Ingersoll-Rand HL1000K, Parts, Operation And Maintenance Manual

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3. Unscrew the valve chest screws (26) and (27) and remove
the valve chest (6) and valve chest gaskets (25).
4. Unscrew and remove the swivel inlet assembly. Push the
inlet stud (24) out of the inlet body (23) to expose the
swivel inlet seals (24A).
5. Unscrew the valve chest cover screws (22) and remove the
valve chest cover (18) and valve chest cover gasket (16).
6. Remove the piston and piston shaft assemblies (14 and 15)
and piston springs (13).
7. Remove the valve seat lock screws (11).
8. While exerting pressure against the valve seats (10), use
retainer ring pliers to remove the valve seat retainers (12).
9. Using a hooked tool, pull the valve seats from the valve
chest or rap the bottom of the valve chest on a block of
wood.
10. Remove the valve assemblies (7) and (8) and valve springs
(9) from the valve chest.
11. If the piston shaft seals (15A) require replacement, press
the piston retaining pins (15B) from each piston and shaft
and slide the pistons off the shafts.
Old Style Valve Chest Disassembly
This procedure describes the disassembly of valve chests used
on hoists with second letter of the Serial Number A through G
or with second and third letters of the Serial Number HA, HB,
or HC. Refer to Dwg. TPA883-3.
NOTICE
• Replacement parts for this valve chest are no longer
available. Order kit No. MLK-K545B (03835519) to replace
this style valve chest if it cannot be repaired.
1. On a hoist with pendant control, disconnect the three
pendant hoses (171) at the elbows (181) and (182). Remove
the valve chest plate screw (30) and disconnect the strain
relief cable (175).
2. Unscrew and remove the inlet strainer (24C).
3. Unscrew the valve chest screws (26) and (27) and remove
the assembled valve chest and valve chest gaskets (25).
4. Unscrew and remove the swivel inlet assembly. Slide the
inlet stud (24) out of inlet body (23) to expose the swivel
inlet seal (24A).
5. Unscrew the valve chest cover capscrews (339), and
withdraw the valve chest cover (334) along with the piston
rods (328) and (329), pistons (330) and piston springs
(333). Remove the valve chest cover gasket (338).
6. Withdraw the two valves (325) and the two valve springs
(327).
NOTICE
• Valves (325) and sleeves are manufactured as a matched
set. Do not mix valves and sleeves. Ensure the valves are
marked for sleeve location at disassembly.
Brake Disassembly
Refer to Dwg. TPB704-3.
1.
Unscrew the four shoulder bolts (89) and lockwashers (90)
and separate the springs (81) and piston housing (80) as an
assembly from the gear case cover (69).
NOTICE
• When assemblies are separated into component parts the
exposed ‘O’ rings and gaskets should be discarded and
replaced with new during assembly.
2. Remove the brake plates (78) and brake discs (79) from the
gear case cover. Remove ‘O’ ring (air port) (77) and
discard.
3. Disassemble the spring and piston housing as follows:
a.
Remove the plate screws (88) and the plate (87).
b. Place the assembly, pressure plate (82) downward, on
an arbor press, or; place the assembly vertically in a
vise.
c. While holding the housing against the compression of
the springs (81), hold the pressure plate screw (82A)
with a wrench and unscrew the piston nut (82B).
d. Relax the tension of the compressed springs (81) by
slowly and carefully easing up on the arbor press or
vise.
e. Remove the pressure plate and push the piston (83)
from the housing. Remove ‘O’ rings (84) and (85) and
discard.
4. To remove the brake driver (73), remove retainer screw
(76) and brake seal retainer (74). Slide brake driver off
motor shaft (38). Remove brake seal (75) and discard.
Motor Disassembly
Refer to Dwgs. TPA958-1 and TPB703-3.
1.
Remove the brake mechanism. Refer to ‘Brake
Disassembly’ section.
2. Drain oil from the gear case.
3. Remove the valve chest (6) as an assembly. Refer to
applicable (new or old style) valve chest disassembly
section.
4. Remove the limit actuator retaining pin (34) and withdraw
the limit actuator (33).
5. Unscrew the remaining valve chest plate screws (30) and
remove the valve chest plate (28).
6. Grasp the rear end plate (41) and pull the motor from the
hoist as an assembly. If the motor is a little “sticky”, tap on
the brake end of the motor shaft (38) with a soft drift to
loosen.
7. Grasp the motor shaft vertically in copper-covered vise
jaws.
8. Remove the motor shaft rear retaining ring (39).
9. Separate the rear end plate (41), rear end plate bearing (40),
cylinder (44), cylinder dowel (45), vanes (43), rotor (42),
front end plate (46) and front end plate bearing (47) into
component parts.
Disassembly of the Gearing, Pocket Wheel, Chain Guide,
Chain Guard, and Throttle Shaft
Refer to Dwgs. TPB705-2 and MHP1065.
NOTICE
• When assemblies are separated into component parts the
exposed ‘O’ rings and gaskets should be discarded and
replaced with new during assembly.
1. Remove the brake mechanism. Refer to ‘Brake
Disassembly’ section.
2. Remove the motor. Refer to ‘Motor Disassembly’ section.
3. Remove the four gear case capscrews (70) and lockwashers
(71). Remove the gear case cover (69). It may be necessary
to use a slide hammer puller attached to a bar and fastened
to two of the brake cover bolt holes.
4. Remove the gear case cover gasket (66) and discard.
5. If required, separate the fixed ring gear (67) from the gear
case cover (69) by gently prying the ring gear from the
cover, or by removing the ring gear pins (68). Discard the
ring gear pins and replace with new.
6. Withdraw the planet frame (54) and gears as an assembly.
The planet frame may then be disassembled.