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Type H & HM Brakes Installation, Dimensions and Service Manual

1. standing or seated operator but it is essential that the foot pad be ONES I in a position convenient for the operator to control the full stroke to provide the feel of the brake torque developed Bolt the bracket to the floor using 3 8 bolts Install air hoses in reservoir and delivery ports All other common ports must be plugged Pipe reservoir and delivery lines to the air relay valve on panel Mount alarm in cab Make connections to using 3 8 tubing provided Install supply pressure gauge in cab panel per wiring diagram 39 INSTALLATION INSTRUCTIONS Type A HM ERC Panel THESE INSTRUCTIONS COVER INSTALLATION OF THE FOLLOWING PANEL ASSEMLIES Power Supply 380 460 or 575V 50 60 Hz AC 230VDC Air Hydraulic Ratio 8x1 5x1 8x1 5x1 D 1 33 x 45 Panel J100650 J100651 J100656 J100657 8 No of 2 Assembly Only J100652 J100653 J100658 J100659 sorvico 2 No Enclosure J100654 J100655 J100660 J100661 o pressure 1 Panel Assy Mounted J103650 J103651 103656 J103657 clusters 2 Inside 36 x 48 x 18 J103652 J103653 J103658 J103659 2 Enclosure J103654 J103655 J103660 J103661 Also Includes 1 8 x 1 ratio parking brake release pressure cluster below service cluster Also includes 2 8 x 1 ratio parking brake release pressure clusters below service clusters 5 16 Hydraulic Tube To Service Brake Cylinders 5
2. ee eee 1 Service the control cylinder if one or more of the following symptoms are suspected 4G 1 If normal pedal force and stroke develops braking pressure but the pedal then drifts to the floor service the head and barrel 13 15 2 If the pedal will not return to normal height after brake application service the spring case 20 5 3 If brake fluid leaks past the shaft or the spring case replace seals 8 12 and 23 4 f the supply tank 3 appears defective discard and replace complete assembly When servicing the assembly always refer to the nameplate assembly number on top of the supply tank Note that only 1 1 2 and 1 3 4 diameter assemblies are now available Two inch diameter assemblies are no longer manufactured SERVICING THE HEAD AND BARREL ASSEMBLY 13 Temporarily block fluid supply from Fluid Reservoir Bleeder and drain fluid from the supply tank 3 Remove four stud bolts and head and barrel assembly 13 Clamp barrel lightly in vise in vertical position with piston end up Remove stop wire 19A support ring 19 piston 18 cup retainer 17 return spring 16 and valve and valve seat 14 Clean cylinder using only brake fluid or isopropyl alcohol Do not use gasoline cleaning solvent or mineral oil Bypass port holes must not be clogged If cylinder bore is scratched or pitted discard and replace head and barrel assembly Reassemble head and barrel in revers
3. 460V 60Hz ELEMENTARY WIRING DIAGRAM FOR SYSTEMS WITH AUXILIARY CAB CONTROL a 13 _ COMPRESSOR MOTOR AYIRMAK et au It lt 44444 cee mapie one 4 b RR mom LLL 4 ir 1 cons SC 1 10 APPLE LOW TORQUE 15 MOTOR Ceeracts _ EMERGENCY 12 MOTOR EMIR BRAKE 5 10 APPLY Provision must be made to protect against short circuits in accordance with requirements of N E C 53 INSTALLATION INSTRUCTIONS Air Compressor and Motor Assembly au 3 Filter r r 4 1 2 NPT Outlet f to Tani gt T 3 4 Hp Votor COMPRESSOR MOTOR MOTOR MOTOR BELT ASSY NO HP VOLTAGE PULLEY PD LENGTH J 70941 3 4 575 3 ph 60 Hz 3 9 51 J 70942 3 4 460 3 ph 60 HZ 3 9 51 J 70943 3 4 230V DC 3 9 51 J 70942 is also suitable for use on 380V 3 ph 50 Hz Mount the compressor near the air hydraulic panel Position the compressor so that the fan type compressor flywheel is at least 12 inches from the wall to allow ample air circulation Elevate the compressor so the 1 2 outlet is above the reservoir inlet on the panel to allow any moisture to drain to the reserv
4. e INSTALLATION INSTRUCTIONS Type H Two Brake One Station System Piping amp Wiring Diagram FRB Fluid Reservior Bleeder 7 qas See Wiring Diagram BPB Bleeder Pushbutton See Insert Below Control Cylinder Refer 6x3 and 8x3 BRAKE ASSEMBLY 10x4 14x6 and 18x8 BRAKE ASSEMBLY Actuating Cylinder WIRING DIAGRAM FOR 230 V DC OR 115V 50 60 HZ AC FRB INSTALLATION INSTRUCTIONS Type H Tubing TUBING INSTALLATION 1 Refer to applicable system piping diagram After all system components are mounted plan layout of hydraulic tubing a The length of the pressure line from the control cylinder or pressure cluster to the brake and to the FRB fluid reservoir bleeder is not critical however horizontal lines should preferably slope up toward the bleeder to aid movement of air out of the hydraulic system Avoid any tubing humps loops or coils which trap pockets of air b The static return line from the FRB reservoir to the control cylinder or pressure cluster should be as short and as direct as possible to aid the gravity flow of fluid Avoid any tubing humps loops or coils which could cause enough re striction to block normal flow of fluid and starve the control cylinder or pressure cluster FILL HYDRAULIC BRAKE SYSTEM 1 Fill system using ONLY 21B Super Heavy Duty Brake Fluid or equal The use of fluid other than SAE J1703 will cause the seals to swell
5. After the brake system is completely piped and wired turn power ON Check preset air pressures 1 Compressor supply pressure at gauge A must range from 75 90 psi This pressure is controlled by 1PS N C pressure switch Emergency pressure step ON when ESV solenoid valve is de energized is factory set at 40 psi by regulator in front of gauge B Abnormally low compressor supply pressure is signalled by 2PS N O pressure switch which must close on 60 psi increasing pressure and open on 50 psi decreasing pressure SPECIAL BLEEDING AND PRESSURE ADJUSTMENT INSTRUCTIONS FOR A H ERC SYSTEM Fill fluid reservoir bleeder s and control cylinder and 2 After the brake system is bled and brakes pilot circuit reservoir if used Bleed the service brake circuit by holding BPB service brake bleeder pushbutton in and stroking the service brake pressure cluster s by repeatedly pushing BFP brake filling pushbutton Bleed the parking brake circuit by holding BPB parking brake bleeder pushbutton in and stroking the parking brake pressure cluster s by repeatedly opening the bleeder screw on the HRC valve and pumping the control cylinder until clear fluid escapes from the bleeder screw Close bleeder screw If HRC circuit includes coiled or looped hose move trolley to cause straightest possible hose length when bleeding system adjusted operate brake system The low step pressure should control the empty crane to a slow stop Th
6. E 27 INSTRUCTIONS FOR CONVERTING Type H to Type HM Brake System FINAL TYPE HM BRAKE ADJUSTMENT OF 10x4 14x6 AND 18x8 BRAKES After brake system is completely reconnected There must be clearance as follows refilled with brake fluid and thoroughly bled step down hard on brake pedal Green signal light should go ON indicating that parking brake is released Release brake pedal Brake shoes WEE UM WEN a TAXA DRAKE should now be free 1 Turn clamp nut B free and tighten adjusting nut A to clamp brake shoes firmly against brake wheel Back off adjusting nut A three turns and tighten clamp nut B Both brake shoes should now be approximately 1 32 from the brake wheel If both brake shoes are not an equal distance from the wheel adjust self centering mechanism at bottom of 5 The brake is now properly adjusted brake shoe arm 6 Check service brake and parking brake With parking brake still fully released sure that operation parking cylinder force does not bear against top brake lever Adjust tubular recheck tubular push rod adjustment to be push rod to give indicated 010 clearance Tighten Allen head set screw on yoke 28 DIMENSIONS 6 x 3 And 8 x 3 Type H and HM Brakes DIRECT OPERATED BRAKE ASSEMBLIES ALL DIMENSIONS IN INCHES TYPE H HYDRAULIC APPLIED BRAKE ASSEMBLY FIGS 1 amp 2 SIZE 6x3 8x3 Assy No J 23020 J 2779 Assy Wt 26 lbs 28 lbs Overall Width X 12 5 8 12 5 8 O
7. Seui 5 5 oinejp Au aui 3uDieu owes 1e jaued Junoy M BR To INVHOVIG 5NIdid WALSAS NOILVLS 1 t OHV H V 38 1001x023 20012311 SINN IY 20 87 emm 321 010 32nnvu0an 00 315 pM 775 oo Ww4t 100108 QA 14 47 DIAGRAM Type A H Four Brake Industrial System ELEMENTARY WIRING DIAGRAM CHO OD _ I2 M L3 M Tih 2 3 1 H CONTROL TRANSFORMER 1 5A FUSE 1PS NC Compressor Start Stop Pressure Switch 80 65 PSI 2PS NC System Pressure Switch 60 50 PSI BPB No Bleeder Pushbutton O Terminals on Control Panel Single Lines Wiring or Components by MagneTek Double Lines Wiring by Purchaser NOTE AC Panels are prewired for 460V High and Low voltage control leads must be reconnected for 230 380 or 575V CAUTION Connect Motor Leads for Rotation as indicated by arrow on compressor Do not start compressor until crankcase is filled with oil Short circuit protection should be provided in accordance with National Electrical Code 48 DIAGRAM Type A H Four Brake Industrial System ELEMENTARY WIRING DIAGRAM 230VDC Urt 1PS NC Compressor Start Stop Pressure Switch 80 65 P
8. LAT _ 2 LL 18 Brake 14 Brake 10 Brake 3 79464 179462 79463 DISASSEMBLY AND REASSEMBLY OF HM PARK RELEASE CYLINDER Disassembly 1 Clamp J 391 Spring Clamp Tool on the brake setting spring Tighten Allen head screws securely then tighten nuts on through bolts to compress spring until it turns freely on cylinder CAUTION THE SPRING 15 6 NOW UNDER 300 LBS LOAD AND DANGEROUS IT SHOULD REMAIN CLAMPED UNTIL IT IS REASSEMBLED ON CYLINDER ASSEMBLY 2 Lightly clamp cylinder body 1 in vise and remove cylinder end 16 with mounting lug 21 3 Now clamp spring retaining shoulder not shaft of piston rod remove piston rod nut 15 and lock washer 14 and pull piston rod 8 from opposite end of cylinder Remove spring and spring clamp from cylinder body 4 Remove piston 13 cup 12 cup retainer 11 piston stop sleeve 10 and gasket 9 from cylinder If necessary push parts out from opposite end of cylinder using 3 4 rod Insert J 394 Expanding Drift Tool through cylinder until seated then fully tighten the expanding drift and tap out the O ring retainer 6 as illustrated above Then remove the O ring 5 and bushing 4 through cylinder Now remove four packing felts 3 and felt washer 7 4 56910111213 2 L O eo Qt amp 3 22 1415 5 D aci N lt lt 21 Exploded view of type HM Park Relea
9. MYDRAULIC CONTRA LED AIR VALVE agay SOLENOID EMERGENCY 1 way CHECK VALVE EJECTION WAL WE EMER PRESS REGULATOR 2 28 5 16 00 HYD LINE FROM CONTROL CYLINDER 1 2 00 SUPPLY LINE FROM COMPRESSOR 38 0D AIR UNE TO COMPRESSOR CONTRO 36 INSTALLATION INSTRUCTIONS Type A H HRC Panel Mount the panel on a rigid vertical support low enough for the 1 2 air line from the compressor to slope down to the air reservoir This permits moisture to drain to the reservoir where it can be automatically ejected by the moisture valve Pipe and wire the panel into the system per applicable connection diagrams After the brake system is completely piped and wired turn power ON Check preset air pressures 1 Compressor supply pressure at gauge A must range from 65 80 psi This pressure is controlled by 1PS N C pressure switch Emergency Brake pressure ON when ESV solenoid valve is de energized is factory set at 40 psi Check gauge B behind pressure regulator This pressure may be reset in field See Pressure Adjustment Instructions below Abnormally low compressor supply pressure is signalled by 2PS N O pressure switch which must close on 60 psi increasing pressure and open on 50 psi decreasing pressure SPECIAL BLEEDING AND PRESSURE ADJUSTMENT INSTRUCTIONS FOR A H HRC SYSTEM Fill fluid reservoir bleeder s pressure cluster s and control
10. C Washer A These instructions show normal floor mounted installation This brake may alternately be wall or ceiling mounted if necessary ut B The brake mounting holes are not equal distances from the brake Wight Angin center Mounting holes on the anti drag side are 5 9 16 from the brake pin center Mounting holes opposite the anti drag side 4 15 16 from the brake pin center Be sure to position the brake over the correct mounting holes C The brake must be installed with the actuator and hinge pins parallel with the brake base If necessary reposition brake by forcing against anti drag friction 54 20682 9 Y HM Brake D The brake was correctly adjusted during factory inspection Since this brake includes spring set parking the clamp nut A and adjusting nut B must be backed off to install brake on wheel E Aright angle connector assembly should be installed at the parking cylinder port The inlet fitting may be rotated to any position and tightened F The C washer below the parking cylinder port is held tight against the spring barrel end by parking spring force BRAKE INSTALLATION FINAL BRAKE ADJUSTMENT 1 Install brake wheel After brake system is completely connected filled with E brake fluid and thoroughly bled step down hard on brake 2 Loosen clamp nutA and joo pedal Green signal light should go ON indicating that the adjusting nut B enou
11. Components Connected By Solid Lines Are Parts Supplied in 1 5 MagneTek Brake System Terminals On Crane Control Panels Terminals On Remote Control Panels Terminals On Brake Control Panel N C Pressure Switch Opens 80 PSI Closes 65 PSI N O Bleeder Pushbutton In Cab BF N C Service Brake Contacts BFP EB 2PS Arrange To Open When Drive Motor Is Started N C Bleeding Pushbutton N O Emergency Brake Contact Arrange To Close When Brake Button On Remote Station Is Depressed N O Pressure Switch Closes 60 PSI Opens 50 PSI CAUTION Connect Motor Leads for Correct Rotation as Indicated by Arrow on Compressor DO NOT START COMPRESSOR UNTIL CRANKCASE IS FILLED WITH OIL Connect MPR Contacts to Prevent Remote Operation Unless Sufficient Air Pressure is Available for Safe Braking 230VDC ELEMENTARY WIRING DIAGRAM FOR SYSTEMS WITH AUXILIARY CAB CONTROL _ COMPRESSOR MOTOS a 21 3 10 GANT MOTOR 4 4 7 PROTICIION Can etii tarn mtem LI J t 38 1 SS 52 7 EE APPS TORDA EMERGENT mar _ MOTOR mare VALVE OF 18 APPLY iC M LI
12. If necessary replace the brake cylinder Before replacing or repairing the brake cylinder inspect the cup 8 If it is enlarged or very soft the system 10 x 4 14 x 6 or 18 x 8 The hinge pins on the brake are grease lubricated at the factory The pins should be sparingly relubricated at the seven fittings using a good grade of light bearing grease that will withstand over 200 F Wipe off any excess grease 11 feet 10 Line amp 9 Sisme 19 wc VOLARE BLUE 8 val Tam v i 9 1 Cylincer amp Body 5 9 Piston amp Guide Rod be contaminated with mineral oil and must be flushed with brake fluid or denatured isopropyl alcohol Never flush system or clean parts with gasoline kerosene cleaning solvent or lubricant Prior to reassembly lubricate parts with brake fluid Replace cylinder on brake reconnect hoses and tubing and rebleed brake system As of January 1993 brake assemblies and replacement shoes have bonded linings These bonded shoes can be rebonded Additionally rivet type replacement linings can still be purchased for use with old style rivet shoes linings SERVICING INSTRUCTIONS Type H Control Cylinders 28 d 7 f 79 WRITES 30 an G3 19 8 3 18 5 9 EO d 272829 7 32 0 X sd CONTROL CYLINDER Ua bss 27 3 16 WITH PEDAL ASSEMBLY
13. 16 HYD Line To Brakes lt Service eg Pressure Cluster 5 16 OO HYO Line To Brakes Patking Moisture Pressure Cluster 38 OD Air Line To Compressor Control 42 INSTALLATION INSTRUCTIONS Type A HM HRC Panel Mount the panel on a rigid vertical support low enough for the 1 2 air line from the compressor to slope down to the air reservoir This permits moisture to drain to the reservoir where it can be automatically ejected by the moisture valve Pipe and wire the panel into the system per applicable connection diagrams After the brake system is completely piped and wired turn power ON Check preset air pressures 1 Compressor supply pressure at gauge Amustrange 3 Abnormally low compressor supply pressure 15 from 75 90 psi This pressure is controlled by 1PS signalled by 2PS N O pressure switch which must N C pressure switch close on 60 psi increasing pressure and open on 50 psi decreasing pressure 2 Emergency pressure step ON when ESV solenoid valve is de energized is factory set at 40 psi by regulator in front of gauge B SPECIAL BLEEDING AND PRESSURE ADJUSTMENT INSTRUCTIONS FOR A HM HRC SYSTEM 1 Fill fluid reservoir bleeder s pressure cluster s and 2 After the brake system is bled and brakes control cylinder and pilot circuit reservoir if used adjusted operate brake system Operation should be Bleed the service brake circuit by holding BPB precise without
14. 161 18x8 J2932 27 3 4 34 3 8 266 Type HM Brake assembly Fig 3 supplied with J23437 hydraulic brake cylinder and with HM spring applied hydraulic released cylinder OVERALL MAX ASSY BRAKE WIDTH HEIGHT WT SIZE ASSY NO X Y LBS 14x6 J34735 29 5 8 28 1 2 180 18x8 J40065 32 1 8 34 3 8 286 NOTE The ports of the hydraulic cylinders on above brakes include 1 2 20 straight threads that match J10160 30 hose which requires F 17 gasket seals All cylinders are compatible only with automotive J1703 hydraulic brake fluid or equal Type S brake assembly Fig 4 supplied with spring applied air released cylinder OVERALL MAX ASSY BRAKE WIDTH HEIGHT WT SIZE ASSY NO X Y LBS 14x6 J53957 30 5 16 28 1 2 182 18x8 J58855 32 5 8 34 3 8 288 31 INSTALLATION INSTRUCTIONS Type A H ERC Panel Small 27 Wide x 33 High THESE INSTRUCTIONS COVER INSTALLATION OF THE FOLLOWING PANELS Power Supply 380 460 or 575V 50 60 Hz AC 230VDC Pressure Cluster A H Ratio 8x1 5x1 8x1 5x1 Panel Assy J70970 470971 470972 470973 V2 14 NPT 1 1 Fram Compressor Tube Connection To Compressor M Hydraulic Line From Reservoir Hydraulic Line To Brake Moisture Valve Terminal Board Trans Only I Motor Starter 6 Holes Drill V2 UT 00 A SUPPLY LINE _ FROM COMPRESSOR 18 00 HYO LINE A H
15. 36 This releases push rod and seal 30 31 as well as piston 32 cup 33 and retaining spring 34 The spring barrel and parking spring 37 38 are not serviceable and normally need not be further disassembled If disassembly is attempted note that the parking spring is preloaded to about 200 pounds force The use of an arbor press is essential If the cylinder walls are scratched or corroded replace the complete J3054 HM Actuator Otherwise wash all parts in denatured isopropyl alcohol Discard items 21 27 28 30 and 33 and use new parts from J73919 Repair Kit Coat all parts with Super Heavy Duty Brake Fluid and reassemble in reverse disassembly order To insure proper seal in park release cylinder be sure the retaining screw 36 is tight Note that the park release cylinder must be kept re leased when the reassembled brake is readjusted qug mmc 37 Exploded view 044 spring barrel and setting spring ACTUATING PISTON CUP ACTUATING PISTON CLAMP NUT 16 j ADJUSTING NUT 15 HINGE PINS LINE TO REMOTE ONTROL BLEEDER 33 RELEASING PISTON Cur 31 BRAKE SETTING 30 PUSH ROO noo SEAL 32 frecasing 36 SPRING PISTON RETAINING SCREW FLUID INLET f ow BRAKE CONTRO UNIT CHECK VALVE 39 C SPRING BARAEL 37 PARKING SPRING FLUID INLET FROM TROL CYLINDER Cross section drawing of the t
16. 8 Use mounting brackets lock washers and jam 2 Slip brake on brake wheel nuts provided to attach free end of hose to rigid support Allow hose slack to permit movement of 3 With clamp nut B loose tighten adjusting nut A to actuator clamp brake shoe tight against the brake wheel 9 The brake is now ready to be piped into the 4 Level brake base by plumbing center of brake wheel hydraulic system Be sure to adjust the brake shaft to index hole C in base of the brake before operation BRAKE ADJUSTMENT 1 Start with brake shoes clamped tight against the brake wheel per item 3 2 Loosen adjusting nut A three turns Tighten 5 Add shims between the brake and support Bolt brake clamp nut B base to support 3 Both brake shoes should now be approximately 1 32 from the brake wheel If both shoes are not an equal distance from the wheel adjust self centering mechanism See item C above 6 Install brake actuating cylinder between pins D and E 7 Using F 17 copper gasket seals screw short thread end of armored hose into both actuating cylinder ports Wrench tighten to provide leak free proof seals Fallow Brake AdjustienE inshuctions whens adjustment is necessary to compensate for lining wear INSTALLATION INSTRUCTIONS Type H Control Cylinder and 18 Pedal Assembly The control cylinder may be located in front to either side or to the rear of the standing or seated operator However it i
17. 881 2D 881 2A 881 2D 883A 883D 884A 884D 961 2A 961 2D 961 2A 961 2D 961 2A 961 2D 964A 964D 1061 2A 1061 2D 1061 2A 1061 2D 1064A 1064D 1181 2A 1181 2D 1181 2A 1181 2D 1183A 1183D 1184A 1184D 1281 2A 1281 2D 1281 2A 1281 2D 1283A 1283D 1284A 1284D Typical Diagrams included in following pages Specified diagrams supplied with order or on request 46 DIAGRAM Type A H ARC Four Brake One Station System P iping ovn wiy 1 M sen uw lt Pee tiles ales VIM TU z Matyas lin suntan 21231 Eno 4 1420 019 jun DLL Al 1931102 ydQ EY ur i unns wv QU tl pu VY 031232044 VE MI MAL Lu 128208383 A138 44 ADI gum I Vidi Non eru md VINYA NOI WI 3441 um mq p v KOLANA WENA 30 3516 yug ajaans BINJSIOW pesuepuoo jiuued ue 5 pue 1055 42907 seui ui sdoo pue aqqn 199 1 Buiqni uoddns 194409 91 9 91915504 se oys se sijejsnjo eunsseJd
18. 9010302400 NUT HEX FIN JAM 1 4 28 2 _____9010302400 NUT HEX JAM 1 4 28 2 4 9010000800 BOLT HEX HD 14 28 X 3 LG 2 4 1 9010000800 BOLT HEX HD 1 4 28 3 LG 2 3 J00848006 CLAMP REMOTE BLEEDER ASSEMBLY 1 3 1 4400848005 ______ REMOTE BLEEDER ASSEMBLY 4 2 PSD 01799 SEE CHART 1 1 l2 PSD 0179902 SEE CHART 4 4 1K PS 0004500 GASKET COVER FRB UNIT 1 1K PS 0004500 GASKET COVER FRB UNIT 4 1 04563096 FLATWASHER 1 4 18 8 SS 4 1 04563096 FLATWASHER 1 4 18 8 55 4 1H 05 003045103 SCREW HEX HD 1 4 20 1 2 LG 18 8 SS 4 L1H 05P003045103 SCREW HEX HD CAP 1 4 20 X 1 2 G 18 8 SS 4 1G F000017998 GASKET COPPER 52 ID X 70 OD X 03 THK 3 1G 000017998 GASKET COPPER 52 ID 7000 03 THK 3 1F J000269006 FITTING OUTLET 5 16 TUBE BRASS 1 4000269006 FITTING OUTLET 546 TUBE BRASS 4 1E 2011955006 ADAPTER FITTING 1 2 20 MALE TO 1 4 NPT MALE 1 011955006 ADAPTER FITTING 1 2 20 MALE 1 4 MALE 4 1D F005228998 GASKET COPPER 1 1D 005228998 GASKET COPPER 1 1 F005227999 FILLER CAP 1 1 F005227999 FILLER CAP 1 1B PSD 01 79700 COVER WELDMENT A FRB UNIT 1 1n 17 7 COWER WEI MENT ERR IINIT 4 1A PSD 0179600 SUPPLY TANK WELDMAN FRB UNIT 1 1 PSD 0179800 RESERVOIR ASSY FRB UNIT 1 ITEM PART NO DESCRIPTION INSTALLATION INSTRUCTIONS 6 x 3 And 8 x 3 Type HM Brake Assemblies Before installing this brake assembly please take note Clamp Nut Hinage Pins
19. Diagram HM Control Unit Hydraulic Tubing Green Light Parking Switch Bleeder Pushbutton Control Cylinder SERVICE INSTRUCTIONS 6 x 3 And 8 x 3 Type HM Brakes CLAMP NUT ADJUSTING 16 NUT 15 HINGE PIN 11 BRAKE RELINING READJUSTMENT AND ANTI DRAG SERVICE Brake lining must be replaced when it has worn to less than 3 16 thickness To reline type HM brakes the brake arms must be opened by removing clamp nut 16 adjusting nut 15 and hinge pin 11 The brake lining and lining bolt assemblies may then be replaced in the same way as the type H brakes on page 3 However the parking cylinder must be pressurized to fully compress the parking spring 37 during the entire period of reassembly and adjustment Reinstall hinge pin adjusting nut and clamp nut Tighten adjusting nut wrench tight and then back off nut two and one half turns to provide 1 32 clearance Tighten clamp nut Operation and service of the anti drag assembly is the same as for type H brakes Kal p er Q8 4 34 TYPE HM ACTUATOR REMOVAL AND SERVICE Use pipe wrench to unscrew and remove spring barrel and parking spring assembly 30 38 See drawing below The remaining actuator on the brake can now be removed in the same manner as the type H actua tor To service the cup seal and retaining spring disassemble the spring barrel and parking spring assembly 30 38 Remove retaining screw
20. Electrical Code Double Lines Wiring by Purchaser 51 1PS BPB BFP EBS 2PS gt DIAGRAM Type A HM HRC Four Brake System With Two HM Parking Brakes 230VDC ELEMENTARY WIRING DIAGRAM 230v DC ELEMENTARY WIRING DIAGRAM L2 vy 4 NC Compressor Start Stop Switch 90 75 PSI Bleeder Pushbutton NC Bleeding Pushbutton Emergency Brake Switch in Cab NO Pressure Switch 60 50 PSI Terminals on Control Panel Terminals by Purchaser Single Lines Wiring or Components by MagneTek Double Lines Wiring by Purchaser 2 COMPRESSOR MOTOR STARTER l 2 Fluid Reservoir Bleeder 1 45 u Fluid Reservoir Bleeder 3 45 To Drive Motor Protection Panel Emergency Brake Solenoid Valve 10 W Motor Pilot Relay 10 W Green Signal Light In Cab CAUTION Connect Motor Leads for Rotation as indicated by arrow on compressor Do not start compressor until crankcase is filled with oil Short circuit protection should be provided in accordance with National Electrical Code 52 DIAGRAM Type A HM ERC Brake System 230VDC ELEMENTARY WIRING DIAGRAM FOR SYSTEMS WITHOUT CAB CONTROL MP I2SAPM _ COMPRESSOR MOTOR _ 10 DANE PROTECTION tentartt B Valve NERO 10 Ab Y LOW RARI 10 uana EMIR 5 OE 10 APPLY TORDUE NOTE
21. No air on emergency port of REV so brake is actuated Brake spongy Air trapped in hydraulic lines system needs to be bled Bleeding Procedure 1 Open fluid reservoir bleeder BPB by depressing push button and holding in 2 Stroke pressure cluster forward by doing one of the following depending on panel A AH ARC depress bleeding control valve or treadle valve B AH ARC depress BFP brake filling push button C AH HRC depress bleeding control valve or control cylinder 3 Release push button BPB 4 Retract pressure cluster by releasing step 2 This procedure will have to be repeated many times to completely bleed the system Fluid travel is only five to seven feet Refill reservoir s frequently during bleeding If the pressure cluster stroke is reduced to a travel of about 1 1 2 this may be an indication that the system is bled 60
22. Panel THESE INSTRUCTIONS COVER INSTALLATION OF THE FOLLOWING PANELS Power Supply 380 460 or 575V 50 60 Hz AC 230VDC Air Hydraulic Ratio 8x1 5 1 8x1 5x1 Pressure Cluster No of Pressure 1 J89660 J89661 J89664 J89665 Clusters 2 J89662 J89663 J89666 J89667 ar Par a gt m Button ie pec Ww 00 r Line Signa from Treadle Valve Two way Check Valve One Way i2 OD Air Line Check Valve 44 77 From Compressor N C Bleed Valve 1 8 veld Thd Relay Emergency Valve we LR Hydraulic Line T Reserves Satety Valve Ww OD Ai Lene To Compressor Moisture Ejection Valve Cluster 137 Dus Mig Moles 7 A H ARC PANEL PIPING DIAGRAM ETAT WAL VALVE omar 11 DD AIA LIRE TREADLE RELAY UEEGEMCT VALVE 19 00 AIR LINE 10 TRERELE VALVE WOOO LIAL FRDM FLUID R SERV cR Mr TURE RJECTIDN VALVE e 38 INSTALLATION INSTRUCTIONS Type A H ARC Panel Foot Operated Air Treadle Valve Mount the panel on a rigid vertical support low pressure alarm should sound below 50 psi This is enough for the 1 2 air line from the compressor to controlled by 2PS N C pressure switch If reservoir slope down to the air reservoir This permits moisture pressure drops below 40 psi the relay emergency to drain into the reservoir where it can be valve app
23. Parking Brake 38 Air Supply 15 To Treadie Valve A HM ARC PANEL PIPING DIAGRAM 15 Timer Solenoid Valve Valve A 1 5 Relay ESV Eam Emergency 1 Way Emer Press gt 4 8 Check Valve Regulator 9 Dual l 5 gt a Air Tank an 5 3 8 Control From Treadie Valve 38 Supply Line To Treacle Valve 1 2 Air Supply i From Compressor Protection V Ray 5 16 OD HYD Line gi From iuid T Valve Reservoir 77 77 eee 516 OD HYD Line 7 2 Way Check Valve p la To Brakes ny 38 Control an To Compressor Service EXH Pressure Cluster Gi 295 T4 5716 OD HYD Line Bleed To Brakes Valve Park Moisture srung Ejection Valve Pressure Cluster 44 INSTALLATION INSTRUCTIONS Type A HM ARC Panel Mount the panel on a rigid vertical support low enough for the 1 2 air line from the compressor to slope down to the air reservoir This permits moisture to drain to the reservoir where it can be automatically ejected by the moisture valve Pipe and wire the panel into the system per applicable connection diagrams After the brake system is completely piped and wired turn power ON Check preset air pressures 1 Compressor supply pressure at gauge A must range from 75 90 psi This pressure
24. and be damaged 2 Fill FRB reservoir full capacity is approximately 2 1 3 qts or 113 in 3 Reservoirs of the control and or pressure cluster are filled by opening the reservoir bleeder screws on the respective assemblies This allows air to escape and fluid to fill the control cylinder and or pressure cluster reservoir from the FRB reservoir Keep FRB reservoir full Do not allow it to run dry Close bleeder screws after all air is vented and only clear fluid escapes 4 The static hydraulic system is now completely full Refill FRB reservoir System 2 Industrial Hydraulic Systems use 5 16 OD copper tubing Support tubing every 3 feet with tube bushings and tube clamps Eliminate tubing kinks or deformities which could restrict fluid flow Tubing Clamp Mounting Bracket Hose Tube Nut Tubing Bushing Jam Nut 3 Install F 86 tube nut and make 45 flare at each hose or component connection or at tube unions Do not permit tubing chips dirt or other foreign matter to enter tube line Make fluid tight connection at every tube nut Static Line Reservoir Bleeder Screw 17 Gasket F 10160 Armored Hose Pressure Line LJ Mounting Bracket Lock Washer and Jam Nut TYPE 2 CONTROL CYLINDER Reservoir Static Line Bleeder Screw Cylinder Outlet i Bleeder Screw fe _ E e Pressure Line le Indicator 29 Max Stroke PRES
25. cylinder is now ready to be piped into the hydraulic system Static Line 22222 Temporarily Set Pedal Height at 17 to Bleed System Reservoir Bleeder Screw F17 Gasket FC10160 Armored Hose Mounting Bracket Lock Washer B and Jam Nut INSTALLATION INSTRUCTIONS Type H FRB Fluid Reservoir Bleeder Assembly BPB Bleeder Pushbutton Operator FLUID RESERVOIR BLEEDER ASSEMBLY For 13080 J3083 Assys Part No J 10008 OIL TIGHT surface mounted en Closure with one normally open PSD0180101 230v DC 45W momentary contact 3080 50 7 V Namplate PS00180100 110V 50 60HZ 45VA Ls Hyd 23083 Brk Bleeder PSD0180102 Manually operated Hold in Then 470806 Pame Master yl Approximate Fluid 27 3 qts Net Weight without fluid 9 los 4 MTG Holes This Assembly is compatible with For 10 32 al Screws 21B Brake Fluid or equivalent 2 Cen PRACI 34 14 Conduit Entrance The fluid reservoir bleeder FRB assembly is needed in all industrial brake systems 1 To supplement the control cylinder reservoir on manually operated brake systems or the pressure cluster reser voir on air power hydraulic operated brake systems 2 To compensate for the normal height of the brakes above the control cylinder keeping the brake line full of fluid at all times 3 To serve as a valuable tool when bleeding the system during installation and maintenance FRB INSTALLATION 1 L
26. is on when the switch is in the ON position If a 2 station system is used use two switch and light assemblies and connect the N C and N O contacts as a SPDT switch Block out DFF and ON legends PS Pressure Switch Subpart of J107206 HM Control Unit B and C contacts are preconnected for Normally Open switch operation Switch must be adjusted so that contacts close at 400 psi and open at 320 psi hydraulic pressure 15 INSTALLATION INSTRUCTIONS 6 x 3 And 8 x 3 Type HM One Brake One Station Piping Diagram Green Light Parking Switch 9 BPB Bleeder Pushbutton 2 2 gt gt HM Control Unit HHEN NN gt Q Ou ri E Type HM Brake 5 16 Hydraulic Tubing 16 INSTALLATION INSTRUCTIONS 6 x 3 And 8 x 3 Type HM Two Brake One Station Piping Diagram a Fluid Reservoir Bleeder EIS Iy ONS A 6 OE I 29 444 XI 1 Ik SS Ab 1 Green Light Parking Switch Bleeder Pushbutton DIILI Ho 9 5 Control Cylinder CAUTION These units are intended for use with SAE J1703 Automotive Brake Fluid only 5 16 Hydraulic Tubing HM Control Unit Type HM Brake 17 INSTALLATION INSTRUCTIONS 10 x 4 14 x 6 And 18 x 8 Type HM One Brake One Station Piping
27. turn parking switch until wheel and tighten nut A until 4 7 Green light is ON Release brake pedal Green light should shoes are clamped firmly against D 1 ja 4 stay ON b On AHM HRC air powered cab controlled the wheel Note that the shoes A i gt systems turn parking switch until Green light is will clamp the wheel before nut A C remote controlled systems power ON will auto reaches original position because en matically compress parking cylinder Parking cylinder should the parking cylinder is extended remain fully compressed during steps 2 7 Additional tightening is not 2 Install pin to connect parking cylinder to bottom bracket on 14 necessary at this time and 18 brakes 14x6 and 18x8 Brakes Free parking cylinder from bottom clamp nut B free and tighten adjusting nut A to clamp bracelet to eliminate all application force Slip brake over brake shoes firmly against the brake wheel wheel Loosen clamp nut B and tighten nut A until shoes 4 Back off adjusting nut A three turns and tighten clamp nut B are clamped firmly against the wheel Do not attach the 5 Both brake shoes should now be approximately 1 32 from the parking cylinder to the bottom bracket until Final Brake brake wheel If both shoes are not an equal distance from the Adjustment steps wheel adjust self centering mechanism See item C above Final adjustments and inspec
28. with HM spring applied hydraulic released cylinder OVERALL MAX ASSY NS WIDTH HEIGHT WT NO X Y LBS J34780 23 23 107 NOTE The ports of the hydraulic cylinders on above brakes in clude 1 2 20 straight threads that mate with J10160 30 hose which requires F 17 gasket seals All cylinders are compatible only with automotive J1703 hydraulic brake fluid or equal Type S brake assembly Fig 4 supplied with spring applied air released cylinder OVERALL MAX ASSY au WIDTH HEIGHT WT NO X Y LBS J53958 23 1 4 23 105 30 DIMENSIONS 14 x 6 And 18 x 8 Type H HM And S Brakes All Dimension in Inches Y BAAKE APPLIED Ws 1 Dimensions common to all 14 and 18 brakes in inches BRAKE SIZE A B D H 14x6 9 1 2 3 7 16 6 1 2 14 7 8 18x8 11 1 2 5 8 1 2 18 1 1 16 J K L 2 14 6 11 5 8 11 1 8 12 15 16 4 1 4 24 1 4 9 5 8 18x8 13 7 8 13 7 8 5 1 4 27 3 4 13 1 2 O Brake wheel offset is based on standard brake wheels Type H brake assembly Fig 2 hydraulically applied by brake cylinder supplied separately Normally use J7905 cylinder for one brake manual systems and use J23437 cylinder for two brake manual systems or see system specifications for cylinders on Air Hydraulic systems OVERALL MAX ASSY BRAKE WIDTH HEIGHT WT SIZE ASSY NO X Y LBS 14x6 J2929 25 7 8 28 1 2
29. 0 50 4 00 16 55 JE76225 8 3 25 3 12 3 50 50 1 00 50 E 4 00 26 1 41 JE76250 10 425 3 12 5 00 62 144 62 1 00 5 50 55 4 25 JE76275 14 650 425 5 00 88 212 88 1 50 5 50 121 24 2 JE76300 18 850 525 7 50 88 2 62 125 1 88 6 38 230 75 8 23 BILL OF MATERIAL Hydraulic Installation Kits J 15576 50 Ft Tubing Kit J 73900 2 Hose 50 Ft Tubing Kit J 73901 4 Hose 100 Ft Tubing Kit J 73902 2 Hose 100 Ft Tubing Kit with bleeder screw amp adaptor J 73903 4 Hose 200 Ft Tubing Kit J 73904 6 Hose 150 Ft Tubing Kit 30 Armored Hose J 10160 Hose Mounting Bracket F 5780 1 2 20 Nut 90 12493 400 1 2 Lock Washer 90 11555 100 Copper Gasket Seal F 17 Use at each hose cylinder connection Ol eie OOO 100 5 16 Copper Tubing 55980 50 x 5 16 O D Copper Tubing A 37051 Tube Bushing J 5137 Bushing Clamp J 5138 Tube Nut J 86 Tube Union J 49087 Tube Tee J 9945 21B Brake Fluid gal F 9314 9 Bleeder Screw Adaptor J 7346 Bleeder Screw F 6446 4 These parts replace breather reser 49 voir of Type 2 Control Cylinder when adding Fluid Reservoir Bleeder system 24 REPLACEMENT PARTS 5 16 Tubing 1 2 20 SAE Fittings amp Misc Accessories A55980 TUBING 5 16 OD x 100 Copper fe gt 5 16 Tubing 4513
30. 16 Hydraulic Tube x From Reservoirs M 5 16 Hydraulic Tube To Parking Brake Release Cylinders we 1 COMP MOTOR I 71 ONLY i STARTERA Low Step Pressure Regulator Gage B HRC Valve Relay Emergency Valve _ 5 16 Hydraulic Tube From Optional Cab Contro Cyl W2 Tube Connection From Compressor High Step Pressure Regulator Protection Valve 2 Way Check Valve Gage A 3 B Tube Connection To Compressor BCV Moisture Valve PANEL PIPING DIAGRAM a 516 OD Hyd Line 2 5 52 1 5 Service Pressure Regulator 5 16 OD HYD Line From Fluid Reservoir 5716 OD HYO Line To Brakes Service Hydraulic Controlled Ait V lve Emer Press Regulator 2 Way Check Valve Salety Valve Pressure Cluster 516 OO HYD Line To Brakes Parking Pressure Cluster Moisture Ejection Valve From Control Cylinder v2 OD Air Supply Line From Compressor A 38 OO Air Line To Compressor Control 40 INSTALLATION INSTRUCTIONS Type A H ERC Panel Mount the panel on a rigid vertical support low enough for the 1 2 air line from the compressor to slope down to the air reservoir This permits moisture to drain to the reservoir where it can be automatically ejected by the moisture valve Pipe and wire the panel into the system per applicable connection diagrams
31. 8 CLAMP M N J15555 RIGHT ANGLE KIT Provides right angle swivel connection and bleeder screw 25137 TUBE BUSHING bur 7902 Support tubing every 3 ft port for any 1 2 20 cylinder Dar 0 0 with J5138 and J5137 port This assembly is ii furnished as standard on 6 J86 TUBE NUT mates 1 2 20 thd with 45 zi and 8 type HM brake parking F17 cylinder Must be ordered a separately if required for any F996 OUTLET PLUG 1 2 20 thd a other port Hoes not 17346 ADAPTOR PLUG 1 2 20 thd with 1 4 28 thd for F6446 Bleeder Screw COPPER GASKETS UNION AND ADAPTOR FITTINGS Part A B F17 1 32 33 64 45 64 F602 1 32 1 2 13 16 A B J49087 UNION Replaces FC4080 1 2 20 1 2 20 ron 18 7 1965 2808 4269 ADAPTOR 1 2 20 1 2 20 F11955 ADAPTOR 1 2 20 1 4 18 J71 052 ADAPTOR 1 2 20 76 24 p 30 INCH ARMORED HOSE CILONXILAENEXXELLELLIIXXIIKNNCXXXXELLXEXEXN 7 Lil J10160 HOSE ASSEMBLY only F5780 HOSE BRACKET anchors hose at long thread J10797 HOSE KIT includes hose F 17 gasket for seal at short thread F5780 hose bracket 1 2 20 jam nut and lock washer J24684 HYDRAULIC PRESSURE SWITCH 1 pole 2 position electric contact Easily read dials allow field adjustment of 50 500 psi pressure range and 10 80 psi pressure differential This replacement part for HM control unit may also be line m
32. ERC SMALL PANEL PIPING DIAGRAM 1m SERVICE PRESSURE REGULATOR US m 14 OD AIR LINE TO COMPRESSOR CONTROL QUAL COMPARTMENT AIR TANK S16 00 WYO LINE FRON FLUID RESERVOIR TO BRAKE PRESSURE 7 CLUSTER AVICE NC EMERGENCY SOLENOID WALWE RELAY EMERGENCY VALVE MOISTURE ERECTION VALVE EWER PRESS REGULATOR 32 INSTALLATION INSTRUCTIONS Type A H ERC Panel Small Mount the panel on a rigid vertical support low enough for the 1 2 air line from the compressor to slope down to the air reservoir This permits moisture to drain to the reservoir where it can be automatically ejected by the moisture valve Pipe and wire the panel into the system per applicable connection diagrams After the brake system is completely piped and wired turn power ON Check preset air pressures 1 Compressor supply pressure at gauge A must range from 65 80 psi This pressure is controlled by 1 PS N C pressure switch 2 Lowpressure step ON when SSV solenoid valve is energized is factory set at 30 psi by regulator at gauge B This may be reset in field See Pressure Adjustment Instructions below 3 High pressure step ON when ESV solenoid valve is de energized is factory set at 40 psi by regulator in front of gauge C This may be reset in field See Pressure Adjustment Instructions below 4 Abnormal low compressor supply pressure is signaled by 2PS N O pressur
33. Gemco Industrial Brakes Sensor Solutions Hydraulic Brake Systems amp HM Installation Dimensions and Service Manual Index HYDRAULIC BRAKES INSTALLATION AND SERVICE DESCRIPTION PAGE NO TYPE H BRAKE SYSTEM Installation e 6x3 and 8x3 Type H Brake 1 e 10x4 14x6 and 18 x 8 H Brake 2 Control Cylinder and Pedal including dimensions 3 e Fluid Reservoir Bleeder Assembly including dimensions 4 e Piping and Wiring Diagram One Brake System 5 Piping and Wiring Diagram Two Brake System 6 e Tubing Installation 7 Service e 6x3 and 8x3 Type H Brakes 8 e 10x 4 14 x 6 and 18 x 8 Type H Brakes 9 Control Cylinders 10 e Fluid Reservoir Bleeders 11 TYPE HM BRAKE SYSTEM Installation 6x3 and 8x3 Type HM Brakes 12 e 10x4 14 x 6 and 18x 8 Type HM Brake 13 e Type HM Parking Brake Control Unit incl J45767 switch amp light 14 e Wiring Diagram Type HM Parking Control Unit 15 e Piping Diagram One Brake 6 x 3 and 8 x 3 Type HM System 16 e Piping Diagram Two Brakes 6 x 3 and 8 x 3 Type HM System 17 e Piping Diagram One Brake 10 x 4 14 x 6 and 18 x 8 Type HM 18 Index HYDRAULIC BRAKES INSTALLATION AND SERVICE Continued DESCRIPTION PAGE NO TYPE HM BRAKE SYSTEM Service e 6x3 and 8x3 HM Brake 19 e 10x4 14x6 and 18x 8 Type HM Brake 20 e Servicing 10 14 and 18 Type HM Park Release Cylinders 21 22 NOTE Installation and service information for control cylinder fluid reservoir bl
34. NTAC VALVE MCIST LECT OR FRESEURE CLUSTERS SIUM 1081802 31812313 SINIT 7070 wem SINIT 01014 TO 295 L TYPE bhAXES Contac fAVICC CONTR 2A TYPE A HM HRC FOUR BRAKE SYSTEM WITH TWO HM PARKING BRKAES 50 _ Ll l O Yui 2 lt DIAGRAM Type A HM HRC Four Brake System With Two HM Parking Brakes AC ELEMENTARY WIRING DIAGRAM OL 3 0 EL Hid 1 5 4 4 o gt alt lt cowenESSOR MOTOR 5 ws 0 STARTER 1 2 3 LJ o amp 1 2 1 o 20 Fluid Reservoir Bleeder 7 1 45 W BPB2 O 2 4A a3 To Drive Motor Protection Panel Emergency Brake Solenoid Valve 10 W Motor Pilot Relay 10 W Green Signal Light In Cab NC Compressor Start Stop Switch 90 75 PSI Bleeder Pushbutton Panels are prewired for 460V High and Low voltage control leads must be NOTE NC Bleeding Pushbutton reconnected for 230 380 or 575V Emergency Brake Switch in Cab NO Pressure Switch 60 50 PSI Terminals on Control Panel CAUTION Connect Motor Leads for Rotation as indicated by arrow on compressor Do not start compressor until crankcase is filled with oil Terminals by Purchaser Single Lines Wiring or Components by MagneTek Short circuit protection should be provided in accordance with National
35. O REV Contacts ery M To Emergency Brake qt le ol Control Contects 1PS N C Compressor Start Stop Pressure Switch 80 65 Psi 2PS N O System Pressure Switch 60 50 Psi BFB Brake Filling Pushbutton 33 INSTALLATION INSTRUCTIONS Type A H ERC Panel Large 33 Wide x 45 High THESE INSTRUCTIONS COVER INSTALLATION OF THE FOLLOWING PANEL Power Supply 380 460 or 575V 50 60 Hz AC 230VDC Air Hydraulic Ratio 8x1 5x1 8x1 5x1 Pressure Cluster No of Pressure 1 J70980 J70981 J70984 J70985 Cluster 2 J70982 J70983 J70986 J70987 516 Hydraulic Tube From Reservoir 5 16 Hydraubc Tubes To Brakes 1 OD HYO LINE SERVICE PRESSUAE HEGULATOR QUAL COMPARTMENT AIR TANK 6 OD HYD LINE FROM FLUID RESERVOIR TO 5 5 Motor 1 NC SERVICE SOLENOID VALVE aFLAY E EMERGENCY t VALVE 2 4 ct 8 pete aa 2 Tube Connection From Compressor 3 Tube Connection To Compressor Moisture Valve NC EMERGENCY SOLENDID VALVE MOISTURE EJECTION VALVE SAFETY VALVE l EMEA PRESS REGULATOR 7270 D AIR SUPPLY LINE FROM COMPRESSOR yB OD AR LINE TO COMPRESSOR CONTROL 34 INSTALLATION INSTRUCTIONS Type A H ERC Panel Large Mount the panel on a rigid vertical support low enough for the 1 2 air line from the compressor to slope down to th
36. SI 2PS NC System Pressure Switch 60 50 PSI BPB No Bleeder Pushbutton Terminals on Control Panel Single Lines Wiring or Components by MagneTek Double Lines Wiring by Purchaser CAUTION Connect Motor Leads for Rotation as indicated by arrow on compressor Do not start compressor until crankcase is filled with oil Short circuit protection should be provided in accordance with National Electrical Code 49 DIAGRAM Type A HM HRC Four Brake System With Two HM Parking Brakes P iping Mount bleeders at the same height in hydraulic tee system making return lines to pressure j clusters and control cylinder as short as possible hydraulic lines are 5 16 copper brake line with flare fittings Fasten every 3 feet with rubber bushing Avoid high loops in hvdratilie linac TYPE contan SN TEN TERNAL COARG EVER 0LENOO VALVE T e beeen f Vaive Y NY D CON TROLICA AUR VALVE H 1 Locate compressor and air lines at an elevation that will permit condensed moisture to drain away from compressor into the air tank Do not operate compressor unless 16 DSi oil pressure is maintained in crankcase AIR RELAY CUCR paccecniow vast CULAR PRESS FAC ULAT OR RUNE AIP SOR ASML MEL VALVE PLPC ome CO
37. SURE CLUSTER SERVICING INSTRUCTIONS 6 x 3 and 8 x 3 Type H Brakes TYPE H HYDRAULIC ACTUATOR REMOVAL AND SERVICE Loosen and remove clamp nut 16 and adjusting nut 15 Tap out hinge pin 8 and remove cylinder from brake To disassemble cylinder slide cylinder cover 22 off the body Unscrew connecting rod 17 being careful that return spring 18 does not force cylinder and connecting rod apart Remove return spring spring guide 20 pin guide 23 piston 24 cup 25 and spring 26 Replace complete J7841 actuator 17 26 if cylinder walls are scratched or pitted If 8 x 3 Type rebuilding actuator discard items 21 24 25 and 26 Wash remaining parts in denatured isopropyl alcohol Before reassembly dip all parts in Super Heavy Duty Brake Fluid BRAKE RELINING INSTRUCTIONS Replace brake lining when it is worn to 3 16 thick Remove clamp nut 16 and adjusting nut 15 and anti drag ANTI DRAG hinge pin 11 Open the brake arms and remove the lining ASSEMBLY bolts and nuts and lining SERVICE The anti drag assembly 10 13 maintains 1 32 clearance between the attached shoe and lining and Use new J387 lining bolt and nuts when replacing the lining Reassemble hinge pin 11 and nuts 15 amp 16 BRAKE ADJUSTMENT the brake wheel regardless The brake is adjusted with clamp nut 16 loose Turn of lining wear If the brake is adjusting nut 15 wrench tight with brake lining clamped adjusted corre
38. ake note the following features INSTALLATION INSTRUCTIONS 10 x 4 14 x 6 And 18 x 8 Type HM Brake Assemblies Adjusting Nut A A This brake is suitable for floor mounting only B The brake shoes are adjusted by nut A and clamped by nut B C Ashoe centering plug is at the base of the shoe arm opposite the brake actuators D An Allen head set screw clamps the tubular push rod in the Bl acd yoke E Index hole C is in the center of the brake base F The brake assembly is completely adjusted after inspection cios at the factory Centering G Spring force of the parking cylinder applies the 10x4 HM brake and adjusting nut A must be loosened to slip the brake over the wheel Spring force of the parking cylinder on 14x6 and 18x8 HM brakes has been temporarily relieved by disconnecting the parking cylinder at the bottom bracket Do not alter the centering adjustment or the tubular push rod adjustment nor attach the parking cylinder to the bottom bracket on 14 and 18 brakes until Final Adjustment steps BRAKE INSTALLATION FINAL BRAKE ADJUSTMENT 1 Install the brake wheel 1 After brake system is completely connected filled with brake 2 10x4 Brake Loosen adjusting Ais fluid and thoroughly bled operate system to fully compress the nut A enough to slip the brake gece parking cylinder a On HM manual cab operated systems over the wheel Sip brake over gt lt E 722 step down hard on brake pedal and
39. ake wheels should be inspected after every two months 150 hours of operation or 5 000 stops whichever occurs first The brake wheel as well as the brake lining should be replaced if any of the following conditions are observed 1 If more than 10 of the original rim thickness note J below has been worn away due to normal service Measurement of brake wheel diameters must not be less than Size Min Dia Size Min Dia 6x3 5 29 32 14x6 13 7 8 8x3 7 29 32 18x8 17 7 8 10x4 9 7 8 2 Ifthe brake wheel is scored more than 1 16 deep over more than 25 of the braking surface 3 If the brake wheel is scored any area more than 1 8 deep on 14x6 or 18x8 brake wheel or more than 3 32 on 6x3 8x3 or 10x4 brake wheel 4 Ifthe brake wheel is heat checked or blued over more than 50 of the brake surface This condition is caused by overheating The cause of overheating should be investigated and corrected 5 crack is found on the rim web or hub the brake wheel should be replaced immediately Replacement Brake Wheels are available STOCK bore brake wheel dimensions and part numbers are tabulated below FINISH bore brake wheels are available for current steel mill type motors Brake Wheels are identified by J part number stamped on the edge of the rim and on the nameplate on the web Wheel DIMENTIONS IN INCHES Weight Wk No D G J L M U E Lbs 76200 6 325 3 12 3 00 50 1 0
40. ctly the against the wheel Then back off adjusting nut two and one opposite lining clearance is half turns and tighten clamp nut This provides 1 32 and the brake cannot approximately 1 32 brake wheel to lining clearance drag The anti drag assembly is prelubricated and no maintenance is required If service is necessary J105190 Anti Drag Kit is available which includes a 9414 retractor spring assembly 10 9429 pin 11 9428 anti drag housing 12 and 9423 pin 13 15 14 9 8 25 26 lt ne 08 in AW FLUID INLET Cross section drawing of hydraulic actuator assembly As of January 1993 brake assemblies and replacement shoes have bonded linings These bonded shoes can be rebonded Additionally rivet type replacement linings can still be purchased for use with old style rivet shoes linings 8 SERVICING INSTRUCTIONS 10 x 4 14 x 6 And 18 x 8 Type H Brakes BRAKE SHOE RELINING INSTRUCTIONS To remove brake shoes remove adjusting nut 16 unhook return spring or springs 1 and remove cylinder pin 11 Open brake arms If necessary remove inner adjusting nut 15 to permit lever to pass through slot in lever arm Remove shoe pins 8 and slide shoes over top of brake wheel Replace lining and reassemble brake Brake lining should be replaced before it has worn down to the heads of the brass lining bolts This will be when the remaining thickness is approximately 1 4 o
41. cylinder and pilot circuit reservoir if used Bleed A H brake circuit by holding BPB bleeder pushbutton in and stroking pressure cluster s by repeatedly pushing BCV bleed control valve Bleed the HRC hydraulic remote controlled circuit by opening the bleeder screw on the HRC valve and pumping the control cylinder until clear fluid escapes from the bleeder screw Close bleeder screw If HRC circuit includes coiled or looped hose move trolley to cause straightest possible hose length when bleeding system 2 After brake system is bled and brakes are adjusted operate brake system Operation should be precise without noticeable time delay Check operation of emergency brake step by disconnecting power The crane should come to a quick stop without abnormal hook swing Adjust emergency pressure if necessary Note Application of emergency brake step initiates slow pressure bleed down Brake system is completely released after 1 2 hours AC WIRING DIAGRAM TYPE A H HRC AIR HYDRAULIC PREWIRED CONTROL PANEL EH la EE E 9 4 1 i r n 45 330 rr Note Standard AC Panels Are Designed For 460V operation DC WIRING DIAGRAM TYPE A H HRC AIR HYDRAULIC PREWIRED CONTROL PANEL 1 N C compressor Start Stop Pressure Switch 80 65 PSI 2PS System Pressure Switch 60 50 PSI BPB N O Bleeder Pushbutton 37 INSTALLATION INSTRUCTIONS Type A H ARC
42. e air reservoir This permits moisture to drain to the reservoir where it can be automatically ejected by the moisture valve Pipe and wire the panel into the system per applicable connection diagrams After the brake system is completely piped and wired turn power ON Check preset air pressures 1 Compressor supply pressure at gauge must range 3 High pressure step ON when ESV solenoid valve is from 65 80 psi This pressure is controlled by 1PS de energized is factory set at 40 psi by regulator in N C pressure switch front of gauge C This may be reset in field See Pressure Adjustment Instructions below 2 Low pressure step ON when SSV solenoid valve is energized is factory set at 30 psi by regulator at 4 Abnormal low compressor supply pressure is gauge B This may be reset in field See Pressure signalled by 2PS N O pressure switch which must Adjustment Instructions below close on 60 psi increasing pressure and open on 50 psi decreasing pressure SPECIAL BLEEDING AND PRESSURE ADJUSTMENT INSTRUCTIONS FOR A H ERC SYSTEM 1 Fill fluid reservoir bleeder and pressure cluster Bleed should control the loaded crane to a quick stop the ERC brake circuit by holding BPB bleeder without abnormal load swing Either pressure steps pushbutton in and stroking pressure cluster by may be reset in field however low pressure step repeatedly pushing BFP brake filling pushbutton must be less than the high pressure step 2 Af
43. e high step pressure should control the loaded crane to a quick stop without abnormal load swing Either pressure steps may be reset in the field however low pressure step must be less than the high pressure step If HRC circuit is used operation should be precise without noticeable time delay Note 20 seconds after high pressure step application the protection valve control pressure is reduced causing the valve to exhaust parking brake release pressure Parking brakes are spring applied High pressure step is then exhausted from the service brake pressure cluster s AC WIRING DIAGRAM TYPE A HM ERC AIR HYDRAULIC PREWIRED CONTROL PANEL To Drive Motor Protection Pare Emergency Contro Switcn Emergency Signa Light Note Standard AC Panels Are Designed For 460V Operation DC WIRING DIAGRAM TYPE A HM ERC AIR HYDRAULIC PREWIRED CONTROL PANEL 1PS N C Compressor Start Stop Pressure Switch 80 65 PSI 2 5 System Pressure Switch 60 50 PSI BPB Bleeder Pushbutton BFP Service Brake Filling Pushbutton 41 INSTALLATION INSTRUCTIONS Type A HM HRC Panel THESE INSTRUCTIONS COVER INSTALLATION OF THE FOLLOWING PANEL ASSEMLIES Power Supply 380 460 or 575V 50 60 Hz AC 230VDC 5 Air Hydraulic Ratio 8x1 5x1 8x1 5x1 D 1 33 x 45 Panel J100330 J100331 J100336 J100337 8 No of 2 Assembly Only J100332 J100333 J100338 J100339 s
44. e order using all new parts 14 16 19A from Head and Barrel repair kit Lubricate parts with 21B Brake Fluid Clean residual fluid from supply tank reservoir and reinstall head and barrel using new head gasket 31 Make sure that piston push rod aligns with socket on lever 5 SERVICING THE SPRING CASE ASSEMBLY 20 If the pedal will not return to normal height loosen the three screws 26 and apply 125 175 in lb counterclockwise torque to the spring case 20 Tighten screws If this does not help the clock spring may be defective Loosen screws and unwind the spring case clockwise remove the screws and spring case The spring case is serviced as a J17626 kit including items 20 26 Note that a new spring case includes a 1 1 4 hex for tightening with standard wrench A J73923 gasket kit is also available including only items 23 26 To reassemble lubricate gasket 23 with brake fluid and slide over spring case 20 Insert assembly into supply tank 3 while rotating to engage pin 21 to slot in shaft 4 Attach three lock washers case washers and screws loosely Use wrench to wind spring counterclockwise to 125 175 torque Tighten the screws and check torque by installing pedal with pad 14 15 above floor With head and barrel 13 in place depressed pedal must return to original height SERVICING THE SHAFT SEAL 8 12 Remove retainer felt seal snap ring retainer plate and O ring Use new parts 8 12 from J10799 shaft kit Di
45. e proper operation of the control unit Any visible fluid leaks will prevent proper operation and must be repaired to prevent the parking brakes from applying when a good magnetic check valve is energized The coil used in the check valve is factory preconnected for 230VDC operation The coil leads must be reconnected at the terminal board for operation at 115V 50 60 Hz The rectifier converts 115VAC to 115VDC coil voltage when connected for AC operation This same rectifier protects the coils from high voltage as is sometimes generated when 230VDC power is interrupted INSTALLATION Mount the control unit on the bridge on a rigid vertical surface On single brake systems locate the unit near the brake On 6 and 8 double brake systems locate the unit midway between the two The green signal light is controlled by the pressure switch in the control unit The signal light assembly uses a standard 115V bulb A resistor is included for 230V Install the parking switch and light in the cab convenient to the operator Connect electrical units per applicable diagram GALIN ier sre 77 2 4 8 MTG HOLES 14 INSTALLATION INSTRUCTIONS Type HM Parking Control Unit Wiring Diagram Pei FRB Fluid Reservoir Bleeder On Crane 9 Supply FRB Transient Suppressor and Rectifier Module 5 o e 9 must be connected in circuit at all times The Pasting Brute TSRM module w
46. e switch which must close on 60 psi increasing pressure and open on 50 psi decreasing pressure SPECIAL BLEEDING AND PRESSURE ADJUSTMENT INSTRUCTIONS FOR A H ERC SYSTEM 1 Fill fluid reservoir bleeder and pressure cluster Bleed the ERC brake circuit by holding BPB bleeder pushbutton in and stroking pressure cluster by repeatedly pushing BFP brake filling pushbutton 2 After the brake system is bled and brakes are adjusted operate system to check performance The low step pressure should control the empty crane to a slow stop The high step pressure should control the load crane to a quick stop without abnormal load swing Either pressure steps may be reset in field however low pressure step must be less than the high pressure step Note Power failure or power shutdown causes high pressure step to apply but initiates slow air pressure bleed down which causes complete brake release after 1 2 hours AC WIRING DIAGRAM TYPE A H ERC AIR HYDRAULIC PREWIRED CONTROL PANEL Compressor Motor sss To Orive Motor E MIL r Protection Pane ur To Drive Motor FWD REV Contacts 1 e ol Emergency Control Contacts Note Standard AC Panels Are Designed For 460V Operation DC WIRING DIAGRAM AIR HYDRAULIC PREWIRED CONTROL PANEL To Compressor Motor To Drive Moter r Protection Panel To Drive Motor Fw
47. eeder and pushbutton illustrated under Type H brake systems also apply to Type HM systems GENERAL e Brake Wheel Service Instructions 23 e Hose and Tubing Installation Kits 24 e Replacement Parts Incl Miscellaneous Accessories 25 e Brake Fluid Specifications 25 H to HM Conversion Instructions 26 28 BRAKE DIMENSIONS e 6x3 and 8x3 Type and HM Brakes 29 e 10x4 Type H and HM Brakes 30 e 10x4 Spring Applied Air Released Type S Brakes 30 e 14 18x8 Type and HM Brakes 31 e 14x6 and 18 x 8 Spring Applied Air Released Type S Brakes 31 Index HYDRAULIC BRAKES INSTALLATION AND SERVICE Continued DESCRIPTION PAGE NO AIR OVER HYDRAULIC TYPE A H BRAKE SYSTEM Installation Type A H ARC Panel small unit J070970 J070973 32 33 A H ERC Panel large unit J070980 J070987 34 35 Type A H HRC Panel J071020 J0701027 36 37 A H ARC Panel J089660 J089667 38 39 AIR OVER HYDRAULIC PARKING TYPE A HM BRAKE SYSTEM Installation Type A HM ERC Panel J100650 J100661 J103650 J103661 40 41 Type A HM HRC Panel J100330 J100341 J103330 J103341 42 43 Type A HM ARC Panel J10440 J104411 J104424 J104435 44 45 TYPE A H AND A HM GENERAL INFORMATION Index for Specific System Piping and Wiring Diagrams 46 Typical Piping and Wiring Diagrams for Type A H and A HM Systems 47 53 Compressor and Motor Information 54 GENERAL TROUBLESHOOTING Bleeding Air from Hydraulic Brake Systems 55 Genera
48. ement is as follows FILLED PER STROKE LENGTH OF TUBING ASSEMBLY MAX DISPLACEMENT J 16320 1 1 2 Dia Control Cylinder 3 4 in 5 ft J 17616 1 3 4 Dia Control Cylinder 4 6 in 7 ft J 54085 or 6 1 3 4 Dia Pressure Cluster 5 7 in 9 ft Example Brake System using JF 17616 control cylinder with 70 foot pressure line from cylinder to brake and to FRB bleeder must be fully stroked at least 10 times to fill the complete system 1 Depress BPB bleeder pushbutton to unseat the 8 Reset brake pedal for comfortable operator FRB bleeder check valve height and to provide approximately 8 maximum travel 2 Step on control cylinder brake pedal through full 17 travel or stroke pressure cluster on panel 9 NOTE Manually operated type HM systems forward see panel installation instructions Keep require a special bleeding procedure in foot on pedal or keep pressure cluster stroked addition to above steps After the service forward brake system is bled 3 Disengage BPB bleeder pushbutton a Temporarily attach a bleeder hose to the bleeder screw on the HM brake releasing 4 Remove foot from pedal or retract pressure cylinder and open the bleeder screw cluster b Pump the brake pedal until only clear fluid 5 Repeat steps 1 4 enough times to fill the complete is expelled from the releasing cylinder system Remember fluid travel is only 5 to 7 feet bleeder screw Do not open the service The above cycle must be performed enough
49. end The replacement or repaired HM cylinder should be reinstalled in reverse order to the above The brake should be readjusted after the cylinder has been reconnected into the system the hydraulic circuit has been completely bled and with the HM cylinder held released with hydraulic pressure 20 SERVICE INSTRUCTIONS 10 14 And 18 Type HM Park Release Cylinders HM parking cylinder may be overhauled using repair kit J73921 However three special tools are needed to safely and correctly disassemble and reassemble this cylinder J 391 Spring Clamp Tool This tool is needed to clamp and hold the setting spring under high force while the piston rod nut piston and other parts are removed from the piston rod The tool consists of two matched pairs of clamps held together with four Allen head cap screws and two through bolts and nuts that clamp and retain the setting spring under 300 pounds force J 394 Expanding Drift Tool This three piece tool is used to remove and reinstall the O ring retainer from the cylinder body J 392 Pilot Tool This tool is needed when reinstalling the piston rod back in the partially reassembled cylinder body m 14 75 1 1 1 16 LLL 21 3 20 E n gt 182 pm M 4 4 ae 2 IL _ T
50. ents as illustrated in panel piping diagrams Air storage tank s Protected air storage tank Starter with controls for compressor Pressure switches Pressure cluster s Moisture ejection valve Relay Emergency Valve REV The relay emergency valve is the heart of the panel operation Understanding this valve function will assist in understanding the AH panel operation This valve controls pressure to the service brake pressure cluster It applies pressure from the right half of the horizontal reservoir Whenever emergency port E is pressurized above 50 psi reservoir port R pressure is poised for application to delivery port D at whatever pressure is applied to service port S Without pressure at the service port no pressure is applied to the delivery port Whenever emergency port pressure drops below 40 psi pressure at the reservoir port is applied to the delivery port Hence the valve applies pressure to the service VALVE PORTS brake pressure cluster in emergencies although a tiny 2 Air Line bleed down bypass bleeds delivery port pressure S Service Air Line through the service port After several hours the emergency brake pressure is fully released R Reservoir D ODelivery Ports 57 GENERAL Type A H Panel Operation And Troubleshooting 1 AH ARC Normal Service Braking 2 AH ERC Normal Service Braking 3 AH HRC Normal Service Braking Panel Operation Summary Air is deliv
51. ered to the service port on relay emergency valve REV via air treadle valve located in operator s cab Applying pressure to service port meters air to the pressure clusters which forces hydraulic fluid to the brake s Air is delivered to service port on relay emergency valve REV by opening energizing the service solenoid valve SSV REV valve meters air to the pressure cluster s which forces hydraulic fluid to the brake s Depressing foot pedal on control cylinder in operator s cab delivers hydraulic pressure to hydraulically controlled air valve Air is metered through a check valve to pressure cluster s which forces hydraulic fluid to the brake NOTE In all cases for normal service braking 50 psi of air pressure must be present at the emergency port on the relay emergency valve REV A For AH ARC panels air is piped through a one way check valve from the storage tank B For AH ERC and AH HRC panels air is piped from the storage tank but through a normally closed solenoid The solenoid emergency solenoid valve must be held open energized so air is delivered to the emergency port 58 GENERAL Type A H Panel Operation And Troubleshooting Panel Operation Summary 4 Emergency Braking NOTE Emergency braking can occur when 5 1 5 Pressure Switch 4078061 6 2PS Pressure Switch 4078061 7 Bleeder Push Button 010068 8 MPR Motor Protection Relay 9 Brake Fill
52. ervice 2 No Enclosure J100334 J100335 J100340 J100341 o pressure 1 Panel Assy Mounted J103330 J103331 J103336 J103337 clusters 2 Inside 36 x 48 x 18 J103332 J103333 J103338 J103339 2 Enclosure J103334 J103335 J103340 J103341 Also Includes 1 8 x 1 ratio parking brake release pressure cluster below service cluster Also includes 2 8 x 1 ratio parking brake release pressure clusters below service clusters 1 T 27 516 Hydraulic Tube c From Master ESV Gage 9 al 1 5 M 5 _ P 3H y ay wy 1 2 Tube Connection 1 i NE ed So 250 Compressor 2 i i Protection Valve 5 25 6 Hydraulic Tube From Reservoirs Gage e S amp Tube Connection HW 516 m Tube _ 1 J 71 To Compressor eX To Service Brak Li de 28 Cylinders 1 1 21 5 16 Hydraulic Tube 7 3 L Moisture Valve To Mus Brake 7 4 Aelease Cylinders e ee nee A HM HRC PANEL PIPING DIAGRAM 5 167 OD Hyd Line Mydraulic Controlled 2775 From Control Cylinder Air Valve Emer Press Regulator 2 Air Supply Line From Compressor 5 16 OO HYO Line From Fluid Reservoir 5
53. gh to slip parking brake is released Release brake pedal The brake over wheel Ea washer just below the parking cylinder port see item F above should now be away from the spring barrel end because the parking spring is now compressed 3 Tighten adjusting nut B until shoes make firm contact with wheel Do not tighten further Final brake adjustment is made after brake is opera tional 1 Retighten adjusting nut B to clamp shoes tight against the brake wheel 2 Loosen nut B two and one half turns and tighten clamp 4 With brake base parallel with nut A actuator per item C above and with brake wheel and brake pin center lines perpendicular add shims between brake base and 4 The brake is now properly adjusted Check service brake platform Attach base k ki k with 5 8 bolts brake and parking brake operation 3 Both shoes should now be approximately 1 32 from the brake wheel 5 Using F 17 copper gasket seals screw short thread end of armored hoses into all three actuator ports Wrench tighten to provide leak proof Follow Final Brake Adjustment instructions when seals readjustment is necessary to compensate for lining wear 6 Use mounting brackets lock washers and jam nuts provided to attach free end of hose to rigid support Allow hose slack to permit movement of actuator 7 The brake is now ready to be piped into the hydraulic system 12 Before installing this br
54. ill protect the solenoid check valve coils 4 1 by suppressing voltage surges that can occur in DC power supplies The module operates as full _ _ Res aes wave rectifier when the power supply is 115VAC A SCV Solenoid Check Valve Subpart of J107206 HM Closes Control Unit E V mors 285 ANV _ PBL Parking Brake Light Subpart of J45767 switch ee L2 ate rr Ea Em and light in cab Connect as shown for 230V ui power supply Use 115V terminal if 115V power M supply used Motor Pilot Relay Supplied by customer Con nect contacts to prevent drive motor operation until hydraulic pressure switch is closed ET GREEN GROUND 1 screw RESISTOR TERMINAL os BLOCK 1 BLACK L RED 7771 A were YELLO ch all 24 11 cow O MOCULE Pressure Switch 320 400 PSI Pressure Switch 320 400 FSI NOTE HM control unit is pre wired for 230V DC operation If the power supply is 115VAC the solenoid coil must be re wired as shown above BPB Bleeder Pushbutton J10008 in cab PBS Parking Brake Switch Sub part of J45767 Switch and Light Assembly Connect Normally Closed terminals so that the TSRM and solenoid check valve are energized to keep the parking brake off when the selector switch is in the OFF position and the parking brake
55. ing Push Button 10 Moisture Ejection Valve Whenever emergency port pressure drops below 40 psi on the REV air from the protected tank will be delivered to the pressure cluster s which forces hydraulic fluid to the brake Loss of air pressure or low air pressure Loss of power AH ERC AH HRC PS2 pressure switch opens AH ERC AH HRC Closing emergency solenoid valve de energized by contact control This is com monly referred to as the second step of braking for AH ERC panels op Turns compressor on off AH ARC panel sounds low pressure alarm Emergency braking occurs as noted above for AH ERC and AH HRC systems Opens bleeder s by energizing solenoid on fluid reservoir bleeder On AH ERC AH HRC panels relay provides contact for customer use as motor protection Strokes pressure cluster for bleeding hydraulic lines Each brake application causes a small amount of air to expel accumulated moisture in storage tank 59 GENERAL Type A H Panel Operation and Troubleshooting Troubleshooting Hints PROBLEM POSSIBLE SOLUTION Brake does not actuate A Observe pressure cluster to determine if unit stroked forward An 8 x 1 cluster has an indicating rod a 5 x 1 cluster has a rubber boot that moves If cluster strokes panel may be operating and problem is at brake B Relay emergency valve not functioning C No power or no air pressure D Solenoid valve not functioning Brake stays set
56. is controlled by 1PS N C pressure switch 2 Emergency pressure step ON when ESV solenoid valve is de energized is factory set at 40 psi by regulator in front of gauge B 3 Abnormally low compressor supply pressure is signalled by 2PS N O pressure switch which must close on 60 psi increasing pressure and open on 50 psi decreasing pressure SPECIAL BLEEDING AND PRESSURE ADJUSTMENT INSTRUCTIONS FOR A HM ARC SYSTEM 1 Fill fluid reservoir bleeder s and pressure cluster s Bleed the service brake circuit by holding BPB service brake bleeder pushbutton in and stroking the service brake pressure cluster s by repeatedly pushing BFP brake filling pushbutton Bleed the parking brake circuit by holding BPB parking brake bleeder pushbutton in and stroking the parking brake pressure cluster s by repeatedly pushing the BCV bleed control valve 2 After the brake system is bled and brakes are adjusted operate brake system Operation should be precise without noticeable time delay Check operation of emergency brake stop by disconnecting power The crane should come to a quick stop without abnormal hook swing Adjust emergency brake pressure at gauge B if necessary Note twenty seconds after high pressure step application the protection valve control pressure is reduced causing the valve to exhaust parking brake release pressure Parking brakes are spring applied High pressure step is then exhausted from the service brake pres
57. l Troubleshooting 56 Air Over Hydraulic Type A H Panel Operation 57 60 INSTALLATION INSTRUCTIONS 6 x 3 and 8 x 3 Type H Brake Assemblies Before installing this brake assembly please take note A These instructions show normal floor mounted installation The brake may alternately be wall or ceiling mounted if necessary B The brake base mounting holes are not equal distances from the brake center Mounting holes on the anti drag side are 5 9 16 from the brake pin center Mounting holes opposite the anti drag side are 4 15 16 from the brake pin center Be sure to position the brake over the correct mounting holes C If necessary the actuator ports may be rotated 180 Temporarily drive out hinge pin to free actuator D The brake must be installed with the actuator and hinge pins parallel with the brake base If necessary reposition brake by forcing against anti drag friction E The brake was correctly adjusted during factory inspection Clamp nut A and adjusting nut B may be temporarily backed off to ease installation of brake on brake wheel BRAKE INSTALLATION 1 Install brake wheel 2 Slip brake on brake wheel HINGE PINS A 7 brake is now ready to be piped into the 3 With clamp nut A loose tighten adjusting nut B to hydraulic system Be sure to adjust the brake clamp brake shoes tight against the brake wheel before operation 4 With actuator and hinge pins parallel with base per item C abo
58. lies system pressure automatically ejected by the moisture valve Special Bleeding Instructions for A H Systems Pipe and wire the panel into the system per applicable 1 Fill fluid reservoir oleeder s and pressure connection diagrams When complete turn power ON cluster s Hold BPB bleeder pushbutton in and Check preset air pressures Compressor supply pres stroke pressure cluster by repeatedly pushing sure at gauge A must range from 65 80 psi This pres Bleeding Control Valve sure is controlled by 1PS N C pressure switch Low ELECTRICAL CONTROL ASSEMBLY WIRING DIAGRAM DC m Ea zug Comoressor Motor To Compressor Motor IIT PUER ra 2 e 9 i f 0 To Fluid Reservoir 9 22 T eM T Bieeders 22 To Fluid Reservoir a e To Low Pressure i el T Bleeders sser le n ne 5 ieee To Low Pressure Buzzer PS Comp essce Start Stop Pressure Sertich TT S T TT 80 65 Ps 225 NC System Pressure Swtenh 160150 BPB Beader Pushbutton LOW AIR PRESSURE ALARM INSTALLATION 115VAC J34778 230VDC J24673 al li OOS 19 J57159 AIR TREADLE VALVE INSTALLATION LA yl I The air treadle valve may be located in front or to either side of the
59. n 10 and 14 brakes and 3 8 on 18 brakes ADJUSTMENT Loosen nut 15 and tighten nut 16 until shoes are against brake wheel Loosen nut 16 three turns and tighten nut 15 Clearance between lining and brake wheel should then be 1 32 If clearance on each side of brake wheel is unequal after this adjustment adjust self centering device at lower end of left brake arm The self centering device on current brakes is adjusted by a 7 16 hex and locked by a 7 8 nut Turning the hex clockwise moves both shoes to the right Old style brakes that use an Allen head adjustment should be converted to the current self centering device by using a J87249 Shoe Centering Lock Kit SERVICING THE HYDRAULIC BRAKE CYLINDER The hydraulic brake cylinder should be replaced or repaired if there is any evidence of brake fluid leaking around the boot To remove the cylinder disconnect the hydraulic lines at the hose connections and temporarily cap the lines to prevent loss of brake fluid Remove the brake cylinder from the brake hoses if they will be replaced or if the brake cylinder will be replaced To service the brake cylinder remove boot 11 and separate the cylinder and body 1 from the link and sleeve 10 The pull the piston and guide rod assembly 5 9 out of the cylinder If inspection of the cylinder bore shows that it is smooth with no pits or scratches the assembly may be serviced with a repair kit which includes items 5 9 and 11
60. noticeable time delay Check service brake bleeder pushbutton in and stroking the operation of emergency brake step by disconnecting service brake pressure cluster s by repeatedly power The crane should come to a quick stop pushing BFP brake filling pushbutton Bleed the without abnormal hook swing Adjust emergency parking brake circuit by holding BPB parking brake brake pressure at gauge B if necessary Note bleeder pushbutton in and stroking the parking brake twenty seconds after high pressure step application pressure cluster s by repeatedly pushing the BCV the protection valve control pressure is reduced bleed control valve Bleed the HRC circuit if used causing the valve to exhaust parking brake release by opening the bleeder screw on the HRC valve and pressure Parking brakes are spring applied High pumping the control cylinder until clear fluid escapes pressure step is then exhausted from the service from the bleeder screw Close bleeder screw If HRC brake pressure cluster s circuit includes coiled or looped hose move trolley to cause straightest possible hose length when bleeding system AC WIRING DIAGRAM DC WIRING DIAGRAM A HM HRC AIR HYDRAULIC TYPE A H HRC AIR HYDRAULIC PREWIRED CONTROL PANEL PREWIRED CONTROL PANEL Compressor Motor Emergency Brake Switch 7 she sabbat aog S Signal tight To Emergency Brake Light 1 2 1 5 N C Compressor Start Stop Pre
61. nt is necessary to com pensate for lining wear 13 INSTALLATION INSTRUCTIONS Type HM Parking Brake Control Unit J107206 Rei stor amp Solenoid Check Valve Assy Pressure Switch Veo MALE THO weve Parting Brake Service Brake FRONT VIEW COVER REMOVED HOW THE CONTROL UNIT WORKS This control unit controls the parking brakes in the Type HM brake system Fluid is forced through the control unit to the brake cylinders Fluid displaced to the service cylinders applies the service brakes and fluid displaced to the parking brake release cylinders releases the parking brake When pressure at the control unit inlet port is relieved the service brakes release but the fluid in the lines to the releasing cylinders is trapped by the energized check valve in this control unit When sufficient pressure 400 psi is built up and trapped in the releasing cylinders the pressure switch in this control unit closes This energizes the signal light in the cab and permits the drive motor to be started When power to this control unit is interrupted pressure is relieved from the releasing cylinders and the parking brakes are automatically applied by spring force PARKING SWITCH AND LIGHT J45767 The parking switch provides operator control of the magnetic check valve in the HM control unit Release Cylinder Cylinder Normal brake operation with this control unit energized tests th
62. ocate the FRB assembly at the highest point in the asc hydraulic system 2 2 Only gravity forces fluid flow in the static return line from the bleeder reservoir to the master cylinder ej reservoir Minimize restrictions in this line Avoid long horizontal static return lines as per Figure 1 OFRE Fluid Reservoir Bleeders Bleeding Control 1 c 1 7 Valve Bleeder Push Button FIG 1 USE ES Short Unrestricted 20 MAXIMUM FROM Static Line USE HEIGHT TO Unrestricted Static Line FIG 2 FIG 3 I NM Locate the FRB assembly so that the static return line is as short and direct as possible Manual brake systems should be arranged per Fig 2 Air power brake system should be arranged per Fig 3 If the FRB assembly is electrically operated J 3080 or J 3083 connect to bleeder pushbutton BPB in cab if manual hydraulic system or on panel if air power hydraulic system Refer to applicable wiring diagram Pressure Clusters INSTALLATION INSTRUCTIONS Type H One Brake One Station System Piping amp Wiring Diagram FRB Fluid Reservoir Bleeder 24 71 See Wiring Diagram Hydraulic Tubing gt BPB Bleeder Pushbutton Type H Brake See Insert Below 6x3 and 8x3 BRAKE ASSEMBLY Actuating Cylinder WIRING DIAGRAM FOR 230 V DC OR 115V 50 60 HZ AC FRB FRB
63. oir Use 1 2 tubing for compressor supply line and 3 8 tubing for compressor control line Fill compressor crankcase with nondetergent oil of grade and type recommended by compressor manufacturer Fill oil bath air filter to indicated line Connect compressor motor to starter on panel Be sure that motor rotates compressor in direction of arrow Start compressor and check pressure Lubrication pressure gauge should indicate 16 psi Air reservoir pressure should reach 80 psi Check for air leakage Tighten fittings if necessary 54 INSTALLATION INSTRUCTIONS Bleeding Hydraulic Brake System Turn crane power ON so that the FRB bleeder solenoid can be operated If air nydraulic system is used the air system must be piped and wired with power ON and with normal air pressure Brake fluid is drawn from the FRB reservoir through the static return line to the master cylinder and pumped through the brake system pressure line The reservoir must initially be completely full of fluid as per filling instructions above The FRB reservoir must be kept full during the bleeding operation Each successive full cylinder stroke forces fluid farther downstream The master cylinder must be stroked enough times to force fluid through the complete brake system Volume of the 5 16 OD tubing is 0 6 per foot With the control cylinder brake pedal temporarily set for maximum 17 pedal travel or the pressure cluster operated at full 1 1 2 stroke displac
64. ounted in parking cylinder hydraulic line to replace function of obsolete J14853 mechanical limit switch in old HM 2 system or J9738 pressure switch in old HM system 1 4 18 NPT J18377 TWO WAY HYDRAULIC CHECK VALVE T LIA This assembly is required for operation of brake system from X 34 Dia Hole more than one control station 459 Chamfer mates flared tubing and J86 tube nut Requires F 17 Gasket Seal at cylinder port m when empty F9314 21B SUPER HEAVY DUTY BRAKE FLUID 6 1 GAL CASE Industrial Brake Systems must be filled only with 21B Super Heavy Duty Brake Fluid meeting SAE J1703 specifications Do not use mineral oil or any other substitute Avoid contamination Purchase brake fluid in 1 gallon cans that can be easily carried to the job site and discarded 25 INSTRUCTIONS FOR CONVERTING Type H to Type HM Brake System Install HM Releasing Cylinder and HM Brake Kit parts Install J 107154 HM Control Unit and J 45767 Parking Switch and Light Add hydraulic tubing and hose to connect HM control unit HM releasing cylinder and existing brake actuator per piping diagram Refill FRB reservoir full using ONLY 21B Super Heavy Duty Brake Fluid or equal Turn crane power ON Temporarily reposition brake pedal to permit at least 17 stroke Depress BPB bleeder push button Step on control cylinder brake pedal through full stroke Repeat this step at least 10 to 15 times Keep FRB reser
65. p O ring and felt seal in brake fluid and reinstall in reverse order 10 SERVICING INSTRUCTIONS Type H Fluid Reservoir Bleeders FRB Fluid Reservoir Bleeder Assembly FRB Fluid Reservoir Bleeder Assembly Assembly No Solenoid Voltage PSD 0180102 Manual Operated COMPONENT PARTS LIST AND DIAGRAM COMPONENT PARTS LIST AND DIAGRAM eo E fn E ne Bp 6 9 4 1 5 14 0 2 FT yo FO A 7 NOTES 1 VALVE TO BE IN THE CLOSED NOTE POSITION DURING STANDARD PIPE SEALANT SWAK MS PTS OPERATING CONDITIONS 250 OF EQUIVALENT TO BE 2 PIPE SEALNT SWAK MS PTS USED ON ALL THREAD JOINTS 250 OR EQUIVALENT TO BE WHEN ASSEMBLING USED ON ALL THREAD JOINTS WHEN ASSEMBLING C2 1E WIRE LEADS PROVIDED CHART 1 2 PSD 0179900 VALVE AND SOLENOID ASSEMBLY 120 1 2 PSD 0179901 VALVE AND SOLENOID ASSEMBLY 240 VDC 1 2A 02546003 SOLENOID COIL BODY ONLY 120 VAC 1 2A 02546004 SOLENOID COIL BODY ONLY 240 VDC 1 8 9990266200 SCREW DRIVER U SIZE 4 X 3 16 LG 2 8 9990266200 SCREW DRIVER SIZE 4 3 16 LG 2 7 J010457999 NAMEPLATE FRB UNIT 1 2 1010457999 NAMEPLATE FRB UNIT 4 6 9012038000 LOCKWASHER SPLIT 1 4 2 6 1 9012038000 LOCKWASHER SPLIT 1 4 2 5
66. place with square cut recess of piston toward cup Reassemble lock washer 14 and nut 15 Tighten to 60 ft lb torque Before replacing cylinder end 16 disassemble mounting lug 21 Dip new filter 20 in brake fluid and install with retainer 19 Reassemble mounting lug and cylinder end Remove spring clamp tool and reinstall cylinder on brake HM PARK RELEASE CYLINDER REPLACEMENT PARTS LIST Item No Name of Part 10 x 4 14 x 6 18 x 8 Complete Assembly J 79463 J 79462 J 79464 21 Mounting Lug J 9681 J 9681 J 9688 8 Piston Rod Assembly J 23040 J 23041 J 23041 34 Piston Rod Guide J 9662 Not Used Not Used 35 C Washer J 9661 Not Used Not Used The following parts are used in all the above Releasing Cylinder Assemblies Item No Name of Part Number Used Part Number 1 Oylinder Body 1 J 14704 Bushing 1 J 9674 3 9691 Packing Felts 4 4 Bushing 1 J 9672 5 10167 O Ring 1 6 10229 O Ring 1 i 7 10231 Felt Washer 1 b 9 1733 Gasket 1 li 10 Piston Stop Sleeve 1 J 9697 11 9696 Cup Retainer 1 12 9694 1 13 Piston 1 J 9695 14 Shake proof Lock Washer 1 15 14707 Piston Rod Nut 1 16 Cylinder End 1 J 79467 19 9680 Filter Retainer 1 i 20 1823 Filter 1 31 25 lot pack F17 Gasket 1 J 105376 32 Bleeder Screw Adaptor 1 J 7346 33 Bleeder Screw 1 F 6446 ORDER J73921 HM CYLINDER REPAIR KIT 22 SERVICE INSTRUCTIONS Brake Wheel Inspection Br
67. readjusted after all other system components are installed and the hydraulic system is refilled and bled a 1 Dia Holes 4 Dia Hole 10 x4 Size Install New Lever Arm Furnished Remove Original D Lever Arm ___ Replace brake lever arm using new lever arm furnished in kit for 10 x4 size brakes CONVERTING 14x6 AND 18x8 BRAKES Install mounting bracket A Brake has three holes in base to mount bracket Loosen adjusting nut A Remove existing hydraulic actuator Attach bottom of new actuator to brake shoe with pin E Attach top of actuator yoke tie links hinge pins and top lever arm as illustrated Thread tubular push rod into yoke Do not tighten yoke Insert HM releasing cylinder shaft in yoke Attach bottom of releasing cylinder to bracket A Insert cotter pins at all hinge pins Brake is now reassembled It must be readjusted after all other system components are installed and the hydraulic system is refilled and bled 25 Dia Holes fT 147 Dia Hole _ C 14 x6 and 19 x8 Size Hinge Pins Vertical e Tie Link vuU Nut A Horizontal 4 5 fey f Tie Links 200 kS Yoke gp Tubular Push Rod if y Releasing F i gt Gi Cylinder 4 E ndi gt Hinge Pin ig Bracke 2 P
68. s essential that the foot pad be in a position for the operator to control full pedal force through up to 8 pedal pad travel Actual pedal travel depends on the specific system used We suggest that the pedal be slipped on the shaft and the control cylinder position be rechecked before the final location is selected NOTE Relocating pedal assembly on shaft changes pad height in increments of 2 4 inches Type 2 Control Cylinder and 18 Pedal Assembly Control Cylinder Assy sy No 11 2 dia J 16320 1 3 4 17616 1 Dia 4 Holes 3 7 16 UNC 28 x 7 53 Thread 2 Holes Mates With m 6 Optional Mounting Z Industrial Brake Pedal Assemblies 44 ee aon 674 rm Pedel Asoy T3 ne E 28 Max Standard 18 long pedal assy includes J 8178 locating bushing No alternate pedal size available INSTALLATION 1 Bolt control cylinder to floor with 1 2 bolts 2 Using F 17 copper gasket seal screw short threaded end of two armored hoses into port C Wrench tighten to provide leak proof hydraulic seals 3 Use mounting brackets lock washers and jam nuts provided to attach free ends of hoses to rigid support 4 Temporarily install foot pedal with pad 17 above floor level This permits maximum control cylinder stroke when bleeding system Pedal height should be lowered to desired height after the hydraulic system is thoroughly bled 5 Control
69. se Cylinder after spring and clamp have been removed 34 21 SERVICE INSTRUCTIONS 10 14 And 18 Type HM Park Release Cylinders Inspect the bore of the cylinder If it is pitted or scratched replace the entire HM park release cylinder If the cup or O ring is very soft or enlarged this is evidence of brake fluid contamination and the entire brake system should be flushed and all other compo nents rebuilt or replaced Inspect J9674 bushing 2 If necessary to replace rebore to 829 831 diameter Reassembly Reassemble all parts in reverse order using all new parts from repair kit J73921 Before reassembly wash all parts clean with denatured isopropyl alcohol Then lubricate all parts before reassembly using Heavy Duty Brake Fluid Reinstall bushing 4 with new O ring 5 Now use J394 expanding drift tool and tap new O ring retainer 6 in place next to O ring Remove tool Now dip new packing felts 3 and felt washer 7 in brake fluid and insert through small end of cylinder body Reinstall brake setting spring with spring clamp tool on cylinder body Do not remove spring clamp tool Now slip J 392 pilot tool over threaded end of piston rod and insert rod through small end of cylinder body Remove pilot tool Slip new gasket 9 piston stop sleeve 10 cup retainer 11 and cup 12 into cylinder and over the piston rod 8 Now holding shoulder of piston rod against setting spring slide piston 13 in
70. ssure Switch 80 65 PSI 2 5 System Pressure Switch 60 50 PSI BPB Bleeder Pushbutton BFP Service Brake Filling Pushbutton 43 Note Standard AC Panels Are Designed For 460V Operation INSTALLATION INSTRUCTIONS Type A HM ARC Panel THESE INSTRUCTIONS COVER INSTALLATION OF THE FOLLOWING PANEL ASSEMLIES Power Supply 380 460 or 575V 50 60 Hz AC 230VDC 5 Air Hydraulic Ratio 8x1 5x1 8x1 5x1 D 1 38 x 45 Panel J104400 J104401 J104406 J104407 8 No of 2 Assembly Only J104402 J104403 J104408 J104409 s nico 2 No Enclosure J104404 J104405 J104410 J104411 o pressure 1 Panel Assy Mounted J104424 J104425 J104430 J104431 clusters 2 Inside 36 x 48 x 18 J104426 J104427 J104432 J104433 n 2 Enclosure J104428 J104429 J104434 J104435 Also Includes 1 8 x 1 ratio parking brake release pressure cluster below service cluster Also includes 2 8 x 1 ratio parking brake release pressure clusters below service clusters 38 Air Control From Treadie Valve 1 2 Air Supply From Compressor Emergency 5 16 Hydraulic Tube Pressure Regulator From Reservoirs LE a gt T 9 Protection Valve 2 Way Air Check Valve i mg P RY 5 16 Hydraulic Tube To Service Cylinders Gage A Release Cylinders T 38 Air Control To Compressor 2 Air Relay Valve 5 16 Hydraulic Tube Dr b To
71. sure cluster s AC WIRING DIAGRAM TYPE A HM ARC AIR HYDRAULIC PREWIRED CONTROL PANEL Note Standard AC Panels Are Designed For 460V Operation DC WIRING DIAGRAM TYPE A HM ARC AIR HYDRAULIC PREWIRED CONTROL PANEL To Compressor otor Protection Pane To Emergency Brake 7 Contic Switch I To Emergency Grate 2 Segnal Light 1PS N C Compressor Start Stop Pressure Switch 80 65 PSI 2PS N O System Pressure Switch 60 50 PSI BPB Bleeder Pushbutton BFP Service Brake Filling Pushbutton 45 System Type AH ARC previously Type A H AHM ARC AH HRG AHM HRC AH ERC With Cab Control AH ERC Without Cab Control AHM ERC With Cab Control AHM ERC Without Cab Control No of Brakes BAN RAND System Piping And Wiring Diagrams Special Features 2 Prk Brks 4 Prk Brks 2 Prk Brks 4 Prk Brks Trdl in Cab Trdl in Cab 2 Prk Brks 4 Prk Brks 2 Prk Brks 4 Prk Brks Piping Diagram Ref No 511 512 514 518 611 612 613 614 711 712 714 811 812 813 814 911 912 912T 914T 1011 1012 1014 1111 1112 1113 1114 1211 1212 1213 1214 Wiring Diagram AC DC Ref No Ref No 561 2A 561 2D 561 2A 561 2D 564A 564D 568A 568D 881 2A 881 2D 881 2A 881 2D 883A 883D 884A 884D 761 2A 761 2D 761 2A 761 2D 764A 764D 881 2A
72. ter the brake system is bled and brakes are Note Power failure or power shutdown causes high adjusted operate system to check performance The pressure step to apply but initiates slow air pressure low step pressure should control the empty crane to bleed down which causes complete brake release after a slow stop The high step pressure 1 2 hours AC WIRING DIAGRAM DC WIRING DIAGRAM TYPE A H ERC AIR HYDRAULIC TYPE A H ERC AIR HYDRAULIC PREWIRED CONTROL PANEL PREWIRED CONTROL PANEL Note Standard A C Panels Are Designed For 460V Operation 1PS N C Compressor Start Stop Pressure Switch 80 65 Psi 2PS N O System Pressure Switch 60 50 Psi BPB Bleeder Pushbutton BFP Brake Filling Pushbutton 35 INSTALLATION INSTRUCTIONS Type A H HRC Panel THESE INSTRUCTIONS COVER INSTALLATION OF THE FOLLOWING PANELS Power Supply 380 460 or 575V 50 60 Hz AC 230VDC Air Hydraulic Ratio 8x1 5x1 8x1 5x1 Pressure Cluster No of Pressure 1 J71020 J71021 J71024 J71025 Clusters 2 J71022 J71023 J71026 J71027 5716 Hydraulic Tube From Reservoir 5 16 Hydraulic Tube To Brakes DUAL COMPARTMENT AIR TANK 5 167 00 MYD LINE 10 BRAKE PRESSURE tLuStER 516 Hydraulic Tube From Master Cylinder HAC Valve Emergency Pressure Beguiator 2 Tube Connection From Compressor 36 Tube Connection To Compressor Moisture Valve w2 Dia 7 Holes
73. times brake bleeder during this step to fill the entire length of interconnecting tubing c Close the releasing cylinder bleeder screw 6 Refill FRB reservoirs frequently during bleeding and repeat at the second HM brake if sequences to prevent reinjecting air in system used 7 The brake system is completely bled when the 10 Refill FRB reservoir to within 1 of opening system is operated without operating the bleeder and replace filler cap and gasket pushbutton and the brake pedal has a solid feel after less than 8 pedal travel or if the pressure It is recommended that the brake system be cluster stroke indicator shows less than 1 1 2 rebled after a short period of operation travel 55 SERVICE INFORMATION Troubleshooting Instructions TROUBLE Complete loss of pedal 1 Actuating cylinder stays extended 1 service brake will not release Gradual loss of pedal during service 1 application Parking brake does not stay released unless operator stands on pedal Parking brake stays released for short interval only CAUTION These units are intended for use with SAE J1703 Automotive Brake Fluid only STEP BY STEP PROCEDURE Check clearance between brake lining and wheel Check bleeder fluid level bleeder solenoid operation and bleed system If system has two stations bleed from both If pedal is extremely light during bleeding on one station system and fluid is not entering bleeder replace control cylinder On
74. tions are made after the brake 6 With parking brake still fully released recheck tubular push is hydraulically operational The brake should remain firmly rod adjustment to be sure that parking cylinder force does not clamed against the wheel throughout the remaining bear against the top brake lever There must be clearance as installation steps follows 3 Level brake base by plumbing center of brake wheel shaft to index hole C in the base of the brake 1004 BAKE 1426 198 BRAKE 4 Add shims between the brake d base and support Bolt brake ic 2 4 M base to support PES Tw A 5 Using F 17 copper gasket seal screw short threaded Push Red Yi end of armored hoses into both 4 2 actuating cylinder ports and in parking d i cylinder port Do not remove bleeder 23 screw and adaptor from the second gt port on the parking cylinder unless second brake is being used See If necessary loosen set screw and adjust tubular push rod to piping diagram Wrench tighten hoses give indicated 010 clearance and tighten set screw to provide leak proof seals 7 brake is now properly adjusted Check service brake and 6 Use mounting bracelets lock washers and jam nuts parking brake operation provide to attach free end of hose to rigid support Allow hose to slack to permit movement of actuator 7 The base is now ready to be piped into hydraulic system Follow above insiructions when readjustme
75. two station system replace control cylinder and if this does not improve operation check crossover valve and replace if necessary A If solenoid fails to function replace solenoid or pushbut ton or correct wiring fault Inspect lines and units for leaks Correct faults Replace control cylinder or fluid reservoir bleeder On two sta tion system check crossover valve Open any tube connection near actuating cylinder A If actuating cylinder does not release replace it B If actuating cylinder releases replace control cylinder on two station system determine which should be re placed Inspect lines and units for leaks If repeated applications do not disclose visible leaks replace control cylinder If necessary replace actuating cylinder If good signal lamp does not light when pressure switch closes check wiring circuits and voltage and check for leaks in hydraulic system If lamp lights but brake will not stay released check at brake control unit for open circuit in unit and for lack of power from switch Power supply interruptions from collector rail breaks or other sources may need correction Bleed system Replace releasing cylinder and or brake control unit 56 GENERAL Type A H Panel Operation And Troubleshooting Hydraulic Brake Systems Industrial Brake Products AH ARC AH ERC and AH HRC Panel Operation for Air Over Hydraulic Brake Systems The AH panels have the following common compon
76. ve and with brake wheel and brake pin center lines perpendicular add shims between brake base and brake platform Attach BRAKE ADJUSTMENT base with 5 8 bolts 1 Start with brake shoes clamped tight against brake wheel per item 3 2 Loosen adjusting nut B two and one half turns and tighten clamp nut A 5 Using F 17 copper gasket seal screw short thread end of armored hoses into both actuator 3 Both shoes should now be approximately 1 32 ports Wrench tighten to provide leak proof from brake wheel hydraulic seals 6 Use mounting brackets lock washers and jam nuts provided to attach free ends of hoses to rigid Follow Brake Adjustment instructions when support Allow hose slack to permit movement of readjustment is necessary to compensate for lining actuator wear INSTALLATION INSTRUCTIONS 10 x 4 14 x 6 and 18 x 8 Type H Brake Assemblies Before installing this brake note the following features A This brake is suitable for floor mounting only B The brake shoes are adjusted by nut A and clamped by nut B C A shoe centering plug is at the base of the shoe arm opposite the brake actuator D The brake assembly is completely adjusted after inspection at the factory Adjusting nut A may be temporarily backed off to ease installation of the brake on the brake wheel E The hydraulic actuator should be installed after brake installation BRAKE INSTALLATION tie H uL 1 Install brake wheel
77. verall Height Y 10 9 16 12 9 16 TYPE HM HYDRAULIC APPLIED BRAKE WITH SPRING APPLIED PARKING FIGS 1 amp 3 SIZE 6x3 8x3 Assy No J 24579 J 3205 Assy Wt 30 Ibs 32 Ibs Overall Width X 18 1 2 18 1 2 Overall Height Y 11 3 32 13 3 32 DIMENSIONS COMMON TO BOTH TYPES Wheel Dia D 6 8 Shaft Height J 431 32 5 31 32 Min Shoe Clearance L 4 7 8 5 29 32 Brake Wheel Offset 3 1 8 3 1 8 Hydraulic cylinders include 1 2 20 thds mating with F 10160 hydraulic hose and F 17 gasket Hydraulic seals are compatible only with 21B Super Heavy Duty Brake Fluid or its equivalent Figure 1 pes Last 01 15 A 29 DIMENSIONS 10 x 4 Type H HM And S Brakes All Dimension in Inches Dimensions common to all 10x4 size brakes Figure 1 A B 8 3 4 1 4 10 7 8 J L 7 9 10 3 1 8 18 1 2 8 3 16 O Brake wheel offset is based on standard Brake wheels Type H brake assembly Fig 2 hydraulically applied by brake cylinder supplied separately Normally use J7905 cylinder for one brake manual systems use J23437 cylinder for two brake manual systems See system specifications for cylinders used on Air Hydraulic systems OVERALL MAX ASSY heen WIDTH HEIGHT WT NO X Y LBS J2926 19 76 19 76 93 Type HM Brake assembly Fig 3 supplied with J23437 hydraulic brake cylinder and
78. voir full while refilling brake system This step will refill the pressure line from the control cylinder to the HM control unit to the brake actuating cylinder to the FRB reservoir 8 To bleed line from HM control unit to HM releasing cylinder a Open bleeder screw at HM releasing cylinder on brake b Use bleeder hose and glass jar or catch rag and step on brake pedal until clear fluid escapes Close bleeder screw Do not operate bleeder during this step c This dead ended line should now be bled free of air 9 Refill FRB reservoir to within 1 of opening and replace filler cap and gasket 10 Adjust brake per instructions 26 INSTRUCTIONS FOR CONVERTING Type H to Type HM Brake System CONVERTING 10 x 4 BRAKES Install mounting bracket A Brake has three holes in base to mount bracket Replace original top lever arm with new lever arm furnished in brake kit Reinstall pin with existing spring hooks new yoke pin and link assembly and new hydraulic actuating cylinder Attach bottom of hydraulic actuating cylinder to brake shoe with pin E Reinstall adjusting nut A but do not tighten Thread tubular push rod on HM releasing cylinder into yoke Do not tighten yoke until brake is read justed Attach bottom of HM releasing cylinder to bracket with J 9670 pin provided Insert cotter pins in the three pins and reinstall return springs Brake is now reassembled It must be
79. ype HM actuator Brake is set for parking when parts are in this position 19 SERVICE INSTRUCTIONS 10 x 4 14 x 6 and 18 x 8 Type HM Brakes Except for an added spring applied hydraulic released HM parking cylinder type HM brakes identical to type H hydraulic applied brakes Type HM brakes are adjusted in the same way as type H brakes However it is essential that the HM parking cylinder be kept fully released and that 010 clearance exist at the top of the HM cylinder see illustration during the entire adjustment procedure Replacement of the brake shoes and service of the self centering mechanism of the hydraulic brake cylinder is the same as for the type H brake SERVICING THE HM PARK RELEASE CYLINDER The HM park release cylinder applies the brake with heavy spring force that is held released by continued application of hydraulic pressure After continued use the hydraulic seals wear and the parking cylinder must be removed for service or replacement To remove the HM parking cylinder first disconnect and temporarily cap the hydraulic line at the brake hose Then loosen the adjusting nut 16 until the fully extended HM cylinder is unable to apply force against the top brake arm Now remove the bottom mounting pin The 14 and 18 HM cylinders can be removed by slipping the piston rod out of the tubular push rod The 10 HM cylinders must be separated by unthreading the piston rod guide out of the rod

Type H & HM Brakes Installation, Dimensions and Service Manual

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Type H &amp; HM Brakes Installation, Dimensions and Service Manual

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Type H & HM Brakes Installation, Dimensions and Service Manual