Ingersoll-Rand ZGB015-KIT User manual

Form 47740328

Edition A

June 2021

Purpose/Objective: This document provides assembly instructions for the Zero Gravity portion of the 150 lbs., 200 lbs., 350 lbs., and 500 lbs. Balancers.

The use of other than genuine In ersoll Rand replacement parts may result in safety ha ards, decreased performance and increased maintenance and

will invalidate all warranties.

For further assistance or parts needed, contact local distributor or IR representative.

Original instructions are in English. Other languages are a translation of the original instructions.

Prior to installing the product, carefully inspect it for possible shipping damage.

Conversion Kit: Zero Gravity Balancer Assembly

WWAARRNNIINNGG

• Prior to installation refer to Product Safety Information Manual for all sections of installation.

• Always wear eye protection when operating or performing maintenance on this Product.

• Make sure that electrical power to the system has been disconnected.

• Always shut off main air supply and bleed down before disconnecting air supply hose before

installing, removing or adjusting any accessory on this Products, or before performing any

maintenance on this Product.

• Never perform maintenance on the Product while it is supporting a load.

• Before performing maintenance, tag controls: WARNING - DO NOT OPERATE - EQUIPMENT

BEING REPAIRED.

• Only allow personnel trained in service and repair of this Product to perform maintenance.

• After performing any maintenance on the Product, test Product before returning Product to

service.

• The lower sheave block or hook assembly must be lying on the floor or a maintenance platform

before beginning service.

CCAAUUTTIIOONN

Owners and users are advised to examine specific, local or other regulations, including American

Society of Mechanical Engineers (ASME) and/or OSHA Regulations which may apply to a particular

type of use of this product before installing or putting product to use.

Table 1. Product Information Manuals

Publication CCN

Product Safety Manual 16598831

Product Information Manual 54072541

Product Parts Information Manual 16598849

Product Installation Manual 47646669001

Product Maintenance Manual 16598856

ZGB User Manual 47726957001

2Form 47740328 Edition A

ZGB Retrofit Kit Components

Fi ure 1. ZGB Retrofit Kit Components Drawin

Table 2. ZGB Retrofit Kit List

Item No. Description of Part Total Qty.

Part Number

ZGB015-KIT for

BW015080

Balancers

ZGB020-KIT for

BW020120

Balancers

ZGB035-KIT for

BW035080

Balancers

ZGB050-KIT for

BW050080

Balancers

1Suspension Kit 1 ZGS00

2 Manifold Kit 1 ZGB-MANIFOLD

3 Brackets Kit 1 ZGE06 ZGE10

4 Control Box Kit 1 ZGB015 ZGB020 ZGB035 ZGB050

5 Command Handle 1 ZGP00B

6(a) Spiral Wire 1 ZGC2

(a) Item not illustrated.

3 Form 47740328 Edition A

Installation

1. Mount Balancer on V-block or other stable surface to support

cylindrical housing. Install two bushings into the suspension ears of

the housing.

2. Mount the suspension brackets onto the housing using a set of

bolts and nuts. Make sure that the flanges of both brackets are facing

outwards.

3. Using a 7/8” and 13/16” wrench to secure the nuts and bolts.

Torque to 54 ft-lbs.

4. Apply thread sealant (example: Loctite 567 or similar) to the fitting

for the manifold.

5. Tighten the fitting and position it to the orientation shown below.

4Form 47740328 Edition A

6. Install O-ring on back side of manifold. A little bit of grease or lube

(example: Super Lube Silicone O-ring Grease or similar) can be used

to help hold the O-ring in place if needed. Install the manifold to the

unit using 1/4" allen wrench, the provided screws and washers.

Torque screws to 8 ft-lbs.

7. Assemble the control box onto the suspension brackets using a

5mm allen wrench, the 4 screws and set of washers. Torque screws to

8 ft-lbs.

8. Air hose should be supplied at pre-cut length. If not, cut the hoses to the following lengths.

a. 150 lbs capacity:

i. Hose #1: 30 cm (11- ¾”)

ii. Hose #2: 17.5 cm (7”)

b. 200/350/500 lbs capacity:

i. Hose #1: 36 cm (14- ¼”)

ii. Hose #2: 19 cm (7- ½”)

9. Gather all the hose/fittings/clamps.

10. Insert fitting #1 into hose #1 (labeled in step 9). Coat the fitting with lubricant/sealant (example: Loctite 567 or similar) for ease of

installation.

11. Remove nut on hose fitting and insert the hose into the hole in the suspension kit. Insert the hose clamp and pinch the ears to secure the

hose to the fitting. Do not tighten the nut on hose fitting.

12. Insert the hose clamp onto the open end of hose #1. Coat fitting #2 with lubricant/sealant (example: Loctite 567 or similar). Install fitting

#2 on hose #1. Pinch the ears of the hose clamp to secure the hose to the fitting.

5 Form 47740328 Edition A

13. Check the presence of the O-ring in the fitting. If necessary, lightly coat the seal with grease/lube (example: Super Lube Silicone O-ring

Grease or similar).

14. Install the fitting on the bottom hole of the control box.

15. Tighten the nut from step 11.

16. Coat the manifold fitting with lubricant/sealant (example: Loctite 567 or similar). Install hose #2 onto the fitting of the manifold. Insert

the hose clamp and pinch the ears to secure the hose to the fitting.

17. Insert the hose clamp onto the end of hose #2. Coat fitting #2 with lubricant/sealant (example: Loctite 567 or similar). Install hose #2 on

fitting #3. Pinch the ears of the hose clamp to secure the hose to the fitting. (It may be easier to install hose on the fitting if the fitting is off of

the manifold).

18. Check the presence of the O-ring in the fitting. If necessary, lightly coat the seal with grease/lube (example: Super Lube Silicone O-ring

Grease or similar).

19. Thread the fitting into the top of the control box. Tighten the nut using a wrench, orienting the fitting in a horizontal direction.

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