Ingersoll-Rand MAB Series Installation guide

PARTS, OPERATION AND MAINTENANCE MANUAL
for
AIR LIFT BALANCER
Form MHD56088
Edition 2
May 1995
71147029
© 1995 Ingersoll-Rand Company
Form MHD56088
WARNING
READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual
contains important safety, installation, operation and maintenance infor-
mation. Make this manual available to all persons responsible for the
operation, installation and maintenance of these products.
Do not use this balancer 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.
Refer all communications to the nearest Ingersoll-Rand Material Handling Office or
Distributor.
®

2
Safety Information
Danger, Warning, Caution and Notice................................................................................................................................... 3
SafetySummary..................................................................................................................................................................... 3
Safe Operating Instructions................................................................................................................................................ 4
Warning Label. .................................................................................................................................................................... 4
Description of Balancer Operation. ................................................................................................................................... 5
Specifications........................................................................................................................................................................ 6
Model Code Explanation ....................................................................................................................................................... 7
Installation
Balancer ................................................................................................................................................................................. 8
Air System ............................................................................................................................................................................. 8
Control Assemblies................................................................................................................................................................ 9
Overhead Assemblies ........................................................................................................................................................... 11
Workstation Assemblies ....................................................................................................................................................... 15
Storing the Balancer ............................................................................................................................................................. 15
Operation............................................................................................................................................................................. 16
Inspection
Records and Reports............................................................................................................................................................. 18
Frequent Inspection .............................................................................................................................................................. 18
Periodic Inspection ............................................................................................................................................................... 19
Balancers Not in Regular Use............................................................................................................................................... 20
Inspection and Maintenance Report ..................................................................................................................................... 21
Lubrication
Wire Rope............................................................................................................................................................................. 22
Hook and Suspension Assemblies ........................................................................................................................................ 22
Trolley .................................................................................................................................................................................. 22
Load Chain ........................................................................................................................................................................... 22
Troubleshooting. ................................................................................................................................................................. 23
Maintenance
General Maintenance Instructions ........................................................................................................................................ 25
Wire Rope Removal ............................................................................................................................................................. 25
Chain Removal ..................................................................................................................................................................... 26
Wire Rope Replacement....................................................................................................................................................... 26
Chain Replacement ............................................................................................................................................................... 27
Balancer Disassembly........................................................................................................................................................... 27
Cleaning, Inspection and Repair........................................................................................................................................... 30
BalancerReassembly ............................................................................................................................................................ 30
Parts Drawings.................................................................................................................................................................34 - 53
Parts Lists.........................................................................................................................................................................35 - 53
Kits and Accessories. .......................................................................................................................................................... 54
Parts Ordering Information. ............................................................................................................................................. 54
Warranty. ............................................................................................................................................................................ 55
TABLE OF CONTENTS

3
The National Safety Council, Accident Prevention Manual
for Industrial Operations, Eighth Edition and other recog-
nized 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 lifting 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, associated with the final installation. It is the
owner’s responsibility and user’s responsibility to deter-
mine the suitability of a product for any particular use. It is
recommended that all applicable industry, trade associa-
tion, federal, state and local regulations be checked. Read
all operating instructions and warnings before operation.
Rigging: It is the responsibility of the operator to exercise
caution, use common sense and be familiar with proper
rigging techniques. See ASME B30.9 for rigging informa-
tion, American National Standards Institute, 1430 Broad-
way, New York, NY 10018.
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 can not know of, nor 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.
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 balancer.
Danger, Warning, Caution and Notice
Throughout this manual there are steps and procedures
which, if not followed, may result in an injury. The
following signal words are used to identify the level of
potential hazard.
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 mainte-
nance information which is impor-
tant but not hazard-related.
Safety Summary
WARNING
• Do not use this balancer or attatched 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 balancers must provide a
safety factor of at least three times the rated capacity of
the balancer. This is the customer’s responsibility. If in
doubt, consult a registered structural engineer.
NOTICE
• Lifting equipment is subject to different regulations in
each country. These regulations may not be specified in
this manual.
SAFETY INFORMATION
DANGER
WARNING
NOTICE
CAUTION

4
8. Do not use more than one hook on a single load.
9. Never place your hand inside the throat area of a hook.
10. Never use the wire rope or chain as a sling.
11. Only operate a balancer when the wire rope or chain is
centered over the hook. Do not “side pull” or “yard”.
12. Never operate a balancer with twisted, kinked or
damaged wire rope or chain.
13. Do not force hook into place by hammering.
14. Be certain the load is properly seated in the saddle of
the hook.
15. Do not support the load on the tip of the hook.
16. Never run the wire rope or chain over a sharp edge.
17. Pay attention to the load at all times when operating
the balancer.
18. Make sure everyone is clear of the load path. Do not
lift a load over people.
19. Never use the balancer for lifting or lowering people,
and never allow anyone to stand on a suspended load.
20. Do not swing a suspended load.
21. Do not leave load suspended when balancer is not in
use.
22. Never leave a suspended load unattended.
23. Never weld or cut a load suspended by the balancer.
24. Ensure safety cable is installed.
25. Do not operate balancer if wire rope or chain jumping,
excessive noise, jamming, overloading, or binding
occurs.
26. Shut off air supply before performing any maintenance.
27. Avoid collision or bumping of balancer.
The following warnings and operating instructions have
been adapted in part from American National (Safety)
Standards and are intended to avoid unsafe operating
practices which might lead to injury or property damage.
Ingersoll-Rand recognizes that most companies who use
balancers have a safety program in force at their facility. In
the event 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.
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 of
this balancer to operate this product.
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, or controls, do not operate the balancer until
the sign has been removed by designated personnel.
4. Do not use balancer if hook gate has been sprung or
broken.
5. Check that the hook gates are closed before using.
6. Before each shift, check the balancer for wear and
damage. Never use a balancer that inspection indicates
is worn or damaged.
7. Never lift a load greater than the rated capacity of the
balancer. See capacity labels attached to balancer.
WARNING LABEL
Each balancer is shipped from the factory with the warning
label shown. If the label is not attached to your balancer,
order a new label and install it. See the parts list for the part
number. Label is shown smaller than actual size.
SAFE OPERATING INSTRUCTIONS
Failure to follow these
warnings may result in
death, severe injury or
property damage.

5
(Dwg. MHTPA0703)
The spool and ball nut travel laterally on a stationary ball
screw. This motion is caused by compressed air pushing
against the piston which rides against a thrust bearing
seated in the spool. The compressed air is regulated by an
external control package.
The control package allows air to exhaust from the same
port. When air enters, the wire rope or chain retracts and is
wound around the spool. When air is exhausted the
chamber loses pressure allowing the piston to retract, and
wire rope or chain unwinds.
Air Lift Balancer Cross Section
DESCRIPTION OF BALANCER OPERATION
Ingersoll-Rand Balancers have a “zero gravity” capability
which allows the operator to effortlessly move and position
a load. The operator grasps the load which is suspended
from the balancer and by exerting a slight downward
pressure causes the regulator to automatically bleed off
control air, allowing the load to be lowered. The load is in
a “zero gravity” condition and can be raised or lowered
with minimal effort through the wire rope or chain length.
All Balancers utilize a recoil control brake which prevents
rapid upward cable or chain movement.

6
SPECIFICATIONS
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Air Balancers "MAB" and MCB" Series
Model
Number Lifting Capacity Vertical Travel Body Diameter Unit Weight Model Number Lifting Capacity Vertical Travel Body Diameter Unit Weight
Single Wire Rope Balancers Wire Rope Reeved Balancers
lb kg in mm in mm lb kg lb kg in mm in mm lb kg
MAB100-56 100 45 56 1422 6 152 43 20 MAB700-27 700 318 27 686 10 254 61 28
MAB120-76 120 54 76 1930 6 152 48 22 MAB700-36 700 318 36 914 10 254 70 32
MAB150-52 150 68 52 1321 6 152 43 20 MAB600-50 600 272 50 1270 12 305 120 54
MAB225-55 225 102 55 1397 8 203 47 21 MAB1000-32 1000 454 32 813 12 305 108 49
MAB225-73 225 102 73 1854 8 203 53 24 Wire Rope Tandem Balancers
MAB225-117 225 102 117 2972 10 254 75 34 MAB450-117 450 204 117 2972 10 254 150 68
MAB350-55 350 159 55 1397 10 254 58 26 MAB700-55 700 318 55 1397 10 254 116 53
MAB350-73 350 159 73 1854 10 254 67 30 MAB700-73 700 318 73 1854 10 254 134 61
MAB300-101 300 136 101 2565 12 305 117 53 MAB600-101 600 272 101 2565 12 305 234 106
MAB500-46 500 227 46 1168 12 305 91 41 MAB1000-46 1000 454 46 1168 12 305 182 82
MAB500-64 500 227 64 1626 12 305 105 48 MAB1000-64 1000 454 64 1626 12 305 210 95
Chain Balancers Wire Rope Tandem Reeved Balancers
MCB150-52 150 68 52 1321 6 152 43 20 MAB1400-36 1400 635 36 914 10 254 144 65
MCB150-68 150 68 68 1727 6 152 48 22 MAB2000-32 2000 907 32 813 12 305 220 100
MCB225-52 225 102 52 1321 8 203 47 21
MCB225-68 225 102 68 1727 8 203 53 24
MCB200-120 200 91 120 3048 10 254 75 34
MCB350-52 350 159 52 1321 10 254 58 26
MCB350-68 350 159 68 1727 10 254 67 30
MCB300-106 300 136 106 2692 12 305 117 53
MCB500-44 500 227 44 1118 12 305 91 41
MCB500-60 500 227 60 1524 12 305 105 48

8
INSTALLATION
Air System
The supply air must be clean and free from water or
moisture. A minimum of 100 psi (6.9 bar/690 kPa) at the
balancer is required to provide rated capacity. Do not
exceed 150 psi (1034 kPa).
WARNING
• Do not exceed 150 psi (1034 kPa) inlet pressure. Do
not use a lubricator of any kind. Oil will damage
internal components.
Air Lines
The inside diameter of the balancer air supply lines must
not be 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 recommended air line sizes for
distances greater than 100 ft. (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 balancer, they
must have at least a 3/8 in. (10 mm) air passage. Use of
smaller fittings will reduce performance.
Air Line Filter
It is recommended that an air line strainer/filter be installed
as close as practical to the balancer air inlet port. The
strainer/filter should provide 10 micron filtration and
include a moisture trap. Clean the strainer/filter monthly to
maintain its operating efficiency.Refer to “ACCESSO-
RIES” in the parts section for the recommended Filter and
Regulator.
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 air motor through the 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 balancer controls or
an aftercooler at the compressor that cools the air prior to
distribution through the supply lines, are also helpful.
Prior to installing the balancer, carefully inspect it for
possible shipping damage.
Balancers 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 balancer to use.
• A falling load can cause injury or death. Before
installing, read “SAFETY INFORMATION”.
Balancer
Make certain your 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.
Always make certain the supporting member from which
the balancer is suspended is strong enough to support the
weight of the balancer plus the weight of a maximum rated
load plus a generous factor of at least 300% of the com-
bined weights.
If the balancer is suspended by a top hook, the supporting
member should rest completely within the saddle of the
hook and be centered directly above the hook shank. Do
not use a supporting member that tilts the balancer to one
side or the other.
Hook Mounted Balancer Installation
Place hook over mounting structure. Make sure hook gate
is engaged.
Trolley Mounted Balancer Installation
When installing the balancer and trolley on the beam, make
certain the side plates are parallel and vertical. After
installation, operate the trolley over the entire length of the
beam with a capacity load. Ensure rail stops are installed
before operating balancer. Use Grade 5 or better bolts
when attaching balancer to trolley assembly. Refer to
Trolley Suspension Kit Assembly in this section.
CAUTION
• To avoid an unbalanced load which may damage the
trolley, the balancer must be centered under the trolley.
Rail Mounted Balancer Installation
For proper and safe installation of the balancer on a rail
system refer to Installation and Maintenance Manual
MHD56091.

9
Resetting Recoil Control Brake
Reset unit after brake has been activated.
1. Turn regulator knob (D) counterclockwise slowly until
hook lowers.
2. This will release the brake. Follow operational
adjustment to reset balancer.
Single Balance Control Module C090
Capacity: 150 lbs. (68 kg) and over
Control Module Installation (See Dwg. MHTPA0705)
1. Place balancer on a clean surface, with end which has
orifice and tapped hole up.
2. Remove single balance control assembly parts from
package. Insert and seat 'O' ring (A) properly into
manifold (B). Attach manifold to end cap with four
enclosed screws.
(Dwg. MHTPA0705)
NOTICE
• The air seal between the manifold and balancer end
cap is vital for proper operation.
3. Attach pilot regulator control (H) to wire rope or chain
(see load hook installation in this section).
4. Open regulator (D) by turning knob (E) clockwise until
it stops.
5. Open pilot regulator (H) by turning knob (G) counter-
clockwise.
6. Attach air line (F) to regulators (D) and (H).
Control Assemblies
NOTICE
• Maximum lift capacity of balancer is calculated at 100
psi (690 kPa).
Single Balance Control Module C018
Capacity: Under 150 lbs (68 kg)
Control Module Installation (See Dwg. MHTPA0704)
1. Place balancer on a clean surface. Position the end cap
which has orifice and tapped hole up.
2. Remove single balance control assembly parts from
package. Insert and seat 'O' ring (A) properly into
manifold (B). Attach manifold to end cap with four
enclosed screws. Install single balance control assem-
bly to manifold.
(Dwg. MHTPA0704)
NOTICE
• The air seal between the manifold and balancer end
cap is vital for proper operation.
WARNING
• Do not exceed 150 psi (1034 kPa) inlet pressure. Do
not use a lubricator of any kind. Oil will damage
internal components.
Connecting Air Supply
Before connecting air supply, close regulator by turning
regulator knob counterclockwise until it stops.
1. Blow out air supply lines before connection. Ensure
lines are free of all contaminants.
2. Connect clean, filtered, contaminant free air supply to
check valve (C). (See Dwg. MHTPA0704)
Operational Adjustment
1. Attach load to be balanced before adjusting air.
2. Slowly turn regulator knob (D) clockwise until load
begins to lift. Adjust knob until it reaches balance
point (no drift).

10
Resetting Recol Control Brake
WARNING
• Do not exceed 150 psi (1034 kPa) inlet pressure. Do
not use a lubricator of any kind. Oil will damage
internal components.
Connecting Air Supply
Before connecting air supply follow steps 1 through 6 in
Control Module Installation.
1. Blow out air supply lines before connection. Ensure
lines are free of all contaminants.
2. Connect clean, filtered, contaminant free air supply to
check valve (C).
Operational Adjustment (See Dwg. MHTPA0705)
1. Attach load to hook.
2. Close pilot regulator (H) by slowly turning ring (G)
clockwise. This will cause the load to lift. Adjust until
load reaches a balance point (no drift up or down).
Then go back to the regulator knob (E) and turn it
counterclockwise. Readjust pilot regulator (H) until it
reaches balance point (no drift).
3. Repeat procedure “2” above until load can be raised
and lowered with minimal effort.
Resetting Unit
Reset unit after brake has been activated.
1. Turn regulator knob (E) counterclockwise slowly until
hook lowers.
2. This will release the brake. Follow operational
adjustment to reset balancer.
Pendant Control Module C017 for 6 and 8
inch Models
Control Module Installation (See Dwg. MHTPA0706)
1. Place balancer on a clean surface, with end which has
orifice and tapped holes up.
2. Remove control module assembly (A) from package.
Insert and seat 'O' ring (B) properly into control
module manifold (A). Attach control module manifold
to end cap with four enclosed screws.
NOTICE
• The air seal between the control module manifold and
balancer end cap is vital for proper operation.
3. Install pendant control assembly to control module
manifold.
WARNING
• Do not exceed 150 psi (1034 kPa) inlet pressure. Do
not use a lubricator of any kind. Oil will damage
internal components.
Connecting Air Supply (See Dwg. MHTPA0706)
1. Blow out air supply lines before connection. Ensure
lines are free of all contaminants.
2. Connect clean, filtered, contaminant free, air supply to
port labeled “IN” on control module assembly (A).
3. Connect hoses (C) and (D) to proper fittings as shown.
4. Hose (C) must be attached to fitting labeled “DN” on
control module (A) and port (2) 'OUT' on pendant
handle. Hose (D) must be attached to fitting labeled
“UP” on control module (A) and port (1) 'IN' on
pendant handle.
Operational Adjustments
NOTICE
• The “UP” (F) and “DN” (G) speed control screws are
closed when shipped to prevent accidental operation.
1. Attach an empty fixture to balancer if available. If an
empty fixture is not available, the load hook must be in
place as a minimum load.
2. Turn the “UP” (F) and “DN” (G) screws counterclock-
wise 1/2 turn each and operate both the up and down
controls. Adjust each screw according to your needs.
Turning the “UP” screw counterclockwise increases up
speed. Turning it clockwise decreases up speed. The
“DN” screw adjusts down speed similarly, and
independently of up speed.
3. After adjusting up and down speeds, place the load
hook (and fixture if attached) in the middle of vertical
travel. Hook (and fixture if attached) should stay in a
stationary position. If hook (and/or fixture) slowly
drop, adjust the balance screw (E) to provide zero, or a
slight upward drift. Turning the screw counterclock-
wise opens valve (G) and will eliminate downward
drift.
(Dwg. MHTPA0706)

11
Connecting Air Supply
1. Blow out air supply lines before connection. Ensure lines
are free of all contaminants.
2. Connect clean, filtered, contaminant free, air supply to
port labeled “IN” on control module assembly (A).
3. Connect hoses (C), (D) and (E) to proper fittings as
shown.
4. Hose (C) must be attached to fitting labeled “DN” on
control module (A) and port (4) on pendant handle. Hose
(D) must be attached to center fitting on control module
(A) and port (1) on pendant handle. Hose (E) must be
attached to fitting labeled “UP” on control module (A)
and port (2) on pendant handle.
OperationalAdjustments
The “UP” and “DN” speed control screws are closed when
shipped to prevent accidental operation. They must be
adjusted before the balance screw on the control module
assembly (A) is adjusted.
1. Attach an empty fixture to balancer if available. If an
empty fixture is not available, the load hook must be in
place as a minimum load.
2. Turn the “UP” and “DN” screws counterclockwise 1/2
turn each and operate both the up and down pendant
controls. Adjust each screw according to your needs.
Turning the “UP” screw counterclockwise increases up
speed. Turning it clockwise decreases up speed. The
“DN” screw adjusts down speed similarly, and indepen-
dently of up speed.
3. After adjusting up and down speeds, place the load hook
(and fixture if attached) in the middle of vertical travel.
Hook (and fixture if attached) should stay in a stationary
position. If hook (and/or fixture) slowly drop, adjust the
balance screw on the control module assembly (A) to
provide zero, or a slight upward drift. Turning the screw
counterclockwise will eliminate downward drift.
Resetting Recoil Control Brake
Reset unit after brake has been activated.
1. Turn regulator screw counterclockwise slowly or depress
the “DN” pendant lever until the hook lowers.
2. This will release the brake. Follow operational adjust-
ment to reset balancer.
Overhead Assemblies
Single Hanger Hook Assembly C016
Hanger Hook Installation (See Dwg. MHTPA0708)
1. Place balancer on clean surface.
2. Bolt hanger hook assembly (A) to universal mounting
bracket, one hole off center (B) toward wire rope guide.
3. Secure hanger bolt (C). Check hook assembly swivels
freely.
WARNING
• Severe injury and/or property damage may occur if
overhead support unit capacity is less than three times
the balancer capacity and/or safety wire rope is not
installed.
Reset unit after brake has been activated.
1. Turn regulator screw (E) counterclockwise slowly or
depress the “DN” pendant lever until the hook lowers.
2. This will release the brake. Follow operational
adjustment to reset balancer.
Pendant Control Module C091 for
10 and 12 inch Models
In certain applications where maximum lowering speed is
not required the C017 pendant control may be used with 10
and 12 inch models.
Control Module Installation (See Dwg. MHTPA0707)
1. Place balancer on a clean surface, with end which has
orifice and tapped holes up.
2. Remove control module assembly (A) from package.
Insert and seat 'O' ring (B) properly into control
module manifold (A). Attach control module assembly
to end cap with four enclosed screws.
(Dwg. MHTPA0707)
NOTICE
• The air seal between the control module manifold and
balancer end cap is vital for proper operation.
3. Install pendant control assembly to control module
manifold.
WARNING
• Do not exceed 150 psi (1034 kPa) inlet pressure. Do
not use a lubricator of any kind. Oil will damage
internal components.

12
(Dwg. MHTPA0709)
Trolley Suspension Kit Assembly
S013 (I-Beam) and S014 (Patented Track)
Trolley Installation (See Dwg. MHTPA0709)
1. Place balancer on clean surface.
2. Attach trolley to balancer as shown.
3. Dimension (A) should be 7/8 in. (22 mm) greater than
rail flange width.
4. To adjust trolley center to center dimensions, remove
bolts (B) and add or remove washers (C) equally at all
four locations to suit.
5. After adjustments, secure flex nuts (D).
Safety Wire rope Installation
1. Attach safety wire rope through universal mounting
bracket and around overhead support.
2. Torque clamp nuts to 7.5 ft lbs (10 Nm).
(Dwg. MHTPA0708)

13
Load Hook Assembly
Load Hook Installation KP2031 and KP2086
(See Dwg. MHTPA0711)
1. Install load hook as shown. (See Figure A.)
2. Remove bolts (A) from wire rope clamp. Lightly
lubricate the bolt and wire rope clamp threads with oil.
Loosely reassemble the bolts into the wire rope clamp.
(See Figure B.)
3. Pass one end of the wire rope (B) through the wire
rope clamp (E). (See Figure B.)
(Dwg. MHTPA0711)
4. Return the end of the wire rope back through the wire
rope clamp forming a loop (C), securing the thimble
close to the face of the wire rope clamp. It is important
that no part of the thimble enters the rope groove of the
wire rope clamp.
5. Using a torque wrench (D), set to 4.3 ft lbs. (6 Nm),
alternate and gradually tighten the bolts, turning the
wire rope clamp as necessary, until the specified
torque has been reached on each bolt. If correctly
assembled, the top of both halves of the wire rope
clamp should be matched.
WARNING
• Severe injury and/or property damage may occur if
suspension kit is not installed correctly, or if installed
on a rail flange other than specified. Rail stops must not
contact balancer housing.
Enclosed Aluminum Rail Trolley Suspension
Kit, 4 in. (102 mm) (S001) and 8 in. (203 mm)
(S806)
Trolley Installation (See Dwg. MHTPA0710)
1. Place balancer on a clean surface.
2. Attach Trolley to balancer as shown.
3. Install safety wire rope as shown.
4. To adjust trolley center to center dimensions, remove
bolts (A) and add or remove washers (B) equally at all
four locations to suit.
5. After adjustments, secure flex nuts (C). Do not
over tighten. Trolley should have 0.062 to 0.93 in.
(1.6 to 2.4 mm) clearance between washers, for track
alignment.
(Dwg. MHTPA0710)
WARNING
• Severe injury and/or property damage may occur if
suspension kit is not installed correctly, or if installed
on a rail flange other than specified. Rail stops must not
contact balancer housing.

14
WARNING
• Do not cut excess wire rope until a trial run has been
performed.
6. If no adjustment is required, cut off excess wire rope.
Leave at least 1 in. (25 mm) protruding past wire rope
clamp (E).
7. After the wire rope clamp assembly has been subjected
to its initial loading, it is important to retighten the
wire rope clamp bolts to the specified torque values.
Where practical, the heaviest loading anticipated
should be applied before retightening the bolts. After
this procedure further retightening should not be
necessary.
Reeved and Tandem Reeved Installation
(See Dwg. MHTPA0712)
1. Install sheave.
2. Follow procedures 2 through 6 in Load Hook
Installation.
3. Attach wire rope free end to eye bolt in can housing on
single reeved balancers. Attach wire rope free end to
the connecting bar on tandem reeved (double sheave)
balancers.
4. Follow procedure 7 in "Load Hook Installation".
(Dwg. MHTPA0712)
Tandem and Tandem Reeved Balancer
Installation
A connecting “tow” bar must be installed between the two
balancers to ensure correct spacing is maintained at all
times. Balancers must be mounted with wire rope guides
toward each other.
Hook and trolley suspension systems for tandem and
tandem reeved balancers are the same as for single balanc-
ers.
(Dwg. MHTPA0781) (Dwg. MHTPA0782)
On tandem reeved balancers the free end of the wire rope
from each balancer is attached to the connecting (tow) bar.
Tandem Balancer Tandem Reeved Balancer

15
Safety Wire rope Installation
Height Measurement (See Dwg. MHTPA0713)
1. Measure the lowest drop or load position (A).
2. Measure the highest point of clearance (B).
3. Hook C = A + B + (3 to 5 in. (76 to 127 mm))
(clearance).
Load Hook Positioning (See Dwg. MHTPA0713)
1. The ideal overhead position of the balancer with
respect to the load hook is vertical. Position balancer
directly above load.
2. The maximum radius of deflection is 10 degrees. A
larger radius will cause the wire rope or chain to wear.
(Dwg. MHTPA0713)
NOTICE
• Follow Installation Procedures described in the
preceding pages to match your particular workstation.
Recoil Control Brake Assembly
All balancers are provided with a recoil control brake. If
the recoil control brake has been activated the balancer will
not operate until the brake arm is reset. Refer to the
“OPERATION” section for instructions on resetting the
recoil control brake.
Storing the Balancer
1. Always store the balancer in a no load condition.
2. Wipe off all dirt and water.
3. Oil the wire rope/load chain, hook pins and hook gate.
4. Place in a dry location.
5. Plug balancer air inlet port.
6. Before returning balancer to service follow instructions
for Balancers not in Regular Service in the “INSPEC-
TION” section.

16
The four most important aspects of balancer operation are:
1. Follow all safety instructions when operating balancer.
2. Allow only people trained in safety and operation on
this product to operate balancer.
3. Subject each balancer to a regular inspection and
maintenance procedure.
4. Be aware of the balancer capacity and weight of load
at all times.
WARNING
• Only allow personnel trained in safety and operation
of this product to operate the balancer and trolley.
• The balancer is not designed or suitable for lifting,
lowering or moving persons. Never lift loads over
people.
Operators must be physically competent. Operators must
have no health condition which might affect their ability to
act, and they must have good hearing, vision and depth
perception. The balancer operator must be carefully
instructed in his duties and must understand the operation
of the balancer, including a study of the manufacturer’s
literature. The operator must thoroughly understand proper
methods of hitching loads and should have a good attitude
regarding safety. It is the operator's responsibility to refuse
to operate the balancer under unsafe conditions.
Initial Operating Checks
Balancers are tested for proper operation prior to leaving
the factory. Prior to placing the balancer into service the
following initial operating checks should be performed.
1. After installation of trolley or rail mounted balancers,
check to ensure the balancer is centered and securely
connected to the rail hanger, trolley or supporting
member.
2. Check for air leaks in the supply hose and fittings.
3. Operate along the entire length of the beam or rail.
4. Check balancer performance when raising, moving and
lowering test load(s). Balancer and trolley must
operate smoothly prior to being placed in service.
5. Check to see that the load is securely inserted in the
hook, and that the hook gate is closed.
Recoil Control Brake
The recoil control brake is a standard feature of all “M”
series air balancers. The recoil control brake prevents rapid
upward wire rope or chain movement. When the recoil
control brake senses overspeeding of the chain or wire
rope, the brake arm (147), is thrown outward until engaged
with the inner diameter of the balancer body. The brake
arm is designed to immediately stop wire rope or chain
movement, preventing an unsafe condition.
OPERATION
Re-Setting of Recoil Control Brake
If the recoil control brake is activated the balancer will not
operate until the brake arm (147) is re-set.
To re-set:
On pendant controlled units, first release air pressure by
depressing the down pendant valve. After the air pressure is
released the brake arm (147) should re-set. If it does not,
depress the down pendant lever while pulling down on the
load hook. This will allow the brake arm (147) to re-set.
The balancer is now ready to be used. If the brake was
activated due to a loss of load resulting from hook, wire
rope or chain damage, see pertinent information in “MAIN-
TENANCE” section.
Single Balance Control Module C018
The C018 Single Balance Control Module's basic function
is to support a constant non varying weight at zero gravity.
The 'O' ring (KP2078), regulator (KP2062), check valve
(KP2063), and manifold (KP2059) are the major compo-
nents of this control package. The 'O' ring is the seal
between the manifold and the balancer housing. The
regulator adjusts the air flow to support the constant, non
varying, weight at zero gravity within the balancer's
capacity range. The check valve prevents the load from
dropping if the main air supply to the balancer is lost, and
the manifold links these components together.
Adjustments to this control package are done with the self
relieving regulator. A clockwise turn of knob (KP2074)
increases the pressure through the regulator. A counter-
clockwise turn of knob (KP2074) reduces the pressure to
regulator. This compensation of air pressure allows the
balancer to support any weight up to the rated capacity.
The only other factor which effects the balancer's lifting
capacity is the amount of air pressure that is supplied.
Example: The MBA100-061 will lift 100 lb (45 kg) at 100
psi (690 kPa). If pressure is only 50 psi (345 kPa), it will
reduce the balancer lifting capacity by 50%.
High Relieving Single Balance
Control Module C090
Like the C018 Single Balance Control Module, the C090
High Relieving Single Balance Control Module's basic
function is to support a constant, non varying, weight at
zero gravity. One of the differences between the two
control modules is the pilot valve which increases or
decreases the pilot pressure to the self relieving regulator.
This control option is recommended for loads above 150 lb
(68 kg).

17
Pendant Control Module C017
The C017 Pendant Control Module's function, unlike the
C018 single balance control, is used for varying weight
applications.
Balancers with a pendant control will function similar to a
chain or wire rope hoist. Unlike other hoists, the balancer's
wire rope or chain travels on a ball screw giving it the
freedom to achieve any position desired (see “Description
of Balancer Operation” Section for a complete explanation
of the internal working procedure). The balancer also has a
free float action. This allows the operator to physically
move the part up and down within a 10 to 12 in. (250 to
300 mm) range without the use of the pendant.
The balancer can achieve up to 400 ft/min. (122 m/min.)
The balancer's speed is dependent on the total weight being
lifted. If the weight being lifted is greater than 75% of the
balancer rated load, it will not achieve maximum speed.
(Dwg. MHTPA0702)
The pendant control module uses a closed valve (KP9009)
which is located in the control handle. A constant flow of
air from the main supply is blocked by the “UP” lever. Live
air enters through the up flow control and through its
corresponding hose to the “UP” lever. When the lever is
depressed, the air passes to the “DN” lever valve and up
through the down hose back to the manifold. This fills the
balancer with air and allows the wire rope or chain to
retract and lift the load. When the “DN” lever is depressed,
it allows the air from the balancer to flow through the
exhaust port and lowers the load.
The control module also allows for varying speeds. The
flow controls for up and down speed can be adjusted to a
maximum rate. If a slower rate is required up or down, the
control handle can compensate for a slower speed. This
compensation is done by slightly depressing the levers
either up or down allowing less pressure to flow through
the control valve.
Pendant Control Module C091
Pilot Air Operation
The pendant control module uses a closed valve KP9001
which is located in the control handle. Pilot air from the
main supply is blocked at the pendant until the “UP” or
“DN” lever is actuated. When the “UP” lever is depressed
pilot air passes through the pendant to the valve on the
balancer which in turn fills the balancer with air allowing
the wire rope or chain to retract and lift the load. When the
lever is released air is exhausted and the load ceases
movement. When the “DN” lever is depressed pilot air
from the pendant is sensed by the valve which allows air
from the balancer to exhaust and lowers the load.
Pendant Control for Tandem and Tandem
Reeved Balancers
One balancer body is mounted with the control manifold,
the second balancer body is mounted with a passive (slave)
manifold. A connecting hose is installed between the two
manifolds. All adjustments are done at the main control
manifold.

18
WARNING
• Never use a balancer that inspection indicates is
damaged.
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 an 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
Some form of inspection record should be maintained for
each balancer, listing all points requiring periodic inspec-
tion. A written report should be made periodically, based
on the severity of usage and the condition of the critical
parts of each balancer. These reports should be dated,
signed by the person who performed the inspection, and
kept on file where they are readily available to authorized
personnel for 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 Inspection
On balancers in continuous service, frequent inspection
should be made by the operator at the beginning of each
shift. In addition, visual inspections should be conducted
during regular operation for indications of damage or
evidence of malfunction.
1. OPERATION. Check for visual signs or abnormal
noises (grinding etc.) which could indicate a potential
problem. Check wire rope or chain feed through the
INSPECTION
balancer. If wire rope or chain binds or jumps clean and
lubricate. If problem persists, replace the wire rope or
chain. Do not operate the balancer until all problems
have been corrected.
2. HOOKS. Check for wear or damage, increased throat
width, bent shank or twisting of hook. Replace hook if
gate no longer contacts hook tip (See Dwg.
MHTPA0662). Refer to the latest edition of ASME
B30.10 “HOOKS” for additional information. Check
hook support bearings for lubrication or damage. Ensure
they swivel easily and smoothly.
(Dwg. MHTPA0662)
3. CHAIN. (MCB Models only) Examine each of the links
for bending, cracks in weld areas or shoulders, traverse
nicks and gouges, weld splatter, corrosion pits, striation
(minute parallel lines) and chain wear, including bearing
surfaces between chain links (see Dwg. MHTPA0102).
Replace a chain that fails any of the inspections. Check
chain lubrication and lubricate if necessary. Refer to
“Load Chain” in “ LUBRICATION” section.
(Dwg. MHTPA0102)

19
NOTICE
• Excessive wear or stretching may not be apparent
from visual observation. Inspect chain by measuring
five links in accordance with instructions under “Peri-
odic Inspection”. A worn load chain may cause the
spool to wear rapidly. Inspect the spool and replace if
damaged or worn.
4. AIR SYSTEM. Visually inspect all connections,
fittings, hoses and components for indication of air
leaks. Repair any leaks found. Check and clean the
filter in the system.
5. PENDANT CONTROL. (Optional Feature) During
operation of balancer, verify response to pendant is
quick and smooth. See that the pendant control levers
return to neutral when released. If balancer responds
slowly or movement is unsatisfactory, do not operate
balancer until all problems have been corrected.
6. HOOK GATE. Make sure the hook gate is present and
operating. Replace if necessary.
CAUTION
• Do not use balancer if hook gate is missing or dam-
aged.
7. WIRE ROPE. (MAB Models only) Visually inspect all
wire rope which can be expected to be in use during the
day's operations. Inspect for 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 balancer until the discrepancies have been
reviewed and inspected further by personnel instructed in
the operation, safety and maintenance of this balancer.
NOTICE
• The full extent of wire rope wear cannot be deter-
mined by visual inspection. At any indication of wear
inspect wire rope in accordance with instructions in
“Periodic Inspection”.
8. WIRE ROPE REEVING. Make sure wire rope spools
evenly and correctly into grooves in the spool. Check
wire rope is not twisted or kinked. Check wire rope
clamps are tight. Visually inspect connecting eye bolt
and sheave if used.
9. SAFETY WIRE. Ensure safety wire clamp is secure
and wire is not damaged.
10. LOAD HOOK CLAMPS. Ensure bolts are correctly
torqued. Refer to “INSTALLATION” section. Check a
minimum of 1 in. (25 mm) of wire rope is visable.
Periodic Inspection
Frequency of periodic inspection depends on the severity of
usage:
NORMAL HEAVY SEVERE
yearly semi-annually quarterly
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
thefollowing:
1. FASTENERS. Check all rivets, split pins, capscrews
and nuts. Replace if missing or tighten if loose.
2. ALL COMPONENTS. Inspect for wear, damage,
distortion, deformation and cleanliness. If external
evidence indicates the need, disassemble. Check
shafts, bearings, spool, piston housing, covers and wire
rope or chain guide. Replace worn or damaged parts.
Clean, lubricate and reassemble.
3. HOOKS. Inspect hooks carefully for cracks using
magnetic particle or other suitable non-destructive
method. Inspect hook retaining parts. Tighten or
repair, if necessary.
4. SUPPORTING STRUCTURE. Check for distortion,
wear and continued ability to support the balancer and
load.
5. TROLLEY. (if equipped) Check that the trolley
wheels track the beam properly and clearance between
trolley wheels and beam is correct. Refer to “INSTAL-
LATION” section. Check that wheels and rail are not
excessively worn and inspectside plates for spreading
due to bending. Do not operate the balancer until all
problems have been corrected.
6. LABELS AND TAGS. Check for presence and
legibility. Replace if necessary.
7. WIRE ROPE END ANCHORS. (MAB Models only)
Ensure both ends of wire rope are securely attached.
Secure if loose, repair if damaged, replace if missing.
8. WIRE ROPE. (MAB Models only) Nominal size of
wire rope is 3/16 in. (5 mm) diameter for all models. In
addition to frequent inspection requirements, inspect
for the following:
a. Build-up of dirt and corrosion. Clean if necessary.
b. Loose or damaged end connection. Replace if
loose or damaged.
c. Check wire rope anchor is secure.
d. Changes in the size of the wire rope diameter.
Periodically measure the diameter of the wire rope
from crown-to-crown throughout the life of the wire
rope. The actual diameter should be recorded when
the wire is under equivalent loading and in the same
operating section. If the actual diameter of the wire
rope has decreased more than 1/64 in. (0.04 mm) a
thorough examination of the wire rope should be
conducted by an experienced inspector to deter-
mine the suitability of the wire rope to remain in
service. (See Dwg. MHTPA0056)

20
Crown
to
Crown
(Dwg. MHTPA0056)
9. LOAD CHAIN. (MCB Models only) Measure the
chain for stretching by measuring across five link
sections all along the chain paying particular attention
to the most frequently reeved links. When any five
links in the working length reaches or exceeds the
discard length, replace the entire chain (see Dwg.
MHTPA0041 and Table 3). Always use genuine
Ingersoll-Rand Material Handling replacement load
chain.
A
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A
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A
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A
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A
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AAAA
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AAAA
AAAA
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AAAA
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AAAA
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AAAA
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A
A
A
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A
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AAAA
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Table 3
Chain
Size
Length When New Discard Length
in mm in mm
3/16 in.
(5 mm)
Diameter 3.147 79 3.24 82
Gauge Length
(Dwg. MHTPA0041)
Balancers Not in Regular Use
1. A balancer which has 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. A balancer which has been idle for a period of more
than one year should be given an inspection conform-
ing with the requirements of “Periodic Inspection”
prior to being placed into service.
3. Standby balancers should be inspected at least semi-
annually in accordance with the requirements of
“Frequent Inspection”. In abnormal operating condi-
tions balancers should be inspected at shorter intervals.