Stearns 65000 Series Operating instructions

®Brake Replacement Parts P/N 8-078-946-04
effective 11/10/06
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
serviced 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,
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 should 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 remove housing, follow instructions
listed for appropriate brake series.
Series 65,300 brakes use four
through-bolts (15S), four flat washers
(15U), four lock washers (15W) and
four hex nuts (15N). Remove all and
pull back on housing (7) to free it.
Service Instructions for No. 4 AC Coil Kit
Single and Dual Voltage Coils
Series 65,000 and 65,300 Brakes
Item Description of Parts Qty
no. Included in Kit per Kit
12A Coil 1
139*Lead wire and terminal assy. 2
(standard brakes only)
139S Terminal screw 2
139W Terminal lock washer 2
82 Plunger guide 2
84 Screw - plunger guide 2
12AN** Wirenut 2
12AT** Crimp terminal 2
*
Series 65,000 brakes use four bolts
(15S), threaded into endplate and four
lock washers (15W). Remove all and
pull back on housing (7) to free it.
Note: Some older design Series
65,300 brakes used the same bolt
arrangement as Series 65,000.
*Dual voltage coils only
*Dual voltage coils only

2. To replace the solenoid coil, disconnect
lead wire terminal screws (139S), lock
washers (139W) and lead wires (139).
3. Insert a screwdriver between support
plate (126) and top of lever arm (17).
With screwdriver wedge apart; remove
bearing pin (26) and solenoid lever (8)
with solenoid link (13) and plunger
(29). It is not necessary to separate
the solenoid lever, solenoid link and
plunger.
4. Remove plunger guide screw(s) (84).
Remove both plunger guides (82) by
prying up on the flanges. Discard
plunger guides.
5. Slide coil (12A) sideways from
solenoid frame (79). If necessary, tap
coil lightly with soft hammer. If coil had
burned out, be sure to remove all
foreign material from the solenoid
plunger (29) and solenoid frame (79).
6. Install new coil (12A) into solenoid
frame with same relative position as
old coil. Assemble new plunger guides
(82) and plunger guide screws(s) (84).
7. Low Voltage:
Jumper leadwire 3 to terminal 1
Jumper leadwire 4 to terminal 2
Incoming power to terminals 1 & 2
8. High Voltage:
Jumper leadwires 3 & 4 together
Incoming power to terminals 1 & 2
9. Be sure to check the following when
installing lead wires:
1) Must not be tight or pinched.
2) Must not make contact with
friction disc.
3) Must not be trapped between
solenoid plunger and frame.
10. 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.)
If solenoid air gap exceeds 11/16”,
adjustment is necessary.
The solenoid air gap measurements
are shown in Table in next column.
11. The solenoid air gap may be
decreased by turning both wear
adjustment screws (10) equal amounts
clockwise, approximately 1/8 turn, until
appropriate solenoid gap is attained.
To increase gap, turn screws
counterclockwise.
12. Reconnect coil leads.
13. Orient housing so that manual release
knob is approximately 20°
counterclockwise from vertical
centerline. Slide housing over
endplate register and rotate clockwise
to align bolt holes. Replace hardware
in reverse order of Step 1.
14. Caution 1! 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.
Caution 2! Class H coils with
terminals. Do not bend lead wire
crimp connection as this causes
fatigue in the metal which may break
under vibration.
NOTE: For complete instructions, with
troubleshooting, request sheet
applicable to the series of brake that
you have.
Nominal Static
Torque (lb-ft)
65,000
Series
65,300
Series
1.5 and 3 13/32 13/32
6 13/32 13/32
10 1/2 1/2
15 9/16 9/16
Table: Solenoid Air Gap Measurement
(inches)
Copyright©1999-2006 by Rexnord Industries, LLC
Rexnord Industries, LLC, Stearns Division, 5150 S. International Dr., Cudahy, Wisconsin 53110, [phone] Fax [phone]