Ingersoll-Rand HL1000K, Parts, Operation And Maintenance Manual

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10. To install in hoist, refer to ‘Hoist Assembly’ section.
Brake Assembly
Refer to Dwg. TPB704-3.
1.
Lightly coat the piston seals (84) and (85) with ‘O’ ring
lubricant, and install them in their respective grooves on
the brake piston (83).
2. Taking care not to cut the seals, slide the piston into the
brake spring and piston housing (80).
3. Place the spring and piston housing on the workbench with
the three spring cavities facing upward.
4. Place a spring (81) in each cavity.
5. For New Style Pressure Plates (82): install the pressure
plate screw (82A) such that the screw head mates with the
counterbore in the pressure plate face. Place the pressure
plate (82) and screw over the springs so that the screw
enters the hole in the brake piston.
For Old Style Pressure Plates with and Integral Stud:
install the pressure plate, stud side first, over the springs so
that the stud enters the hole in the brake piston.
NOTICE
• For improved brake control it is recommended that the old
style pressure plate be replaced with the new style pressure
plate (82) and screw (82A). The old style pressure plate is not
available as a replacement part. To replace order Brake Kit
No. MLK-ABK1.
6. Carefully place the assembly in a vise and compress the
pressure plate against the brake springs and piston housing
until the screw protrudes through the piston. Thread the
piston nut (82B) onto the screw at least two full thread
lengths, but not enough to fully engage the nut.
7. Slowly release the assembly from the vise.
8. For New Style Pressure Plates: tighten the pressure plate
screw (82A) and piston nut (82B) until a 0.006 to 0.012 in.
(0.15 to 0.30 mm) gap exists between the pressure plate and
piston. Refer to Dwg. MHP0488.
NOTICE
• When adjusted, the piston (83) assembly should free float
between piston nut (82B) and pressure plate (82). Ensure
piston moves freely between nut and pressure plate.
For Old Style Pressure Plates: torque the piston nut to 50 to
70 inch-lb (6 to 8 Nm).
NOTICE
• Ensure the piston extends completely through the spring
and piston housing and contacts the pressure plate.
9. Install the plate (87) in the recess of the spring and piston
housing (80) and secure using two plate screws (88).
10. To complete brake installation in hoist, refer to ‘Hoist
Assembly’ section.
(Dwg. MHP0488)
Valve Chest Assembly (New Style)
This procedure describes the assembly 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, or hoist valve chests that have been
updated with Valve Chest Kit No. MLK-K545B. Replacement
part numbers are listed in the Parts section. Refer to Dwg.
TPA958-1.
1.
If the valve chest cover pins (17) were removed, install
them in the bottom of the valve chest (6).
2. Apply a thin film of ‘O’ ring lubricant to the valve seals
(7A) and (8A) and install them on the valves (7) and (8).
CAUTION
• Do not substitute any other ‘O’ rings for the valve seals.
3. Install a valve spring (9) on the non-tapered end of each
valve and insert the valves, valve spring first, into the
openings at the bottom of the valve chest. Make certain the
valve marked UP is inserted into the opening marked UP
VALVE and the valve marked DOWN is inserted in the
opening marked DOWN VALVE.
NOTICE
• Some valves (7) and (8) were not marked UP and DOWN.
To determine correct placement, inspect these valves. A valve
with a shallow annular groove around the spring end hub is
the DOWN valve. A valve without an annular groove around
the spring end hub is the UP valve.
4. Apply a thin film of ‘O’ ring lubricant to the valve seat
shaft seals (10B). Install a seal in each valve seat (10).
5. Apply a thin film of ‘O’ ring lubricant to the valve seat
seals (10A) and install two seals on each valve seat.
6. Align the smaller diameter crosshole of the valve seat with
the threaded hole in the side of the valve chest for the valve
seat lock screw (11). With the hub end trailing, install the
valve seats in the valve chest.
7. Screw the valve seat lock screws into the valve chest. Make
certain they enter the valve seats. Torque the screws to 24
in lb (3 Nm).