Stearns 56,000 Series Operating instructions

Service Instructions for No. 4 AC Solenoid Kit
Series 56,000; 56,100; 56,300; 56,400; 56,500 and 56,600 Disc Brakes
®Brake Replacement Parts P/N 8-078-945-11
effective 09/22/06
Item
no.
Description of parts
included in kit
Qty.
per
kit
29
13
79
13C
13N
132
Solenoid plunger
Solenoid links
Solenoid frame
Solenoid link cap screw
Solenoid link nut
Solenoid mounting screw
1
3
1
1
1
3
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, LLC, 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, dis-
connect 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. The exterior surface of an operating
brake may be hot enough to cause
injury. Allow sufficent time for the brake
to cool before disassembly.
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
Note: Solenoid replacement can be
accomplished without removing the
support plate from the brake.
1. To remove housing, follow instructions
listed under each individual brake
series shown in next column.
2. Disconnect coil lead wires. Remove
three solenoid mounting screws (132)
to free solenoid frame (79). Note
mounting position.
3. Disconnect solenoid plunger (29) and
solenoid link (13) as an assembly and
discard.
4. To remove coil (12A) unscrew plunger
guide screw (84) and lock washer
(84W). Remove both plunger guides
(82) by prying up on the flanges.
a) To remove coil (12B) lift plunger
guide (82A) out of top of solenoid
frame (79). To remove coil (12B)
from solenoid frame (79), depress
lock tab at opposite lead wire side
of coil and slide coil sideways from
frame.
56,000; 56,400 & 56,500 Series
Remove housing nuts (15) by unscrewing
from housing studs (150). Remove
housing (7) by pulling back.
Remove housing nuts (15) by unscrewing
from housing studs (150). Remove
housing (7) by pulling back.
56,100; 56,300 & 56,600 Series
56,000; 56,400 & 56,500
1.5 & 3 lb-ft6 thru 25 lb-ft
All Torques
56,100; 56,300;
56,600

5. Install coil (12A) or (12B) in reverse
order. Be sure that coil is installed in
solenoid frame in same position and
lock tab on coil (12B) latches on
solenoid frame.
6. Join new link (13) with cap screw
(13C) and nut (13N) to plunger (29).
Reinstall link to pin with spacers,
plunger stop (29A) and retaining ring.
Mount frame (79) (with plunger
installed) with screws (132) in same
mounting position as removed. Torque
screws to 43 in-lbs after aligning
frame and plunger.
7. Manually lift solenoid plunger to
maximum travel. Depress 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.)
8. If solenoid air gap exceeds gap in
Table, adjustment is suggested. The
solenoid air gap measurements are
shown in Table below.
9. The solenoid air gap can be
decreased by turning both wear
adjustment screws (10) equal
amounts clockwise, approximately 1/8
turn, until proper solenoid gap is
attained. Counterclockwise rotation
will increase gap.
10. Reconnect solenoid coil leads.
11. Replace housing (and housing nuts) in
reverse order of the appropriate point
in Step 1.
12. 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© 1998-2006 by Rexnord Industries, LLC
Rexnord Industries, LLC, Stearns Division, 5150 S. International Dr., Cudahy, WI 53110, [phone] Fax: [phone]
.38”
.45”
.50”
1.5; 3; 6
10; 15
20; 25
Minimum
Airgap
±.03
Nominal
Static Torque
(lb-ft)
Table: Solenoid Air Gap
Measurements