Stearns Nail Gun 1 048 151 User Manual

P/N 8-078-924-06  
effective 2/23/04  
®
Spring-Set Disc Brakes  
Installation and Service Instructions  
for 48,100 Series Brakes (rev. A)  
(Models 1-048-151, 1-048-161 and 1-048-171)  
Figure 1  
4. Be careful when touching the exterior  
of an operating brake. Allow sufficient  
time for brake to cool before  
disassembly. Surfaces may be hot  
familiar with the construction and  
operation of the brake.  
Important  
Please read these instructions carefully  
before installing, operating, or servicing  
your Stearns brake. Failure to comply with  
8. For proper performance and operation,  
only genuine Stearns parts should be  
used for repairs and replacements.  
enough to be painful or cause injury.  
these instructions could cause injury to  
5. Do not operate brake with housing  
removed. All moving parts should be  
guarded.  
personnel and/or damage to property if  
the brake is installed or operated  
incorrectly. For definition of limited  
warranty/liability, contact Rexnord  
Industries, Inc., Stearns Division,  
5150 S International Drive.,  
General Description  
The 48,100 series is a spring-set,  
electrically released disc brake for  
controlled stopping and holding of a load.  
It has a single-phase solenoid coil for  
operation on alternating current only. The  
nominal static torque is factory set.  
6. After usage, the brake interior will  
contain burnt and degraded friction  
material dust. This dust must be  
removed before servicing or adjusting  
the brake.  
Cudahy, WI 53110, (414) 272-1100.  
Caution  
Construction  
DO NOT BLOW OFF DUST using an  
air hose. It is important to avoid  
dispersing dust into the air or inhaling it,  
as this may be dangerous to your  
health.  
1. Installation and servicing must be made  
in compliance with all local safety  
codes including Occupational Safety  
and Health Act (OSHA). All wiring and  
electrical connections must comply with  
the National Electric Code (NEC) and  
local electric codes in effect.  
The 48,100 series brake utilizes one  
composition friction disc driven by a metal  
hub that is fastened to the motor shaft.  
Manual release with automatic electrical  
reset is provided. Splined hub and friction  
disc is standard. Only open enclosure is  
available.  
a) Wear a filtered mask or a respirator  
while removing dust from the inside  
of a brake.  
2. Do not install the brake in atmospheres  
containing explosive gases or dusts,  
corrosive substances, water, oil or dust.  
Operation  
When brake is properly wired, starting the  
motor will energize the solenoid and  
compress the pressure spring. This action  
removes the force against the stationary  
plate and friction disc and allows the disc  
to rotate freely. Stopping the motor will de-  
energize the solenoid and restores  
b) Use a vacuum cleaner or a soft  
brush to remove dust from the brake.  
When brushing, avoid causing the  
dust to become airborne. Collect the  
dust in a container, such as a bag,  
which can be sealed off.  
3. To prevent an electrical hazard,  
disconnect power source before  
working on the brake. If power  
disconnect point is out of sight, lock  
disconnect in the off position and tag to  
prevent accidental application of power.  
7. Installation and servicing should be  
performed only by qualified personnel  
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personnel or damage to equipment  
before any disassembly of the brake is  
attempted or before the manual release  
lever is operated on the brake.  
the screws and slide entire brake off  
motor and hub.  
wires positioned as before. Install  
plunger guide(s) in reverse order of (4).  
3. Remove housing support nut (19) and  
solenoid mounting nut (19) from one  
side of the solenoid mount. Slide  
carriage bolt (sA) out the backside of  
the endplate (2). Remove solenoid  
spacer (3C) and shock pad (3G).  
5A. For solenoid assembly replacement,  
remove plunger screw (9) and plunger  
nut (9B). Install new plunger (29A)  
with new plunger screw and nut.  
2. Observe all cautions listed at the  
beginning of this manual before  
attempting to service brake.  
6. Reassemble brake in reverse order of  
Steps 1, 2 and 3. Tighten solenoid  
mounting nuts (19) to 15 lb-in of torque  
to compress the shock pad (3G).  
3. Remove housing screws (15) and  
housing (7) or (7A).  
4. Slide old friction disc out the side of the  
brake assembly.  
Wear adjustment  
5. Insert new friction disc between  
endplate (2) and stationary plate (5).  
Reassemble brake in reverse order of  
Steps 2 & 3. Tighten the solenoid  
mounting nut (19) to 15 lb-in to  
compress the shock pad (3G).  
Note: If solenoid buzz is noted, readjust  
solenoid mounting nut (19) to “tune out”  
the buzz.  
1. Normal friction disc wear will cause  
solenoid air gap to become larger from  
the original set 1/8” air gap. An  
increase in stopping time and a slight  
reduction in torque will consequently  
occur. See Figure 6.  
7. Reposition the housing support hot (19)  
165" from the top of the housing bolt.  
8. Replace housing.  
Note: If solenoid buzz is noted, readjust  
solenoid mounting nut (19) to “tune out”  
the buzz.  
2. When the solenoid air gap increases to  
1/4”, the brake must be adjusted. The  
gap is measured between the mating  
ground surfaces of the solenoid frame  
and solenoid plunger.  
9. Restore power to brake.  
VI. Troubleshooting  
A. If brake does not stop shaft properly  
or overheats, check the following:  
6. See Wear adjustment. It may be  
necessary to turn wear adjust screw  
(10) CCW for clearance.  
Note: To measure air gap on brakes  
mounted vertical above motor, push  
plunger into frame until spring pressure is  
felt. Holding firmly in this position,  
measure air gap between mating (ground)  
surfaces on solenoid frame and solenoid  
plunger. If adjustment is made, check air  
gap by again holding plunger as directed.  
7. Repostion the housing support hot (19)  
165" from the top of the housing bolt.  
1. Is brake manually released rather than  
electrically released while motor is  
running?  
8. Replace housing.  
9. Restore power to brake.  
2. Is friction disc excessively worn,  
charred, or broken?  
Coil or solenoid assembly replacement  
1. Disconnect coil (12C) from circuit.  
3. Has hub become loose and shifted on  
shaft?  
3. To decrease air gap, turn the wear  
adjusting screw (10) clockwise until an  
air gap of 1/8” minimum is attained.  
To increase gap, turn screw  
2. Cut the plastic wire tie holding the coil  
leads onto the housing stud (18).  
4. Is hub clean, and does friction disc  
slide freely?  
3. Remove housing and solenoid  
mounting nuts (19) and lift solenoid /  
coil assembly off the mounting bolts.  
5. Does stationary plate slide freely on  
guide pins?  
counterclockwise.  
4. After adjustment, push in plunger and  
allow it to snap out. Recheck air gap,  
see Note.  
6. Are pressure springs improperly  
assembled, or broken?  
4. Remove plunger guide (82A) by lifting  
out of top of solenoid frame. Coil (12C)  
has a lock tab, located at top of coil  
opposite lead wire side, which is  
pressed against coil and coil is slid  
sideways from solenoid frame.  
7. Is solenoid air gap adjusted correctly?  
See Wear Adjustment.  
5. Replace friction disc when wear area is  
one half original disc thickness of 3/16”.  
8. Does solenoid linkage move freely?  
9. Is voltage supply at coil correct?  
Friction disc replacement  
5. For coil replacement, inspect and clean  
solenoid assembly. Install the new coil  
in original solenoid frame or original  
coil in new solenoid frame with the lead  
1. Disconnect power source to brake.  
10. Are controls which govern start or  
stop of braking cycle operating  
properly?  
2. Align friction disc (4) notches with the  
two 1/4” flat head cap screws. Remove  
Figure 6  
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11. Is brake coil energized at same time  
or prior to energization of motor, and  
de-energized at same time or after  
de-energization of motor?  
8. Does solenoid linkage move freely?  
9. Check for excessive voltage drop in  
motor line when motor is started.  
Check wire gauge of supply line  
against motor starting current and  
solenoid inrush current. Measure  
voltage drop at solenoid coil leads  
during maximum inrush current  
condition. To accomplish this, connect  
voltmeter at brake coil. Insert a block of  
wood, or other non-magnetic material,  
between solenoid plunger and frame.  
Block thickness should approximately  
equal solenoid air gap. Energize motor  
and brake simultaneously, take reading  
and immediately shut down. (This is to  
prevent motor, brake, or solenoid burn  
up, since brake will be set during  
procedure.)  
12. Is stopping time more than one  
second (rule of thumb) and/or is  
application more than five stops per  
minute? If so, consult factory. Check  
thermal requirements of load versus  
thermal rating of brake.  
13. Replace friction disc when worn area  
is one half of original thickness of  
3/16”.  
B. If brake hums, solenoid pulls in  
slowly, or coil burns out, check the  
following:  
1. Voltage supply at coil versus coil rating  
and connection.  
C. If disc noise occurs, check:  
2. Is solenoid air gap excessive?  
3. Shading coils may be broken.  
1. If friction disc (4) becomes noisy, check  
stabilizing spring (4A) to be sure it is  
installed.  
4. Plunger guides may be excessively  
worn. Does solenoid plunger rub on  
solenoid frame laminations?  
2. Check that the leaf spring (5A) is  
supporting stationary plate (5). If  
distorted, replace.  
5. Solenoid frame and plunger may be  
excessively worn.  
6. Is solenoid dirty?  
7. Housing studs may have become loose  
causing frame to shift and plunger to  
seat improperly.  
Copyright© 2000 by Rexnord Industries, Inc.  
Rexnord Industries, Inc., Stearns Division, 5150 S. International Drive, Cudahy, Wisconsin 53110  
(414) 272-1100 Fax: (414) 277-4364 www.rexnord.com  
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