount front mast.
8. Install cable guide (43) on front mast and secure with screws
(40) and pins (41).
9. Install the Balancer on rear mast (3). Secure with capscrews
(17), nuts (15) and bushings (16). Feed wire rope through
mast. Ensure wire rope sits in pulley grooves. Refer to ‘Wire
Rope Replacement.’
10. Slide air manifold (5) onto front mast (2). Tighten setscrew
(44).
11. Install pivot assembly (7) on rear mast (3) with capscrews
(11), washers (19) and nuts (20). Torque to 72 ft. lbs. (98
Nm).
12. Install manipulator arm to carriage or support with
capscrews (10), nuts (20) and washers (9). Connect air line.
13. Install hook assembly on end of wire rope and adjust per
Lash-Up procedure in “INSTALLATION” section.

MHD56162 - Edition 2 19
713 Manipulator Arm
Refer to Dwg. MHP1888 on page 30.
1. Install bearings (38) in cable sheave (39). Position sheave
assembly in front mast (2) and secure with capscrew (40) and
nut (45).
2. Install washer (53) and bearing cone (23) on front mast pivot
post.
3. Install bearing cups (24) in rear mast (3).
4. Install front mast pivot post through bore in rear mast. Install
second bearing cone (23), washer (53), lockwasher (52) and
locknut (51). Ensure inside tab of lockwasher locates in slot
on front mast pivot post. Torque nut to 40 ft. lbs. (54 Nm).
5. Increase torque as needed to bend one lockwasher (52) tab
into locknut (51) slot.
6. Install the Balancer on front mast (2). Secure with capscrews
(17), nuts (15) and bushings (16). Feed wire rope through
mast.
7. Slide air manifold (5) onto front mast (2). Tighten setscrew
(44).
8. Install pivot assembly (7) on rear mast (3) with capscrews
(11), washers (19) and nuts (20). Torque to 72 ft. lbs. (98
Nm).
9. Install manipulator arm to carriage or support with
capscrews (10), nuts (20) and washers (9). Connect air line.
10. Install hook assembly on end of wire rope and adjust per
Lash-Up procedure in “INSTALLATION” section.
Pivot Assembly and Installation
Refer to Dwgs. MHP1566 and MHP1873 on page 29.
1. Clean bearings (62) and (68) with mineral spirit solution to
remove all grease. Dry bearings.
2. Re-pack bearings with grease (Zimmerman P/N 10885 –
refer to “LUBRICATION” Section).
3. Install bearings to bearing hub (64) and bearing post (61).
4. Install bearing hub (64) on bearing post (61).
5. Install lockwasher (65) on bearing post (61).
CAUTION
• The following torque procedure must be followed to ensure
that spanner nut torque is correct, bearings have been seated,
and nut will not lose torque. Failure to follow these
instructions will decrease performance of the pivot and may
cause damage to the arm assembly.
6. Tighten spanner nut (66) to 200 ft.-lbs. (271 Nm)
7. Rotate pivot assembly left and right to seat bearings.
8. Torque spanner nut to 200 ft.-lbs. (271 Nm)
9. Rotate pivot assembly left and right to seat bearings.
10. Torque spanner nut to 200 ft.-lbs. (271 Nm)
11. Rotate nut clockwise until a lockwasher tang is aligned with
a slot on spanner nut. Bend tang into slot.
12. Install pivot assembly on arm and mounting carriage/
column.
13. Torque pivot mounting bolts to 50 ft.-lbs. (68 Nm)
NOTICE
• Ensure the tang on the lockwasher in the upper housing
engages a slot on the pivot pin.
• Tighten pivot spanner nut securely, but not so much that the
lower housing assembly will not swivel.
Test in g
Prior to initial use, all new, altered or repaired Manipulator Arms
shall be tested to ensure proper operation.
1. Check Manipulator Arm movement through full operational
range. Ensure movement is smooth and without binding.
Ensure there are no obstructions through the operation range.
2. Ensure all guards are in place and undamaged.
3. Install handling device expected to be used. Check position
and regulator adjustments.
4. Check operation of balancer. Ensure balancer responds
correctly to control operation.

20 MHD56162 - Edition 2
SERIES 600 SINGLE MAST ARM ASSEMBLY PARTS DRAWING
(Dwg. MHP2403)
103
7
100
101
102 103
104
105
106 108
118
120
121
128
129
127
107
124
122
123
125
126
117
115
116
114
113
111
113
112
102
109
110
6
Single Balancer
Dual Balancer
Single Balancer
Dual Balancer