Parts Book. Bricking Machine. Made in America REV G

Transcription

1 Parts Book Bricking Machine Made in America REV G

2 Contact Information For information regarding the purchase, operation or repair of your product contact Bricking Solutions at: Toll Free Local Fax: Web: BrickingSolutions.com Domestic Parts: Stacey Rice International Parts: Heather Soraparu Printing Revision F Revision Log: A: : Updated Parts, new content and layout B: Corrected part # HC139 to HC159 C: Removed parts AC761 and AC762 page 21 D: Corrected part JE210 to CE250 E: Added Steel fittings F: Corrected MF447 Lub Filter muffler to AF447 G: Corrected page #s

3 Contents Master Valve Avoid heart Failure 3 Lubricator Filter Avoid Lung Collapse 4 Lubricator Filter 5-6 Master Valve 7-12 Air Cylinders Bleeder Parts 19 Spacer Assemblies 20 Hoses 21 Fittings 22 Long Jack 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 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. 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. 4

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. 5

6 Lubricator Filter ASM500 - Lubricator Filter Complete 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 improvement 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 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 customer s machine, where the machine pressure drops of during use, the culprit may simply be a plugged filter. AF002 AF508 AF268 NEW CV004 OT988 AF447 CHECK VALVE Keeps cylinders from dropping due to a sudden loss of plant air 6

7 Lubricator Filter Anatomy AF508 Brass Elbow fitting Emergency shut off valve LFC001 Long Cover Drops dial AF268 Threaded fitting OT988 Elbow fitting AF002 Chicago fitting AF447 Muffler Filter bowl Air regulator Lubricator bowl CV004 Check Valve Please note that some Lubricator Covers will be longer and expand over the entire length. This may require trimming of the cover. 7

8 Master Valves with steel fittings Please note that all machines built after January 2014 will have steel fittings ASM463FSSet up for the Downkiln Arch ASM463BS Set up for the Upkiln Arch 8

9 Master Valve Exploded Views ASM463BS Set up for the Upkiln Arch ASM463FS Set up for the Downkiln Arch 9

10 Master Valves ASM463F Set up for the Downkiln Arch ASM463B Set up for the Upkiln Arch ASM463 Loaded Body for easy replacement ASM460F Set up for the Downkiln Arch ASM460B Set up for the Upkiln Arch 10

11 Master Valve Exploded Views ASM463B Set up for the Upkiln Arch ASM463 Loaded Body for easy replacement ASM463F Set up for the Downkiln Arch 11

12 Master Valve Anatomy A I K L N M R Q P O B S C D Available for a limited time: Will be phasing out to quick disconnects T E F U G H V 12

13 Master Valve Anatomy 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 ASM461 Master Valve Repair Kit E H PART NO. QUANTITY DESCRIPTION H. AF446 2 MUFFLER, SINTERED E. MV445 6 CENTER SEALS D. MV449 3 GASKET D For maintenance and trouble shooting issues with your master valve please see your maintenance manual for further instructions. 13

14 Air Cylinders Please note that all machines built after January 2014 will have steel fittings ASM4058S 8 cylinder assembly with steel quick disconnects AC cylinder with steel quick disconnects ASM4056S 6 cylinder assembly with steel quick disconnects AC4056S 6 cylinder with steel quick disconnects 14

15 Air Cylinder Exploded Views ASM4058 Cylinder Complete: Comes with the following: 1 AC mm 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 Mounting Hardware 2-HW075 5/8 cap screws (top) 2-HW076 1 cap screws (bottom) 2-HW010 Spacer (bottom) ASM4058S ASM4056Cylinder Complete: Comes with the following: 1 AC mm 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 ASM4056S Mounting Hardware 2-HW075 5/8 cap screws (top) 2-HW076 1 cap screws (bottom) 2-HW010 Spacer (bottom) 15

16 Air Cylinders ASM cylinder assembly with quick disconnects ASM cylinder assembly with barbed fittings Fittings are being phased out, quantities are limited AC cylinder with quick disconnects AC cylinder with barbed fittings ASM cylinder assembly with quick disconnects ASM cylinder assembly with barbed fittings AC cylinder with quick disconnects AC cylinder with barbed fittings 16 Fittings are being phased out, quantities are limited

17 Air Cylinder Exploded Views ASM4058 Cylinder Complete: Comes with the following: 1 AC mm 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 Mounting Hardware 2-HW075 5/8 cap screws (top) 2-HW076 1 cap screws (bottom) 2-HW010 Spacer (bottom) ASM4058 ASM4056Cylinder Complete: Comes with the following: 1 AC mm 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 ASM4056 Mounting Hardware 2-HW075 5/8 cap screws (top) 2-HW076 1 cap screws (bottom) 2-HW010 Spacer (bottom) 17

18 Air Cylinders CB208 8 Cylinder Change over Kit CB206 6 Cylinder Change Over Kit 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 available for a limited time. When you purchase new cylinders, this kit will allow you to order the current style of cylinders and add them in between to upgrade your equipment. Air Cylinder Repair Kit ASM453 ASM453 1-CH006 Cylinder Handle 1-CS001 Cylinder Shaft 2-CW002 Cylinder Washer 1-CR003 Cylinder Rotor 1-CS004 Cylinder Spring 1-CP005 Cylinder pin 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 according 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. 18

19 Cylinder Parts PART # DESCRIPTION A. CE250 Cylinder E Clip A D B. CH006 Cylinder Handle C. CP005 Cylinder Pin D. MB001 Cylinder Bracket E. CR003 Cylinder Rotor B E F. CS001 Cylinder Shaft G CR008 Cylinder 8 Rod C H CR006 Cylinder 6 Rod I CF001 3/8 Ribbed Fitting J CW002 Cylinder Washer F 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 I J P AT007 Spring Depressor Tool Q AF103S 3/8 Elbow Steel Quick Disconnect Fitting Fittings are being phased out, quantities are limited G H K M Installation Hardware: 2-HW x 5/8 Cap Screw 2-HW010 Spacers 2-HW x 1 Cap Screw L O N Q P 19

20 Bleeder Parts PART # QTY DESCRIPTION A AF /8 straight Quick Disconnect B R Bleeder Stem C OR200 2 O-Ring D CB504 1 Bleeder Block D A B C ASM207 Bleeder Assembly 20

21 Spacer Assemblies 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) 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 Standard Installation hardware 3- HW049 1/2 x 1 Tapped Hex Bolt 1- HW034 1/2 x 3 Tapped Hex Bolt 4- HW020 1/2 Split Washer Metric Installation Hardware (From July 2013) 3 M14x30mm Tapped Hex Bolts 1 M14x60mm Tapped Hex Bolts 4 M14 Split Washers ASM450 Spacer Assembly A D C B E 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. 21

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 ASM 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) K N L A C B F D E G H I J M O R S T U P Q 22

23 Fittings PART # DESCRIPTION A AF739 Quick Disconnect 1/2 B B AF018 Quick Disconnect Nipple 1/2 C AF074 1/8 x 1/4 Straight Quick Disconnect A D AF103 3/8 x 3/8 Elbow Quick Disconnect E AF138 1/8 x 1/4 Swivel Elbow Quick Disconnect C D 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 E F J AF x 8 x 8 Brass Pipe Street Tee K AF x 8 Brass 45 Degree Street Elbow L AF544 C5255 x 4 x Steel Female Connector G H M AF734 1/4x 1/8 Socket Head Quick Disconnect N AH604 3/8 NPTF Regular Flow Coupler O OT x 6 x 8 Steel Fitting P OT x 8 x 8 Steel Fitting Q AF450 1/2 Brass Plug I J R CF001 3/8 Ribbed Fitting S OT x 8 x 8S Steel Elbow Fitting T AF002 Chicago Fitting U CH604 High Flow steel coupler K L W AF103S 3/8 Elbow Steel Quick Disconnect Fitting X AF139S Steel Straight Quick Disconnect Fitting M N O P Q R S T U W X 23

24 Long Jack Assembly Old phased out Long Jack (parts are still available) ASM800 Old Style Long Jack Foot Trundle Long Jack ASM790 Foot Trundle Long Jack New style Long Jack 24 ASM800A New Style Long Jack

25 Long Jack Assembly Exploded View ASM800A New Style Long Jack HC159 State whether you have a Regular or High Flow coupler when ordering HC159 AP132 GA300 ASM723 AC760 ASM721 HSS36 ASM801 ASM830A AH475 25

26 Long Jack Assembly Exploded View ASM790 Foot Trundle Long Jack HC159 ASM718 ASM801 ASM476 GA300 PA133 26

27 Long Jack Assembly Exploded View ASM800 Old Style Long Jack HC159 ASM724 AP133 ASM723 CJ002 HW015 HSS36 ASM727 ASM830 AH745 GA300 ASM801 27

28 Long Jack Parts 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 G HSS36 Hose Clamp 10 Ton Cylinder for Long Jack (regular or high flow coupler?) 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 E G H B A C K L D M N O 28

29 Notes 29

30 Long Jack Block Assemblies ASM727 Release Block Assembly 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 AF /8 x 1/4 Swivel Elbow Quick Disconnect F HW x 1 Cap Screw ASM724 Set Block Assembly PART NO. QUANTITY DESCRIPTION A LJ803 1 Set Block #2 B AF /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 ASM723 Control Block Assembly 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 AF /8 x 1/4 Straight Quick Disconnect F AF /8 x 1/4 Socket Head Quick Disconnect 30

31 Long Jack Block Exploded View 31

32 Shim Drivers 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 SS USN Round Round Shanks ASM900 Shim Driver Assembly A B C F D E 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 A B C D 32

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) All Castors have an integrated kick brake. MCS010 Machine Castor Green MCS020 Machine Castor Red MCS030 Machine Castor Blue MCS040 Machine Castor Yellow HJ318 3 Ton Hydraulic Jack HJ317 2 Ton Hydraulic Bottle Jack Specify if you have Knuckle or Flat Bottom? 33

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 ( ). Machine Number Location 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 34

35 Tool Box 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 LEATHER MALLETS PART # DESCRIPTION A. TH310 RAWHIDE MALLET B. TH210 SET OF REPLACEMENT FACES C. TH350 HANDLE B A 1 3/4 WRENCH 1 15/16 WRENCH 1 7/16 WRENCH C 1 ALIGNMENT PIN 3 1/8 HEX KEY 3 5/32 HEX KEY 1 SPEED WRENCH 1 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 35

36 Circle of Refractory Maintenance CONTACT US AT TO REQUEST AN ONSITE PRE-OUTAGE MACHINE EVALUATION AND SERVICE