Ingersoll-Rand HL1000K, Parts, Operation And Maintenance Manual

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8. Using retainer ring pliers and applying pressure to the hub
of the valve seat, install the valve seat retainers (12). Make
certain the retainers seat in the grooves of the valve chest.
9. If the pistons (14) were separated from the piston shafts
(15), apply a thin film of ‘O’ ring lubricant to each piston
shaft seal (15A) and install them in the grooves of the
piston shafts.
10. Slide the pistons onto the piston shafts with the small hub
of the piston toward the smallest diameter of the shaft.
Align the crosshole in each piston with the crosshole in
each shaft and install the piston retaining pins (15B).
11. Apply a thin film of ‘O’ ring lubricant to the piston seals
(14A) and install one on each piston.
12. Apply a thin coat of ‘O’ ring lubricant on the piston
cylinder walls and insert the piston springs (13) into the
valve chest against the valve seat retainers.
13. Install the assembled pistons and shafts in the valve chest.
14. Apply a thin coat of ‘O’ ring lubricant to the valve chest
cover seals (18A) and install them in the valve chest cover
(18).
15. Align the valve chest cover gasket (16) with the valve chest
cover pins and place the gasket against the valve chest.
16. Align the valve chest cover with the valve chest cover pins
and piston shafts and place the cover against the valve
chest.
17. Install the six valve chest cover screws (22). Tighten screws
evenly and torque to 72 in lb (8 Nm).
18. Thread the adjustment screw locknuts (21) onto the bleed
adjustment screws (19) and install the screws in the valve
chest cover.
NOTICE
• Use these screws to adjust hoists with pendant control.
Refer to ‘Pendant Control Adjustments’ in the
“INSTALLATION” section.
19. Manually work the piston shaft assemblies up and down
when installed in the valve chest. The piston shafts must
shift smoothly with no indication of binding of parts.
Valve Chest Assembly (Old Style)
This procedure describes the assembly 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. The following
assembly instructions are provided for reference only.
1. Moisten the valve sleeve seals (326) with ‘O’ ring lubricant
and install them on the valve sleeves (325).
CAUTION
• When installing the valve and valve sleeve assemblies (325),
make certain the valves do not get mixed. These are
assembled as matched sets.
NOTICE
• Each valve sleeve has a notch in one end and a 7/16 inch (11
mm) diameter port in the wall of the sleeve. Inside the valve
chest there is a 7/16 inch (11 mm) diameter cross-port that
connects the two valve chambers.
2. Insert the valve sleeves, notched end first, into the valve
chest so that the 7/16 in. (11 mm) diameter port in each
sleeve is aligned with the cross-port in the valve chest, and
so that the notches in the sleeves face each other.
3. Stand the valve chest up on the inlet port and insert a valve
spring (327) and a valve (325) into each valve sleeve. Make
certain each valve goes into its proper sleeve. These are
matched sets.
4. Moisten each piston seal (331) with ‘O’ ring lubricant and
install a seal in the groove on each piston (330).
5. Insert each piston rod (328 and 329), small end first,
through its respective hole in the piston.
6. Install a piston nut (332) on each piston rod. Tighten the
nut to a snug fit.
7. Moisten the valve chest cover seals (335) with ‘O’ ring
lubricant, and install them in the valve chest cover (334).
8. Position the valve chest cover so that the bleed holes and
adjustment screws (336) are facing you. Moisten the large
diameter of the piston rods with ‘O’ ring lubricant. Insert
the longer piston rod (328) through the hole on the left
from the gasket side of the valve chest cover. Insert the
shorter piston rod (329) through the hole on the right from
the gasket side.
9. Place a piston spring (333) in each valve cavity in the valve
chest, and position the valve chest cover gasket (338) on
the bottom of the valve chest.
10. Taking care not to pinch the piston seals, install the
assembled valve chest cover to the bottom of the valve
chest. Check to make sure the long stem piston rod (328) is
installed in “UP VALVE” side as marked on gasket face of
valve chest. Tighten the valve chest cover screws (339)
evenly a little at a time until all are tight.
Assembly of Hoist
1.
If removed, install new throttle shaft bearings (2) in the
housing and apply a light coating of grease.
2. Install the ‘O’ ring seal (51) in the housing.
3. Install the chain guard (5) in the housing.
4. Install a new oil seal (53) in the output ring gear (52) with
the lip facing inward. Coat the lip with a film of oil or
grease.
5. Ensure the retainer ring is located on the shaft bearing (50).
Install the bearing on the ring gear (52) with the retainer
ring end located towards the ring gear.
6. Lubricate the gear splines on the ring gear (52) shaft and
the chain wheel (51A) with Ingersoll-Rand No. 11 grease.
Install the chain wheel on ring gear shaft.
7. Install shaft bearing (49) onto the ring gear (52).
8. Install ring gear (52) assembly in housing.
9. Install the chain guide (4), four chain guide capscrews (4A)
and lockwashers (4B).
10. Insert the motor retainer washer (48) in the housing. The
raised outer diameter should be toward the open/motor end
of the housing.
11. Install the motor assembly in the housing by aligning the
motor guide rod with the dowel hole in the bottom of the
housing and sliding the motor into the housing.
12. Remove the guide rod and replace it with a cylinder dowel
(45). Tapered end of dowel pin must enter first. Dowel
should be positioned approximately 1/8 in. (3 mm) below
the rear end plate (41) surface.