Stearns 87,000 Series Operating instructions

Service Instructions for Gasket and Seal Kit
Series 87,000 DTWP Disc Brake
Important
Please read these instructions carefully
before 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, Inc., Stearns
Division, 5150 S. International Dr., Cudahy,
Wisconsin 53110, [phone].
Caution
1. Servicing shall be in compliance with
applicable 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. 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.
3. Be careful when touching the exterior
of an operating brake. Allow sufficient
time for the brake to cool before
disassembly. Surface may be hot
enough to be painful or cause injury.
4. Do not operate brake with housing
removed. All moving parts should be
guarded.
5. 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.
6. Maintenance shall be performed only
by qualified personnel familiar with the
construction and operation of the brake.
7. For proper performance and operation,
only genuine Stearns parts should be
used for repairs and replacements.
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.
Instructions
1. To replace the endplate oil seal (2S)
and lead wire bushing (2L), use the
following procedure:
a) Remove manual release knob
(148), housing screws (15) and
housing (7).
b) Depress solenoid plunger (29) and
pull release rod (146) back to lock
brake mechanism in manual
released position or tie plunger to
frame (79).
c) Remove entire support plate
assembly (142) by evenly
unscrewing screws (142S).
d) Remove pressure plate (5), friction
discs (4), and stationary discs (3)
Note: Brakes with a single friction disc will
contain no stationary discs.
Vertically mounted brakes will have
special pins which hold spacer springs
and, in some cases, spring washers.
®Brake Replacement Parts
P/N 8-078-941-05
effective 2/22/05
Item
Number Description of Part Included in Kit Quantity
per Kit
2S
7S
15B
69
2L
7D
Endplate oil seal
Housing seal
Housing nut gasket
Housing to endplate gasket
Lead wire bushing
Pipe plug
1
1
2
1
3
1
4A 16A 4B 16B
16S
16S
REV A Spline Pre-Revision Spline

Note color coded sequence of springs and
location of washers, if used. Refer to
Instruction Sheet 301.3 for proper
assembly of vertical mounting
components.
e) Remove hub (16) and endplate (2)
from motor.
f) To replace endplate oil seal (2S),
remove old seal from endplate (2)
and install new seal from inboard
face, be sure lip is toward outboard
face and have seal face flush with
face of casting.
g) To replace lead wire bushing (2L),
remove bushing (2L) from endplate
(2) select the equal length replace-
ment bushing, install from inboard
face. The end of bushing must be
flush with the mounting face.
2. The housing gasket (69) is placed over
the register of endplate (2).
3. Gasket-housing nut (15B) is placed
over the turned portion of the housing
nut (15).
4. Housing seal (7S) must be removed by
pressing it out from the inboard housing
face. The new seal is installed from the
outboard housing face so that the lip
points outward. Press the seal down
into the counterbore hole until it seats
on the counterbore face.
5. Reassemble the brake in the reverse
order of Steps 4 through 1B and
remove plunger tie-down, if used.
6. Manually lift solenoid plunger to
maximum travel. Depress fully and
allow solenoid plunger to snap out
several times. Measure solenoid air
gap between mating surfaces of
solenoid frame and solenoid plunger.
(On vertically mounted brakes, it will
be necessary to push solenoid plunger
into solenoid frame to the point where
spring pressure is felt, before measuring
solenoid air gap.) The solenoid air gap
measurement should be as factory set
between 13/16 to 15/16.
7. The solenoid air gap may be increased
by raising or decreased by lowering the
wrap spring stop (76). To accomplish
this, loosen two stop screws (76S),
move wrap spring stop slightly and
retighten screws. Repeat Step 6 after
each change in wrap spring stop
position to obtain correct solenoid air
gap measurement of 13/16 to 15/16.
8. Replace housing, screws and manual
release knob.
Caution! Do not run motor with brake in
manual release position. It is intended only
for emergency manual movement of the
driven load, not as a substitute for full
electrical release.
NOTE: For complete instructions, with
troubleshooting, request sheet
applicable to the series of brake that
you have.
Copyright' 1998-2003 by Rexnord Industries, Inc.
Rexnord Industries, Inc., Stearns Division, 5150 S. International Dr., Cudahy, Wisconsin 53110 [phone] Fax [phone]