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Bricking Machine
Parts Book
Made in America REV G 2015-01
Contact Information
For information regarding the purchase, operation or repair of your product contact Bricking Solutions at:
Toll Free 800.621.7856
Local 360.794.1277
Fax: 360.805.2521
Web: www.BrickingSolutions.com
E-MAIL: info@ BrickingSolutions.com
Domestic Parts: Stacey Rice—[email protected]
International Parts: Heather Soraparu—[email protected]
Printing
Revision F
Revision Log:
A: 2013-08-28: Updated Parts, new content and layout
B: 2013-10-01 Corrected part # HC139 to HC159
C: 2013-12-10 Removed parts AC761 and AC762 page 21
D: 2014-01-17 Corrected part JE210 to CE250
E: 2014-03-20 Added Steel fittings
F: 2014-06-17—Corrected MF447 Lub Filter muffler to AF447
G: 2015-01-20—Corrected page #s
Contents
Master Valve—Avoid heart Failure 3
Lubricator Filter—Avoid Lung Collapse 4
Lubricator Filter 5-6
Master Valve 7-12
Air Cylinders 13-18
Bleeder Parts 19
Spacer Assemblies 20
Hoses 21
Fittings 22
Long Jack 23-27
Shim Driver 31
Castors & Jacks 32
Hardware Sets 33
Tool Box 34
4
Avoid Heart Failure
T he Master Valve and Lubricator-Filter system are the two most important components of our bricking machines. They are what we would call the “Heart” and “Lung.” They
keep the machine breathing and pumping so the brick can be installed safe, fast, and efficiently. Without preventative maintenance and basic repair knowledge, their failure can cause delays in work.
The second step is to know the warning signs and what to troubleshoot. As outlined in our Maintenance and Repair Guide, the reaction of the cylinders is the key. If they extend too slow, you need to check the Master Valve and replace the necessary components. A possible plugged or almost plugged muffler could cause the cylinders to act sluggish. Muffler replacement is recommended rather than attempting to clean them. A pre-outage evaluation and inspection of the Master Valve will eliminate problems before you are in the kiln.
The “HEART” of our machine is a set of two 3-Way Master Valves. Positioned on the down kiln and up kiln center arches, the 3-way air valves allow for rapid advancement up the kiln by engaging or releasing cylinders simultaneously or individually without resetting. Keeping the “HEART” pumping and knowing the signs of a failure will reduce or even eliminate dead time.
The first step is to keep the following replacement parts in stock: Master Valve repair kits (ASM461) A loaded Master Valve body (MV441) A complete Master Valve assembly (ASM465) Having any one of these as a spare part on your inventory shelf will do nothing but save your company lost time if the heart of the system should fail.
5
And/Or Lung Collapse
The “LUNGS” of our bricking machine is the Lubricator-Filter system. Without this system maintaining clean dry air and continual lubrication to the pneumatic system, the life of the bricking machine would be short lived. Keeping those “LUNGS” breathing smoothly and recognizing the signs of a failure shortens the time on the outage time clock.
As with the heart, keep the following replacement parts in stock for a collapse: Check Valve (CV004) (NOTE: the check valve is a safety feature that should not be removed from the
machine Lubricator-Filter system (ASM500)
Take a look at your spare parts and consider these items as essential tools needed. See your maintenance manual for further explanation on how to maintain your lub filter.
6
Lubricator Filter
Bricking Solutions has made a change to our bricking machine’s lubricator / filter system. All assembly part #’s will remain the same for this component, but the “mounting’ will be different. Instead of the 4 hole mount that holds it in place the new system will mount using only the 2 top holes in the mounting bracket. The change from four to two brackets won’t affect the strength of the bracket when in position as the mounting brackets provided on the new system are designed with the change in mind.
The connectors between all parts (Emergency Shut Off / Filter / Regulator / Lubricator / Check Valve) are much stronger and holding performance is greatly improved over the previous system. Another improve-ment is a finger tip operated drip setting. Yes, no more tiny screwdriver needed to set the 2-4 drips per cycle of master valve, now this can be done by hand, setting lubrication flow without any special tool required.
If the ability of getting machine air pressure set within our recommended 90-120 psi becomes unachievable, it may be due to the simple fact that within the filter housing is a “FILTER” and it is possible to see a drop in machine pressure by as much as 20 psi when this filter becomes plugged. If while working with your or a cus-tomer’s machine, where the machine pressure drops of during use, the culprit may simply be a plugged filter.
ASM500 - Lubricator Filter Complete
CHECK VALVE Keeps cylinders from
dropping due to a sudden loss of plant air
AF002 AF508
AF447
AF268 NEW CV004 OT988
7
CV004 Check Valve
Emergency shut off valve
Air regulator Lubricator bowl
Filter bowl AF447 Muffler
AF002 Chicago
fitting
Drops dial
Lubricator Filter Anatomy
LFC001 Long Cover
AF508 Brass Elbow fitting
OT988 Elbow fitting
AF268 Threaded fitting
Please note that some Lubricator Covers will be longer and expand over the entire length. This may require trimming of the cover.
8
Master Valves with steel fittings
Please note that all machines built after January 2014 will have steel fittings
ASM463BS Set up for the Upkiln Arch
ASM463FSSet up for the Downkiln Arch
9
Master Valve Exploded Views
ASM463FS Set up for the Downkiln Arch
ASM463BS Set up for the Upkiln Arch
10
Master Valves
ASM460B Set up for the Upkiln Arch
ASM460F Set up for the Downkiln Arch
ASM463B Set up for the Upkiln Arch
ASM463 Loaded Body for easy replacement
ASM463F Set up for the Downkiln Arch
11
Master Valve Exploded Views
ASM463 Loaded Body for easy replacement
ASM463B Set up for the Upkiln Arch
ASM463F Set up for the Downkiln Arch
12
Master Valve Anatomy
K
O
F
G H
I
L N
P Q R
M
E
T
C D
S
Available for a limited time: Will be phasing out to quick disconnects
B
A
V
U
13
PART NO. DESCRIPTION PART NO. DESCRIPTION
L AF446 Muffler 1/4"
A MV430 Valve Base M AF450 Brass Plug 1/2”
B MV441 Valve Body N MK443 Handle
C MV449 Small O -Rings O MV442 End Cap
D MV445 Center Seal O-Rings P HW075 Cap Screws - 5/8" x 10/32"
E HG742 Handle guard Q HW076 Cap Screws - 1" x 10/32"
F AF103 Elbow Quick Disconnect Fitting R HW077 Cap Screws - 2" x 10/32"
G AF139 Straight Quick Disconnect Fitting S CF001 Barbed Fittings (phasing out)
H OT868 Steel Fitting 1168x6x8 T AF739 1/2” Quick Disconnect
I OT888 Steel Fitting 1168x8x8 U AF103S Steel Elbow Quick Disconnect Fitting
K MV444 Spool V AF139S Steel Straight Quick Disconnect Fitting
PART NO. QUANTITY DESCRIPTION
H. AF446 2 MUFFLER, SINTERED
E. MV445 6 CENTER SEALS
D. MV449 3 GASKET
H
E
D
Master Valve Anatomy
For maintenance and trouble shooting issues with your master valve please see your maintenance manual for further instructions.
ASM461 Master Valve Repair Kit
14
Air Cylinders
AC4058 8” cylinder with steel quick disconnects
ASM4056S 6” cylinder assembly with steel quick disconnects AC4056S
6” cylinder with steel quick disconnects
ASM4058S 8” cylinder assembly with steel quick disconnects
Please note that all machines built after January 2014 will have steel fittings
15
Air Cylinder Exploded Views
ASM4058S
ASM4056S
1—AC48 8” 40mm Cylinder 1—CR003 Cylinder Rotor 1—CS004 Cylinder Spring 1—CP005 Cylinder Pin 4—AF103S Cylinder Steel Fittings 1—CW002 Cylinder Washer 1—CS001 Cylinder Shaft 1—BCB001 Cylinder Bumper 1—CE250 Cylinder E clip 1—CR008 Cylinder Guide Rod 1—MB001 Cylinder Bracket 1—HW023 Cylinder Cap Screw 1—MB002 Cylinder Bushing
ASM4058 Cylinder Complete: Comes with the following:
2-HW075 5/8” cap screws (top) 2-HW076 1” cap screws (bottom) 2-HW010 Spacer (bottom)
Mounting Hardware
1—AC46 6” 40mm Cylinder 1—CR003 Cylinder Rotor 1—CS004 Cylinder Spring 1—CP005 Cylinder Pin 4—AF103S Cylinder Steel Fittings 1—CW002 Cylinder Washer 1—CS001 Cylinder Shaft 1—BCB001 Cylinder Bumper 1—CE250 Cylinder E clip 1—CR006 Cylinder Guide Rod 1—MB001 Cylinder Bracket 1—HW023 Cylinder Cap Screw 1—MB002 Cylinder Bushing
ASM4056Cylinder Complete: Comes with the following:
2-HW075 5/8” cap screws (top) 2-HW076 1” cap screws (bottom) 2-HW010 Spacer (bottom)
Mounting Hardware
16
Air Cylinders
ASM4058 8” cylinder assembly
with quick disconnects
ASM4068 8” cylinder assembly with barbed fittings
AC4058 8” cylinder with
quick disconnects
AC4068 8” cylinder with barbed fittings
ASM4056 6” cylinder assembly
with quick disconnects
ASM4066 6” cylinder assembly with barbed fittings
AC4056 6” cylinder with
quick disconnects
AC4066 6” cylinder with barbed fittings
Fittings are being phased out, quantities are limited
Fittings are being phased out, quantities are limited
17
Air Cylinder Exploded Views
ASM4058
ASM4056
1—AC48 8” 40mm Cylinder 1—CR003 Cylinder Rotor 1—CS004 Cylinder Spring 1—CP005 Cylinder Pin 4—AF103 Cylinder Fittings 1—CW002 Cylinder Washer 1—CS001 Cylinder Shaft 1—BCB001 Cylinder Bumper 1—CE250 Cylinder E clip 1—CR008 Cylinder Guide Rod 1—MB001 Cylinder Bracket 1—HW023 Cylinder Cap Screw 1—MB002 Cylinder Bushing
ASM4058 Cylinder Complete: Comes with the following:
2-HW075 5/8” cap screws (top) 2-HW076 1” cap screws (bottom) 2-HW010 Spacer (bottom)
Mounting Hardware
1—AC46 6” 40mm Cylinder 1—CR003 Cylinder Rotor 1—CS004 Cylinder Spring 1—CP005 Cylinder Pin 4—AF103 Cylinder Fittings 1—CW002 Cylinder Washer 1—CS001 Cylinder Shaft 1—BCB001 Cylinder Bumper 1—CE250 Cylinder E clip 1—CR006 Cylinder Guide Rod 1—MB001 Cylinder Bracket 1—HW023 Cylinder Cap Screw 1—MB002 Cylinder Bushing
ASM4056Cylinder Complete: Comes with the following:
2-HW075 5/8” cap screws (top) 2-HW076 1” cap screws (bottom) 2-HW010 Spacer (bottom)
Mounting Hardware
18
Air Cylinders
CB206 6” Cylinder Change Over Kit CB208 8” Cylinder Change over Kit
ASM453
Cylinder Maintenance Note: When using mud or other adhesives it is imperative to maintain clean cylinders. When mud gets on the shaft and hardens, it will break down the top seal. This seal can not be replaced. You will have to replace the whole cylinder. We suggest using a silicone spray to keep the mud from sticking to the shaft and wipe down accord-ing to the mud’s drying time. The faster the dry time the more often you will need to wipe down the shafts and re-spray with silicone. You can also cover the arches with plastic to protect the cylinders from unwanted build up of mud or other debris.
For those of you on a budget and can not upgrade your equipment all at once, here is a simple way to upgrade to the
Quick Disconnect fittings. As you might have read the CF001 Ribbed Fittings will be discontinued and only availa-
ble for a limited time. When you purchase new cylinders, this kit will allow you to order the current style of cylin-
ders and add them in between to upgrade your equipment.
1-CH006 Cylinder Handle 1-CS001 Cylinder Shaft 2-CW002 Cylinder Washer 1-CR003 Cylinder Rotor 1-CS004 Cylinder Spring 1-CP005 Cylinder pin
Air Cylinder Repair Kit ASM453
19
A
PART # DESCRIPTION
A. CE250 Cylinder E Clip
B. CH006 Cylinder Handle
C. CP005 Cylinder Pin
D. MB001 Cylinder Bracket
E. CR003 Cylinder Rotor
F. CS001 Cylinder Shaft
G CR008 Cylinder 8” Rod
H CR006 Cylinder 6” Rod
I CF001 3/8 Ribbed Fitting
J CW002 Cylinder Washer
K CS004 Cylinder Spring
L BCB001 Cylinder Bumper
M AF103 3/8 Elbow Quick Disconnect Fitting
N MB002 Cylinder Bushing
O AT009 Clamp Style Spring Depressor Tool
P AT007 Spring Depressor Tool
Q AF103S 3/8 Elbow Steel Quick Disconnect Fitting
B
C
D
E
I
N
K
J
H G
L
P
F
Cylinder Parts
M
O 2-HW075 10-32 x 5/8 Cap Screw 2-HW010 Spacers 2-HW076 10-32 x 1 Cap Screw
Installation Hardware:
Q
Fittings are being phased out, quantities
are limited
20
Bleeder Parts
PART # QTY DESCRIPTION
A AF139 2 3/8 straight Quick Disconnect
B R600-2 2 Bleeder Stem
C OR200 2 O-Ring
D CB504 1 Bleeder Block
A B
C
D
ASM207 Bleeder Assembly
21
Spacer Assemblies
PART # DESCRIPTION
A SA340 3/4 INCH FLANGE BEARING
B. SA100 1 INCH FLANGE BEARING
C. AT439 ANTI-TURN LEVER
D. AB438 ALUMINUM BOLT
E SW729 SPEED WRENCH
A
D C
B
NOTE: It is important to keep the aluminum bolts free from damage and debris build up. Also keep the bearings
well greased to keep them moving freely. A build up of dirty grease will damage the bearings. SEE Maintenance
Manual for proper care.
ASM450 Spacer Assembly
E
3- HW049 1/2 x 1 Tapped Hex Bolt 1- HW034 1/2 x 3 Tapped Hex Bolt 4- HW020 1/2 Split Washer
Standard Installation hardware
3– M14x30mm Tapped Hex Bolts 1– M14x60mm Tapped Hex Bolts 4– M14 Split Washers
Metric Installation Hardware (From July 2013)
Please note that the new spacer assemblies have metric hardware. You will need to drill out the holes on your arch panels to accommodate the metric hardware (M14)
22
Hoses
PART # DESCRIPTION
A. AH809 1/2” Blue Poly Hose
B. AH004 3/8” Blue Poly Hose
C. AH006 3/8” Red Poly Hose
D. AH001 1/4” Blue Ploy Hose
E. AH002 1/4” Red Poly Hose
F. AH003 1/4” Yellow Poly Hose
G AH732 3/8" Black Weatherhead Hose
H AH733 1/2" Blue Weatherhead Hose
I AH734 5/8" Blue Weatherhead Hose
J AH735 3/4" Blue Weatherhead Hose
K AH745 Long Jack Finger Tip Supply Hose (2ft)
L ASM719 10 Ton High Pressure Hose (6ft)
M ASM476 Foot Treadle Long Jack Supply Hose (6ft)
N CH022 Crossover Hose (3ft)
O ASM830A Long Jack Control and Pressure Hose (6ft)
P AF902 Hose Welting (by the foot)
Q AW384 Shim Driver Air Whip (10ft)
R HH801 Long Jack Gauge Hose (2ft)
S ASM801 Long Jack Gauge Hose with Gauge (2ft)
T ASM718 Foot Trundle 10 Ton HP Hose (10Ft)
U AH475 Long Jack Finger Tip Supply Hose (2ft)
A
B
C
D
E
F
G
H
I
J
K
N
P Q
S
R
T
L
U
O
M
23
Fittings
PART # DESCRIPTION
A AF739 Quick Disconnect 1/2”
B AF018 Quick Disconnect Nipple 1/2”
C AF074 1/8 x 1/4 Straight Quick Disconnect
D AF103 3/8 x 3/8 Elbow Quick Disconnect
E AF138 1/8 x 1/4 Swivel Elbow Quick Disconnect
F AF139 3/8 x 3/8 Quick Disconnect
G AF140 1/4 x 1/4 Elbow Quick Disconnect
H AF268 1/2 Brass Closed Pipe Nipple
I AF504 1/4Brass Pipe Street Tee
J AF506 3750 x 8 x 8 Brass Pipe Street Tee
K AF508 3350 x 8 Brass 45 Degree Street Elbow
L AF544 C5255 x 4 x Steel Female Connector
M AF734 1/4x 1/8 Socket Head Quick Disconnect
N AH604 3/8 NPTF Regular Flow Coupler
O OT868 1168 x 6 x 8 Steel Fitting
P OT888 1168 x 8 x 8 Steel Fitting
Q AF450 1/2 Brass Plug
R CF001 3/8 Ribbed Fitting
S OT988 1169 x 8 x 8S Steel Elbow Fitting
T AF002 Chicago Fitting
U CH604 High Flow steel coupler
W AF103S 3/8 Elbow Steel Quick Disconnect Fitting
X AF139S Steel Straight Quick Disconnect Fitting
C
A
B
N
D
E
F
G H
I J
K
M
L
O P Q R
S T U
X
W
24
Long Jack Assembly
Old phased out Long Jack (parts are still available)
New style Long Jack
Foot Trundle Long Jack
ASM790 Foot Trundle Long Jack
ASM800 Old Style Long Jack
ASM800A New Style Long Jack
25
Long Jack Assembly Exploded View
ASM800A New Style Long Jack
AP132
HSS36
HC159
AC760
GA300
AH475
ASM801
ASM830A
State whether you have a Regular or High Flow coupler when ordering HC159
ASM721
ASM723
26
ASM790 Foot Trundle Long Jack
Long Jack Assembly
Exploded View
HC159
ASM476
GA300
PA133
ASM801
ASM718
27
ASM800 Old Style Long Jack
GA300
AH745
ASM801
ASM830
AP133
HSS36
HC159
ASM723
ASM724
ASM727
CJ002
HW015
Long Jack Assembly
Exploded View
28
Long Jack Parts
A
E
D
K
L
N
O
G
M
H
PART # DESCRIPTION
A. AP133 (old Style) Air Pump
B AP132 (New Style) Air Pump (As of 2013)
C PA133 Foot Trundle Air pump
D PA134 Foot Bracket for Foot Trundle pump
E HC159 10 Ton Cylinder for Long Jack (regular or high flow coupler?)
G HSS36 Hose Clamp
H ASM760 Swivel Foot Assembly
K ASM721 Extension Kit (9”, 19”, 17”, 15”)
L CJ002 Long Jack Block Cover
M HW015 Hardware for Cover
N GA300 Long Jack Gauge Block
O A13 Long Jack Threaded Saddle
C
B
29
Notes
30
PART NO. QUANTITY DESCRIPTION
A LJ804 1 Release Block #3
B LJ805 2 Release Block C Clip
C LJ806 1 Release Block Piston
D LJ119 1 Release Block O-Ring
E AF138 1 1/8 x 1/4 Swivel Elbow Quick Disconnect
F HW076 2 10-32 x 1 Cap Screw
Long Jack Block
Assemblies
PART NO. QUANTITY DESCRIPTION
A LJ803 1 Set Block #2
B AF074 1 1/8 x 1/4 Straight Quick Disconnect
C LJ115 1 Set Block O-Ring
D LJ802 1 Set Block Piston
E HW014 2 Spring Pin 1/8 x 1 1/4
F LJ001 1 Set Block Return Spring
G JO870 1 Set Block Retainer clip
PART NO. QUANTITY DESCRIPTION
A LJ101 1 Control Block #1
B LJ903 2 Control Block Valve
C LJ904 2 Control Block Cap
D JO680 2 Control Block Retainer Clip
E AF074 2 1/8” x 1/4” Straight Quick Disconnect
F AF734 1 1/8” x 1/4” Socket Head Quick Disconnect
ASM727 Release Block Assembly
ASM724 Set Block Assembly
ASM723 Control Block Assembly
31
Long Jack Block
Exploded View
32
Shim Drivers
Shim Driver Shanks (USN RD & USN HEX RETAINER TYPE)
PART NO. DESCRIPTION
A. SS427 USN HEX-OVAL COLLAR
B. SS425 USN RD-OVAL COLLAR C. SS426 USN HEX-ROUND COLLAR
D. SS424 USN RD-ROUND COLLAR
PART NO. QUANTITY DESCRIPTION
A AH394 1 Shim Driver Gun
B ATC001 1 Collar Spring
C AH301 1 Collar
D AW384 1 Air Whip Hose
E AC733 2 Shim Driver Heads
F SS0424 4 USN Round Round Shanks
A B
C
D
E
F
A
B
C
D
ASM900 Shim Driver Assembly
33
Castors / Jacks
6000 lb OSCILATING CASTORS
As of January 2008 all machines will have color coded wheels. (Most of these castors are interchangeable with the old style)
MCS010 Machine Castor Green
MCS030 Machine Castor Blue MCS040 Machine Castor Yellow
MCS020 Machine Castor Red
All Castors have an integrated
kick brake.
HJ317
2 Ton Hydraulic Bottle Jack
HJ318
3 Ton Hydraulic Jack
Specify if you have Knuckle or Flat Bottom?
34
Hardware Sets
Hardware sets are now available for all machine models. If you have the machine number or the year it was
purchased we can help you be better prepared for your next outage. The Hardware sets come in Metric for
newer machines (2013 and up) and Standard Hardware for older machines (1966-2012).
If you do not know what year your equipment was purchased or the machine number, Here is where you can
locate the numbers. The first two number correspond to the year it was manufactured.
On the frames
Or on the Arch
Machine Number Location
35
ASM174S Standard Tool Box
1 8 ADJ. WRENCH
1 RAWHIDE MALLET
1 SET OF 2 REPLACEMENT FACES
1 6” SLIP JOINT PLIERS
1 1/8” SCREWDRIVER
1 1/4” SCREWDRIVER
1 3/16” SCREWDRIVER
1 9/16” WRENCH
1 3/4” WRENCH
1 15/16” WRENCH
1 7/16” WRENCH
1 ALIGNMENT PIN
3 1/8” HEX KEY
3 5/32” HEX KEY
1 SPEED WRENCH
1 TOOL BOX
LEATHER MALLETS
PART # DESCRIPTION
A. TH310 RAWHIDE MALLET
B. TH210 SET OF REPLACEMENT FACES
C. TH350 HANDLE
Tool Box
ASM174M Metric Tool Box (shown)
1 8 ADJ. WRENCH
1 RAWHIDE MALLET
1 SET OF 2 REPLACEMENT FACES
1 6” SLIP JOINT PLIERS
1 1/8” SCREWDRIVER
1 1/4” SCREWDRIVER
1 3/16” SCREWDRIVER
1 #13 WRENCH
1 #19 WRENCH
1 #22 WRENCH
1 #24 WRENCH
1 ALIGNMENT PIN
3 1/8” HEX KEY
3 5/32” HEX KEY
1 SPEED WRENCH
1 TOOL BOX
B
A
C
Circle of Refractory Maintenance
CONTACT US AT 360-794-1277 TO REQUEST AN ONSITE PRE-OUTAGE MACHINE EVALUATION AND SERVICE