WPT POWER WDA-26 Instruction Manual

Caliper BrakeDuctile Iron Version
Installation & Maintenance
Manual
WPT Power Corporation
1600 Fisher Road - Wichita Falls, TX 76305
P.O. Box 8148 - Wichita Falls, TX 76307
Ph. 940-761-1971
www.WPTpower.com

Page 2 of 12 WIM-DA-002_B
Table of Contents
Page No.
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.0 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.0 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Preparation
3.2 Brake rotor disc face run out inspection
3.3 Shaft bearing endplay inspection
4.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Preparation
4.2 Brake disc expansion
4.3 Brake disc installation
4.4 Caliper installation
4.5 Drawing and parts list reference
4.6 Caliper clearance adjustment
4.7 Air lines
5.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1 Clearance inspection
6.2 Burnish friction linings
6.3 Disc warm up in cold weather
6.4 Air applied/spring release actuator
6.0 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.1 Air applied caliper brake
7.2 Clearance inspection
7.3 Clearance adjustment
7.4 Friction lining alignment
7.5 Adjust friction alignment (balancing link)
7.6 Periodic inspection
7.7 Friction lining replacement
7.8 Remove rivets/ hardware
7.9 Install shoe assembly
7.0 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
8.0 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
9.0 BOLT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
10.0 ACTUATOR ASSEMBLY - AIR APPLIED BRAKE . . . . . . . . . . . . ..10
11.0 AIR APPLIED BRAKE ASSEMBLY.... . . . . . . . . . . . . . . . . . . . . . . .11
12.0 STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Page 3 of 12 WIM-DA-002_B
1.0 INTRODUCTION
1.1 The WPT Power Corporation Caliper Brake is one of the finest available on the market today. Follow the
procedures detailed in this Installation Maintenance Manual for years of service.
1.2 When ordering parts, use the part numbers from the Bill of Materials supplied with this unit. Also, please
include the part number and the serial number from the unit itself. These will be found on the mounting
bracket. Your WPT Distributor can provide a copy of the Bill of Materials if the one provided should become
lost.
1.3 When performing installation and maintenance functions, refer to the drawings at the back of this manual,
pages 13 thru 15. The references on the drawing in this manual DO NOT correspond to the references on
the assembly drawing and Bill of Materials. Do not use the item numbers from the drawing in this manual for
ordering parts.
1.4 A customer supplied protective cover must be used to protect the caliper brake. The cover must not restrict
air flow to and from the disc rotor. The free flow of air is required to prevent overheating. Air pumped
through the disc rotor must be exhausted away from the disc rotor to allow fresh cool air to enter.
CAUTION:
Under no circumstances should the disc rotor cooling fins be painted or shielded.
WARNING:
To avoid damage or personal injury, insure that adequate lifting devices and hand tools are available.
WARNING:
Read these instructions thoroughly and review until you fully understand all warning and hazards before
proceeding with the work described in this manual. Failure to follow these instructions in this manual can
result in unreasonable exposure to hazardous conditions and/or personal injury and/or death.
Throughout there are several HAZARD WARNINGS that must be read and adhered to in order to prevent possible loss of
equipment and/or personal injury and /or loss of life. The three warning words are “DANGER”, “WARNING” and
“CAUTION”. They are used to indicate the severity of the hazard and are preceded by a safety alert symbol.
“DANGER” –-Denotes the most serious injury hazard and is used when serious injury or death WILL result from
misuse or failure to follow the specific instructions sit forth in this manual.
“WARNING” -Denotes when serious injury or death MAY result from misuse or failure to follow the specific instructions
set forth in this manual.
“CAUTION” –Denotes when injury or product or equipment damage may result from the misuse or failure to follow the
specific instructions set forth in this manual.
It is the responsibility of the personnel involved in the installation, operation and maintenance of this equipment, on which
this brake is mounted, that they must fully understand the warnings and dangers that are listed in this manual and are
aware of what the correct procedures must be to safety install, operate and maintain this equipment.

Page 4 of 12 WIM-DA-002_B
2.0 SPECIFICATIONS
2.1 Brake Disc Rotor specifications.
Caliper Size
WDA-26
WDA-28
A
30”
[762]
40”
[1016]
48.3”
[1227]
48.5”
[1232]
54.7”
[1389]
60.5”
[1537]
B
7”
[178]
7”
[178]
7”
[178]
10.5”
[267]
10.5”
[267]
10.5”
[267]
C
14”
[356]
23.7”
[602]
31”
[787]
24”
[610]
32”
[813]
37”
[940]
D Min.
8”
[203]
19.6”
[498]
19.7”
[500]
17.7”
[450]
23.2”
[589]
27.3”
[693]
D Max.
11”
[279]
21”
[533]
28”
[711]
22”
[559]
28”
[711]
32.5”
[826]
E
.91”
[23.1]
.95”
[24.1]
1”
[25.4]
.91”
[23.1]
1”
[25.4]
1.09”
[27.7]
F Min.
5/8” or 16mm
5/8” or 16mm
5/8” or 16mm
5/8” or 16mm
1” or 24mm
1” or 24mm
G
30°
20°
20°
30°
18°
18°
Wt. Lbs. (Kg)
360 (163)
430 (195)
620 (281)
780 (354)
900 (408)
990 (449)
Max. RPM
1150
860
710
710
630
570
NOTE: All fasteners must be SAE Grade 8 or better.
2.2 When running at elevated temperatures, allow adequate mounting holes clearance for disc to expand and
contract during operation. Contact WPT Power with all the operating data for assistance.
2.3 When running at elevated temperatures, allow adequate male to female pilot clearance for disc to expand
and contract during operation. Brake rotor disc may also shrink and could become smaller depending on
the maximum operating temperature. Contact WPT Power with all the operating data for assistance.
2.4 Brake disc maximum RPM, see section 2.1 Brake Disc Rotor specifications.
2.5 Brake rotor disc alignment tolerances, see section 3.0 INSPECTION.
2.6 Recommended bolt torque values see section 9.0 Torque values.

Page 5 of 12 WIM-DA-002_B
3.0 INSPECTION
3.1 Preparation. Upon receipt of your WPT product, inspect for and report any evidence of damage.
WARNING:
To avoid damage or personal injury, insure that adequate lifting devices and hand tools are available.
3.2 Check Brake Rotor Disc face run out.It is strongly recommended that dial indicator checks be made
prior to installation of the caliper brake. Mount the indicator base on the caliper mounting pad and position
the dial indicator tip so that its movement is perpendicular to the face of the brake rotor disc. Position the
indicator tip near the outside diameter of the brake rotor disc, see sketch below.Rotate the disc 360
degrees.
The indicator reading should not exceed 0.015 inches (0.38 mm) T.I.R.
3.3 Check Brake Rotor Disc Concentricity. Mount the indicator base on the caliper mounting pad and
position the dial indicator tip so that its movement is perpendicular to the brake rotor disc outside diameter.
Rotate the disc 360 degrees.
The indicator reading should not exceed 0.030 inches (0.76 mm) T.I.R.
3.4 Check bearing shaft endplay.
Measure and document the shaft’s endplay before installing the brake caliper. Using dial indicator as
shown in 3.2 move the shaft back and forth axially against bearings. Endplay must be kept at a minimum.
Record the total movement as shown by the dial indicator and keep for future reference.

Page 6 of 12 WIM-DA-002_B
4.0 INSTALLATION
4.1 Clean the friction surfaces of the brake rotor disc with an appropriate cleaning solvent to remove any oil and
grease.
4.2 When installing a brake rotor disc that is running at elevated temperatures, it is important to allow for disc
expansion and contraction, see section 2.0 Specifications.
WARNING:
Failure to leave clearance for brake rotor disc expansion and contraction may result in premature failure.
WARNING:
The brake rotor disc and caliper brake are heavy. Use appropriate equipment and procedures to prevent
accident or injury.
4.3 Mount brake rotor disc using grade 8 hex head cap screws or socket head cap screws. Tighten bolts
evenly using a crisscross pattern. For bolts specifications see section 9.0 Torque values.
4.4 Mount caliper brake using grade 8 hex head cap screws or socket head cap screws. For bolts
specifications see section 9.0 Torque values. Check to insure proper clearance between O.D. of the disc
rotor and the inner caliper brake frame.
IMPORTANT: Mounting foot used to mount the caliper bake on must be flat and square to the disc rotor face and strong
enough to withstand the maximum torque generated by the brake caliper.
4.5 Refer to caliper brake illustrations and parts lists in the back of this manual, pages 10 and 11.
4.6 For initial adjustment of caliper brake: for adjustment see section 6.0 MAINTENANCE.
4.7 Air lines to the actuators should be sufficient size to allow quick response of the brake.
4.8 When installing a protective cover, ensure that air recirculation through the disc is not restricted. Air
pumped through the disc must be exhausted away from the disc to allow fresh cool air to enter the inner
vent openings of the disc. Back pressure should not be generated on the exhaust side of the disc.
5.0 OPERATION
5.1 Check to ensure friction linings do not contact the disc rotor when disengaged and are square to the disc
rotor. The clearance should be equally divided on both sides of the disc rotor.
IMPORTANT: Friction linings must be burnished in order to achieve maximum brake torque.
5.2 Burnishing can be accomplished by engaging the caliper brake, using low air pressure, approximately three
times for 10 to 15 minutes.
NOTE: On some equipment it may not be possible to burnish the linings because of slow rotating speed and/or limited
HP available.
5.3 In cold weather it is important to warm the disc rotor slowly to not cause excessive thermal stresses in the
disc rotor.
WARNING:
Failure to warm the disc rotor slowly may cause instant disc failure.

Page 7 of 12 WIM-DA-002_B
6.0 MAINTENANCE
DANGER:
Turn off engine and prevent from being restarted while adjustments are being performed.
IMPORTANT: Before making any adjustment, ensure that the brake is released.
6.1 Set the distance between friction linings to 4.06”/4.13” [103.12/104.90] before mounting the brake.
6.2 To adjust the distance between friction linings, remove cotter pins, lever pins and turn both clevis pins an
equal amount. Turn counterclockwise to decrease clearance and clockwise to increase clearance.
6.3 Friction linings must be parallel to brake disc rotor to ensure even lining wear.
6.4 To adjust alignment, loosen SHCS and adjust balancing links to align the shoes parallel with the disc.
6.5 Periodic inspection should be performed for wear of friction linings.
IMPORTANT: Friction linings must be replaced before hardware contact the disc rotor.
6.6 Replace friction lining by removing cotter pins, nuts and shoe rod holding shoe assembly to the lever.
Remove bolts holding outer bearing and center bearing to the shoe assembly.
6.7 Drill out the rivets and install new friction linings with rivets or screws.
NOTE: If screws are used see detail below.
26” Version
28” Version
6.8 Install shoe assembly to the caliper assembly by reversing steps 6.6 & 6.7 above. Be sure to re-engage the
balancing link. To adjust alignment, see step 6.4.
CAUTION:
Protective means must be used to prevent oil or grease from coming in contact with friction linings or the
brake rotor disc. Contamination of the friction linings could result in erratic response and/or loss of torque.
6.9 This caliper brake should not need any lubrication as all the grease zerks have been removed and graphite
bearing have been installed.
6.10 Refer to caliper brake illustrations and parts lists in the back of this manual, pages 10 and 11.

Page 8 of 12 WIM-DA-002_B
7.0 DISASSEMBLY
WARNING:
Use a hoist or other suitable lifting equipment to support the weight of the caliper brake and disc rotor.
WARNING:
The caliper brake and disc rotor are heavy. Use approved lifting eyes and procedures to prevent accident or
injury.
WARNING:
Use care when removing the caliper brake from the disc rotor to avoid damage to shoe assemblies and any
other components.
7.1 Refer to caliper brake illustrations on pages 10 and 11.
7.2 Remove any air lines and bolts holding caliper brake to frame. Lift caliper brake and place on work bench.
7.3 Remove cotter pins, lever pins and bolts holding actuator assembly to caliper brake.
7.4 Remove cotter pins, nuts and shoe rod holding shoe assembly to the levers. Remove bolts holding outer
bearing and center bearing to the shoe assembly.
7.5 Remove cotter pins, nuts and saddle rod holding levers to the caliper brake.
7.6 Remove tie rod nuts and lock washers from tie rods.
7.7 Remove saddles and spacers from tie rods.
7.8 Remove tie rods from mounting foot.
7.9 Disassemble actuator assembly, refer to actuator assembly illustrations on page 10.
IMPORTANT: Retain end caps with an adjustable clamp before removing bolts and nuts. Internal springs are under
compression and must be retained.
7.10 Remove nuts and bolts from actuator assembly. Then slowly release spring pressure with clamp until all
pressure is relieved.
7.11 Slide end caps off guide pins and separate the other parts.
7.12 Inspect parts for wear or damage and replace as necessary.
8.0 ASSEMBLY
8.1 Assemble caliper brakes by reversing steps 7.1 through 7.12 above.
8.2 Torque bolts to the requirements specified see section 9.0 Torque values.
8.3 Adjust caliper brake as indicated under maintenance section see section 6.0 MAINTENANCE.

Page 9 of 12 WIM-DA-002_B
9.0 TORQUE VALUES
TORQUE VALUES FOR SOCKET HEAD AND HEX HEAD CAPSCREWS
SOCKET HEAD CAP SCREWS
BOLT SIZE
As Received
Lubricated**
IN INCHES
LB - FT
LB - IN
Nm
LB - FT
LB - IN
Nm
1/4
13
150
17
10
120
13
5/16
23
305
34
18
244
27
3/8
45
545
62
36
436
49
7/16
70
840
95
56
672
76
1/2
108
1300
147
86
1040
117
9/16
155
1860
210
124
1488
168
5/8
211
2530
286
168
2024
228
3/4
367
4400
497
293
3520
397
7/8
583
7000
791
466
5600
632
1
867
10400
1175
693
8320
940
1 1/8
1242
14900
1684
993
11920
1347
1 1/4
1750
21000
2374
1400
16800
1899
1 3/8
2317
27800
3142
1853
22240
2513
1 1/2
3042
36500
4125
2433
29200
3300
1 3/4
4950
59400
6714
3960
47520
5371
2
7492
89900
10161
5993
71920
8128
HEX HEAD CAP SCREWS - Grade 8
BOLT SIZE
As Received
Lubricated**
IN INCHES
LB - FT
LB - IN
Nm
LB - FT
LB - IN
Nm
1/4
8
100
11
6
80
9
5/16
17
200
23
13
160
18
3/8
30
360
41
24
288
32
7/16
48
570
64
38
456
51
1/2
83
990
112
66
792
89
9/16
107
1285
145
85
1028
116
5/8
143
1714
194
114
1371
155
3/4
256
3070
347
204
2456
277
7/8
417
5000
565
333
4000
452
1
625
7500
848
500
6000
678
HEX HEAD CAP SCREWS - Grade 5
BOLT SIZE
As Received
Lubricated**
IN INCHES
LB - FT
LB - IN
Nm
LB - FT
LB - IN
Nm
1/4
6
71
8
5
56
6
5/16
12
142
16
9
113
12
3/8
22
260
29
17
208
23
7/16
34
410
46
27
328
36
1/2
53
636
72
42
508
57
9/16
74
890
101
59
712
80
5/8
104
1250
141
83
1000
112
3/4
183
2200
249
146
1760
199
7/8
298
3570
403
238
2856
322
1
440
5280
597
352
4224
477
1 1/8
553
6640
750
442
5312
600
1 1/4
775
9300
1051
620
7440
840
1 3/8
1012
12140
1372
809
9712
1097
1 1/2
1350
16200
1831
1080
12960
1464
CHART 1
** NOTE: For Loctite use lubricated values

Page 10 of 12 WIM-DA-002_B
10.0 ACTUATOR ASSEMBLY DRAWING AND PARTS LIST
Item
Description
Item
Description
1
End Cap
7
“O” Ring
2
Spring
8
HHCS
3
Guide Pin
9
Nut
4
Nut
10
Diaphragm
5
Plate, Diaphragm
11
Plug
6
Housing

Page 11 of 12 WIM-DA-002_B
11.0 CALIPER BRAKE DRAWING AND PARTS LIST
ITEM
Description
ITEM
Description
ITEM
Description
1
LEVER
12
NUT
23
ACTUATOR ASSEMBLY
2
PIN
13
PIN,COTTER
24
PIN,CLEVIS
3
BALANCING LINK
14
SHCS
25
PIN
4
WASHER,FLAT
15
SADDLE ROD
26
PIN,COTTER
5
SHCS
16
WASHER,FLAT
27
SPACER
6
BALANCING LINK
17
NUT
28
SADDLE
7
KIT,RELINE
18
PIN,COTTER
29
FOOT
8
SHOE ASSEMBLY WITH
LINING
19
TIE ROD
30
STRAIGHT BUSHING
LARGE
9
BEARING,CENTER
20
WASHER,LOCK
31
STRAIGHT BUSHING
SMALL
10
BEARING,OUTER
21
NUT
11
BRAKE SHOE ROD
22
HHCS

Page 12 of 12 WIM-DA-002_B
General Storage Guidelines
Upon receipt of parts or assemblies, they should be inspected for corrosion or other related
damage. If any problem is detected, contact WPT’s warranty department.
It is the owner’s primary responsibility to store and protect the WPT product.
Products should be stored in a manner that it is protected from the environment and outside
sources, which may include but are not limited to the following:
•Environmental storage requirements should be maintained as follows:
oNo exposure to rainwater
oTemperatures 32F° (0C°) to 110F° (43C°)
oBelow 50% average humidity
oAverage sunlight
•Hazards that require addition protection:
oDust and debris
oOil, water, saltwater, acids, or other chemicals
oAny other foreign items which may damage the product
oOther measures include covering the product to prevent ingress
of foreign matter
•Additional Protection Measures for Long-Term Storage
(For storage exceeding one month):
oCoat exposed metal with Cosmoline RP-342 "HEAVY" Military-Grade Rust
Preventive Aerosol Spray, or equal
oCoating of painted surfaces is not required or recommended
oVisually inspect the product for degradation once every three-months
STORAGE