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7/26/2019 Brake Disc Replacement Storyboard
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SEW Maintenance Series
Brake Disc Replacement
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Product Training
Brake Disc Replacement 2
Objectives
After studying the contained information you will be able to accomplish thefollowing:
– Perform the removal of the existing brake disc
– Perform the installation of the replacement brake disc
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Product Training
Brake Disc Replacement 3
Tools and Materials
What you will need:
- 1 10mm Nut-driver
- mm u - r ver
- 1 Medium Flat Tip Screwdriver
- 1 External Snapring Pliers
- 1 Metric Feeler Gage Pack
- 1 Dead-blow Hammer
- 1 Cutting Pliers
- 1 Metric Dial-calipers- 1 Replacement Brake Disc
- 1 Roll of Electrical Tape
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Product Training
Brake Disc Replacement 4
Safety
Always follow the proper lockout/tagout procedures.
Make sure to use the proper safety equipment at all times.
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Product Training
Brake Disc Replacement 5
Step 1
Disconnect all power sources to the motor.
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Product Training
Brake Disc Replacement 6
Step 2
Remove the 4 small screws that hold the motor fan guard in place with the 8mm nut-driver.
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P d T i i
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Product Training
Brake Disc Replacement 7
Step 3
Remove the fan guard.
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P d t T i i
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Product Training
Brake Disc Replacement 8
Step 4
Using the external snapring pliers, remove the snapring that holds the fan secure.
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Z-Fan Instructions
P d t T i i
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Product Training
Brake Disc Replacement 9
Cast Iron Z-Fan Removal Instructions
1 2Use pullers and air wrench
to remove the Z-Fan
Ensure proper
placement of puller
blades
-
from the motor
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Brake Disc Replacement 10
Step 5
With the medium sized flat-tip screwdriver, use a prying action to remove the motor fan, using caution
to not damage the fan.
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Brake Disc Replacement 11
Step 6
Remove the fan key using the pair of cutting pliers.
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Brake Disc Replacement 12
Step 7
Using the flat tip screw driver, remove the 2 brake sealing band clamps (if applicable).
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Product Training
Brake Disc Replacement 13
Step 8
Remove the brake sealing band with the flat tip screwdriver, using caution not to damage the sealing
band.
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Product Training
Brake Disc Replacement 14
Step 9
Using the 10mm nut-driver, remove the 3 retaining nuts on the brake housing.
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Product Training
Brake Disc Replacement 15
Step 10
Wrap the fan end of the rotor with electrical tape to protect the brake seal from the keyway.
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Brake Disc Replacement 16
Step 11
Carefully remove the brake assembly from the motor.
Caution!
Make sure that there is
enough slack in the
brake wires.
With some applications,
disconnecting the wires
may be necessary to
provide more slack.
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Brake Disc Replacement 17
Step 12
Remove the old brake disc.
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Brake Disc Replacement 18
Step 13
Using the metric dial-calipers, measure the old brake disc to determine its current thickness.
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Brake Disc Replacement 19
Step 14
To determine the proper brake disc thickness, please refer to the second chart on page 4 of the Motor
and Brakemotor Operating Instructions (Document # 09 793 77).
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Brake Disc Replacement 20
Step 15
If the thickness of the current brake disc is within the specified tolerance and the disc is undamaged,
reinstall it. Otherwise, replace it with a new one.
Caution!
Verify that the brake
disc splines are
aligned with the brake
carrier splines.
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Brake Disc Replacement 21
Step 16
Reinstall the brake assembly, sliding it over the motor rotor and studs.
Caution!
Verify that the brake
wire sleeve is ro erl
inserted into the relief
area for wiring.
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Brake Disc Replacement 22
Step 17
Remove the protective tape from the fan end of the motor rotor.
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Brake Disc Replacement 23
Step 18
Before adjusting the air-gap, determine its proper value. Refer to the first chart on page 4 of the Motor
and Brakemotor Operating Instructions (Document # 09 793 77).
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Brake Disc Replacement 24
Step 19
Using the metric feeler gage and the 10mm nut driver, tighten or loosen the three retaining nuts, until
you have arrived at the proper air-gap.
Adjustments to the air-gap
must be made evenly.
Adjust each nut and recheck
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adjustment once the final gap
has been set.
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Brake Disc Replacement 25
Step 20
Any adjustment to the air gap will affect the play in the manual release.
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Brake Disc Replacement 26
Step 21
To determine the correct free play (clearance), please refer to the next to last paragraph on page 4 of
the Motor and Brakemotor Operating Instructions (Document # 09 793 77).
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Brake Disc Replacement 27
Step 22
Using the 8mm nut driver and the metric feeler gage, adjust the manual release arm until the proper
amount of play is achieved.
Verify the free play on the release arm.
adjust the locking nuts as needed to achieve1.5 – 2.0 mm gap. (S Dimension)
Caution!There must always be
clearance on the lever.
Note: The brake release
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change the brake’s torquesetting.
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Brake Disc Replacement 28
Step 23
Using the flat tip screwdriver, install the rubber brake band, using caution not to damage the band.
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Brake Disc Replacement 29
Step 24
Re-install the 2 brake band clamps using the flat tip screwdriver.
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Product Training
B k Di R l t
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Brake Disc Replacement 30
Step 25
Insert the fan key and lightly tap it into place using the dead-blow hammer or rubber hammer.
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Product Training
B k Di R l t 31
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Brake Disc Replacement 31
Step 26
Re-install the fan.
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Z-Fan Instructions
Product Training
B k Di R l t 32
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Brake Disc Replacement 32
Cast Iron Z-Fan Installation Instructions
Heat the Z-Fan in an oven toapproximately 250 degrees
Fahrenheit1 2 Apply a light coat of oil to the
rotor end
Install the Z-fan3
Install the Circlip
4
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Product Training
Brake Disc Replacement 33
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Brake Disc Replacement 33
Step 27
Reinstall the snapring using the snapring pliers.
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Brake Disc Replacement 34
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Brake Disc Replacement 34
Step 28
Re-install the motor fan guard, using the 8mm nut driver.
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Product Training
Brake Disc Replacement 35
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