Rexnord Stearns 1-081-X00 Series User manual

1-081-X00 & 1-082-X00 Series
Important
Please read these instructions
carefully before installing,
operating, or servicing your
Stearns brake. Failure to comply
with these instructions could cause
injury to personnel and/or damage
to property if the brake is installed
or operated incorrectly. For
definition of limited warranty/
liability, contact Rexnord
Industries, LLC, Stearns Division,
5150 S International Dr, Cudahy,
WI 53110, [phone].
Caution
1. Installation and servicing must
be made in compliance with all
local safety codes including
Occupational Safety and
Health Act (OSHA). All wiring
and electrical connections must
comply with the National
Electric Code (NEC) and local
electric codes in effect.
2. Do not install the brake in
atmospheres containing
explosive gases or dusts.
3. To prevent an electrical
hazard, disconnect power
source before working on the
brake. If power disconnect
point is out of sight, lock
disconnect in the off position
and tag to prevent accidental
application of power.
4. Make certain power source
conforms to the requirements
specified on the brake
nameplate.
5. Be careful when touching the
exterior of an operating brake.
Allow sufficient time for brake
to cool before disassembly.
Surfaces may be hot enough to
be painful or cause injury.
6. Do not operate brake with
housing removed. All moving
parts should be guarded.
7. Installation and servicing
should be performed only by
qualified personnel familiar with
the construction and operation
of the brake.
8. For proper performance and
operation, only genuine
Stearns parts should be used
for repairs and replacements.
9. After usage, the brake interior
will contain burnt and degraded
friction material dust. This dust
must be removed before
servicing or adjusting the
brake.
DO NOT BLOW OFF DUST using
an air hose. It is important to avoid
dispersing dust into the air or
inhaling it, as this may be
dangerous to your health.
a) Wear a filtered mask or a
respirator while removing dust
from the inside of a brake.
b) Use a vacuum cleaner or a soft
brush to remove dust from the
brake. When brushing, avoid
causing the dust to become
airborne. Collect the dust in a
container, such as a bag,
which can be sealed off.
Re-setting the lever arm
position
Warning! Any mechanism or load
held in position by the brake
should be secured to prevent
possible injury to personnel or
damage to equipment before any
disassembly of the brake is
attempted or before the manual
release knob or lever is operated
on the brake.
Use this sheet with the 1-081-x000 and 1-082-x00 series service booklets which can be found at
www.stearns.rexnord.com.
The solenoid plunger must be restrained in the solenoid frame (Picture A) before unbolting the support plate from the
endplate. Otherwise, the lever arm will rapidly move along the sector gear with a rapid snap action and the support
plate will not re-mount to the brake and disc pack problems may occur.
The manual release can also be pulled out to engage
the solenoid lever arm and move the plunger into the
frame.
Picture A: Cable strap holds the plunger into the solenoid
frame of a new brake.
Issue 17 April 2011

The lever arm is located as shown in the diagram with a new disc pack in place. (Diagram, Picture B & C). The lever
arm will angle forward into the support plate as the lever arm moves along the sector gear as the disc pack
wears.
Picture B & C: The correct position of sector gear to pinion with a
new disc pack.
On older brakes, check for notching or wear in the sector gear and pinion that could cause binding.
Re-setting the Lever Arm when installing a new disc pack or unplanned movement occurs:
Method one: Remove the spring tension while the support plate is bolted to the endplate with the disc pack in place.
Remove the support plate. Reposition the lever arm with the sector gear at the free end as shown in Picture B and C.
Push the plunger into the solenoid frame. Bind the plunger into the solenoid frame with a cable tie ( Picture A), or by
locking the manual release into place. Return the support plate assembly to the endplate with the disc pack in place.
Tighten the nut and pressure spring until fully compressing the torque spring to the spring spacer. Remove the cable
tie strap holding the plunger into the solenoid frame. Manually push the plunger into the coil and solenoid, and then
allow the plunger to snap out under spring force. Repeat. Check air gap and correct if needed using the brake
installation sheet as a guide.
Pinion, Sector Gear &
Self Adjust Mechanism
Self Adjust Lever Arm
Solenoid Link
Solenoid Plunger
Air Gap
Solenoid Frame & Coil
Torque Spring, Spacer and
Pressure Spring Nut
Disc Pack
Hub
Lever Arm Pressure Button
Lever Arm Pivot Point

Method two: The support plate assembly is
bolted to the endplate with the disc pack in
place. Use a screw-driver as a lever at the
edges of the lever arm to pry the lever arm
outward from the disc pack
( Pictures E, F & G).
Picture E: Use the screwdriver as a lever.
Apply a prying force to the lever arm while applying hand force to push the plunger downward into the solenoid
(Picture F). Keep the lever force in place and allow the spring to draw the solenoid plunger out of the solenoid
(pictures G). Repeat in a jacking motion. Continue to reposition the lever arm while moving the plunger in and out of
the solenoid frame until the lever arm is in the position shown in Picture B, C & Sketch page two.
Picture F (plunger down) Picture G (plunger up):
Check air gap and correct if needed using the brake installation sheet as a guide.
Apply power to the coil and re-confirm air gap.
Reliable brakes through design, manufacture and support.
Prior e-letter tech sheets are posted on the Stearns website: www.stearns.rexnord.com