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5. Place the brake cylinder on a clean work surface with
the splined end down. Install the spring spacer (Item
10), then the springs (Item 9).
6. Install the pressure plate (Item 7) into the brake cylin-
der. Be careful that none of the springs fall over. Install
the steel backup ring (Item 6). Apply petroleum jelly or
an oil soluble grease to a new O-ring (Item 13) and
install it in the brake cylinder.
NOTE:
The close fitting backup ring may be depressed
slightly to one side to lodge it in the brake cylinder bore
and temporarily hold the pressure plate and springs in
place while the brake cylinder is inverted and lowered
over the motor adapter.
As an alternate, the motor adapter and brake plates
can be turned over and installed into the brake cylinder,
holding the brake plates and spacer in place through
the center opening. Be careful to not pinch your fingers
between the spacer plate and the pressure plate.
7. Apply petroleum jelly or an oil soluble grease to the
sealing surface of the brake cylinder and the piston
seal. Turn the brake cylinder over and lower it onto the
motor adapter, being careful not to damage the piston
seal or O-ring on the adapter. Be careful the O-ring
(Item 13) does not fall out of place, and the oil passag-
es are aligned. The alternate assembly method above
could also be used.
8. Turn the entire assembly over and install the four cap-
screws and lockwashers. After the capscrews make
contact with the motor adapter, evenly tighten them
one turn at a time until the motor adapter is drawn tight
against the brake cylinder, then torque to the recom-
mended value.
BRAKE CYLINDER PRESSURE TEST
1. Install a -6 ORB fitting into the brake release port on
the motor adapter. Connect a hand pump with an ac-
curate 0–2,000 PSI (0–138 bar) gauge and shut-off
valve to this fitting. Apply 1,000 PSI (69 bar) to the
brake and close the shut-off valve. Let the unit stand for
five minutes. If there is any loss of pressure, the brake
cylinder should be disassembled for inspection of the
sealing surfaces, seal and O-ring. When the source of
the pressure leak has been determined and corrected,
reassemble the brake cylinder and repeat the test.
2. WHILE PRESSURE IS APPLIED AND THE BRAKE IS
RELEASED, install the overrunning clutch assembly
into the brake pack. Turn the clutch back and forth to
align the splines on all the friction discs. Release the
pressure on the brake cylinder and remove the clutch
assembly. The brake cylinder is now complete and
ready to be installed in the hoist.
Always use the molded spring spacer to properly posi-
tion the springs in the brake cylinder. Failure to install
the spring spacer may allow the springs to contact each
other and become damaged. This could result in loss of
load control, property damage, injury, or death.