Ingersoll-Rand HL1000K, Parts, Operation And Maintenance Manual

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NOTICE
• On double chain fall hoists the total number of load chain
links must be an ODD number. Ensure the new load chain
has an odd number of total chain lengths. Refer to Dwg.
MHP0441.
• The first link of new chain over the powered chain wheel
must be a standing link.
2. After the new chain has been reeved over the powered
chain wheel, remove the old chain and the ‘C’ link. Secure
the dead end of the load chain to the dead end chain anchor
located on the hoist. Refer to Dwg. TPA706-3. Make
certain the load chain is not twisted between the chain
wheel and dead end chain anchor.
3. Reeve the load end of the load chain around the bottom
block idler chain wheel. Ensure the chain is not twisted
between the hoist chain wheel and the bottom block chain
wheel. Refer to Dwg. TPA706-2.
4. Ensure the load chain remains straight and attach the load
end of the load chain to the chain anchor bracket located on
the hoist. Refer to Dwg. TPA706-1.
5. Lubricate the load chain. Refer to “LUBRICATION”
section.
6. Operate the hoist slowly in both directions. Hoist must
operate smoothly, without sticking or binding.
HL4500K and HL6000K Chain Replacement
Complete the initial steps described in ‘Chain Replacement’.
Conduct the following additional steps on three and four fall
hoists to complete load chain replacement installation. Refer to
Dwg. TPA1056 for HL4500K hoists and TPA1057 for
HL6000K hoists.
1.
Keeping the new load chain straight, slowly operate the
hoist in the raise direction to run off the old load chain and
reeve the new load chain over the powered and idler chain
wheels.
NOTICE
• Make certain the welds and links on the new chain match
the positioning of the welds and links on the chain being
replaced. The new chain must be installed such that as it is
reeved through the hoist the first link of new load chain over
the powered chain wheel will be a standing link with the weld
facing away from the powered chain wheel.
2. After the new load chain is reeved over the powered chain
wheel, remove the old chain from the dead end chain
anchor at the side of the hoist and attach the end of the new
chain. Ensure the load chain is not twisted between the
powered chain wheel and the dead end chain anchor.
WARNING
• Twisted load chain can jam as it passes over the chain
wheels, damaging to the hoist and possibly breaking the
chain resulting in injury and property damage.
3. Keep the load end of the load chain straight, attach the load
end link to the load end chain anchor located in the bottom
block (HL4500K) or in the upper suspension housing
(HL6000K). Do not twist the chain when attaching it to the
load end chain anchor. If necessary cut the last link from
the load chain and remove it to prevent twisting. Refer to
Dwg. MHP0441.
4. Lubricate the load chain. Refer to the “LUBRICATION”
section.
5. Run the hook up and down several times under power with
no load to ensure the load chain is running smoothly over
the chain wheels. There must be no apparent binding or
evidence of malfunctioning.
Servicing the Filter and Strainer
1. Disconnect the air supply from the hoist.
2. Unscrew the air hose from the inlet strainer (24C).
3. Unscrew the inlet strainer from the inlet body (23).
4. Clean the screen inside the inlet strainer by washing with a
quality, non-toxic, nonflammable commercial solvent in a
well ventilated area. If the screen is damaged or cannot be
cleaned, replace the inlet strainer.
5. Unscrew the inlet stud (24) from the valve chest (6) and
remove the inlet stud and inlet body from the valve chest.
6. Push the inlet stud out of the inlet body.
7. Remove the two swivel inlet seals (24A) from the inlet
stud.
8. If the swivel inlet gasket (24B) is damaged, replace it.
9. If hoist is equipped with a filter inside the inlet stud, clean
by washing with a quality, non-toxic, nonflammable
commercial solvent in a well ventilated area. If the filter
cannot be cleaned, replace the inlet stud. (New style inlet
studs do not have filters).
10. Moisten the new swivel inlet seals with ‘O’ ring lubricant
and install them in the grooves around the body of the inlet
stud.
11. Push the inlet stud into the inlet body until the 'hex' of the
stud is flush against the face of the inlet body.
12. Keep the threaded hole of the inlet body facing away from
the hoist and screw the inlet stud into the valve chest.
13. Screw the inlet strainer into the inlet body.
14. Screw the air hose into the inlet strainer.
15. Reconnect the air supply to the hoist.
Disassembly
WARNING
• Disconnect the air supply hose before performing any
maintenance or repairs on this hoist.
Refer to ‘General Maintenance Instructions’ and also note:
1.
The HLK hoist is constructed of various modules. During
the process of disassembly it is not always necessary to
disassemble a particular module just because it is removed
from the hoist. For example, the valve chest assembly must
be removed (as an assembly) to access and disassemble the
motor. However, the valve chest need not be disassembled
unless parts within the valve chest require replacement. Do
not disassemble the hoist any further than necessary to
replace or repair damaged parts.
2. Do not disassemble this hoist unless you have a complete
set of new gaskets, ‘O’ rings and seals on hand for
replacement. These are available in overhaul gasket kit No.
HLK-K445. Idler wheel seals (108) and hook pins (130)
are not included in the kit and must be ordered separately.
3. Do not attempt to wash sealed bearings.
New Style Valve Chest Disassembly
This procedure describes the disassembly of valve chests used
on hoists with the second letter of the Serial Number other than
A through G, or with second and third letters of the Serial
Number other than HA, HB or HC. Replacement part numbers
are listed in the parts section. Refer to Dwg. TPA958-1.
1.
On hoists with pendant control, disconnect the three
pendant hoses (171) from the fittings (181) and (182).
Remove the valve chest plate screw (30) and disconnect the
strain relief cable (175).
2. Remove the pendant links (183).