Se Ske spi L SeeDate : 1-27-08 (13:38) MOLET-LEVEL PRODUCTION BOME FARTS LISTING Page =: 2 wIceITA cLoTeH Company 03 Menutactured Tee5 7-437-482-200-0002 “426K S65 CVCP 80-05 BAL PRES nit: BA, ‘DRAWING FO.7-137-482-200-0001 Revision: Renewal Kt Wo key | PART KUNGER DESCRIPTION ory eo | weroer ro. EACH 7-137-482-100-0999 46H ssB CVC 80-85 BAL PRES 1.0000) __ 0.000 2 J>4-293-006-054-3 JSS BACKPLATE SPECIAL (EPOXY) 10000) 368000, 3 2-177-200-034-0 SECS INC X 3.50 GRADE 8 28,0000] 1-080 a ‘2299-004-08: sorrow Rona 36H Sen- MARINE iiaoee| ass e00 5 + £293-033-008. ISERING-HD 1x 2.5 RED 384.0000] *0.213, 7 §2293-021-000-1 cewres Late 36 11 ‘s:0000] 22000, 5 + X2e27ea7 040-6 por’ 36 628 STAG K/EPR H1-co sis0c0] “sezco0 a + ¢-2e2-020-012-0 ATRTUBE 36H, 4S90D REGULAR 29000] 21.000, 2 $2997008-011-88 [Sum ~_ 36H ~ SLOTTED ~ 9/587 9810000] “0.280 a 4-262-002-031-2 arse, 26H ss xx, GARINE) 10000] 3907000 i 4-253-100-001 Jsrun'-_éseuisse’- 1°xc x 25.00 rs.0000] 3.334 15 §-262-009-003-3, SHIM, 36" 4/887 200000] 0.354 16 4-576-006-003-1 SUPERSEDED BY: 4-526-006-005-2 poooo| 353.000, 0 6-293-008-006-2 SUPERSEDED BY: 4-293-005-007-2 iioo00] 333.000, ae 2-173-100-040-0, RHCS INC X 4.00 GRADE 8 @oo0o] — 3050, 30 4-293-008-048-2 RING, OP. 436 LISSB - WARING roo0o] 358000, 32 + easaceas0r7« jsrains, 50 co x 3.00 F LENGTH 2410000] "0.080 3 2201-025-175-2 rome bru = t/a 1.75 LONG ‘eco000] L024 50 2-220-006-112-0, lpxee pLvG 1/2iPT EXTERNAL SO 40090) 0.000, ie 2ois7-a00-141-0 leaner 1-00 Fux? ss. 18/0000] 0/070 Ma 4-299-018-015-3, NC, STEEL 43,0000] _0.0c0 z =283-001-081-4 «71,000 > Purchased item has 30M 1s spcoveeenDnD SEARE PARTS Nore: PLEASE STATE SERIAL NONDER OF UNIT WHER ORDERING SPARE PARTSHaP De. hug Date: 01-17-08 09:33] MULTI-LEVEL, PRODUCTION BOMS PARTS LISTING Page 1 Michite Falls Prosietien company: 02T Manufactured Teen 7-337-482-200-c002 “36H S6B CVCP 60-05 BAL PRES Unit: BA DRANING HO, 7-137-462-100-0001 Renewal RAE to. ‘Revision: B EEE Dave:06-23-07 nex] PART HOKSER DESCRIPTION cr neg | wercur 0, EACH ¢ 7-137-482-100-0999, 4268 a5p VCP 80-85 BAL PRES 2.0000] 0.000, 2 I> “4-295-006-084-2 J&S “BACKFLATE SPECIAI~ (EPOXY) 10000} 389:c00 3 22377-100-034-0, sucs inc x 3.50. GRADE & 38.0000] 1.080 ‘ 4-299-004-089-2 lnorros nine 36x ssB- vaRINE i!0000] 385.000 5 + € 299-033-0234 ISERING 2.500 X 4.5 LONG 28.0000] 8.000 3 S3s3-011-000-2 center Plate 36-2 10000] 2827000 6 + 362-427-0006 For. 36 G2s STAG W/sPR H1-co 310000] “58-000 a + €2e2e20-012-0 JAIRroar. 36x, ¢SPUD REGULAR il0000| 21000 i 4-293-008-011-88, SHIM - 36H - SLOTTED ~ 9/957 9/0000] 0.250 3 4-2¢2-002-011-2 Janke, 36H SS XK, (HARINE) 10000] 390000, ie 4-293-100-001-4 fsru0'- 43euisss'~ I°xc x 18.00 2870000] "31334 is 262-009-003-3 Ska, 36 4/SEP 200000] 01394 36 4"528-006-005-2 JSPR. REL. PLT. 3enssB, wARINE 1.0000) 0.000, ” 4-293-008-008-2 [SPRING PLT 36ir S53 MARINE ioooo| 393000, Pa 234-401-011-« fsnes.inc-.50, LONG TOLL THREAD B.co0| “3303, 2 42253-004-048-2 JarnG, Top 436 Lissn ~ MARINE ooo] 28:00, 2 + @escos3-017-4 SPRING, 50 OD X 3.00 F LENGTH 24.0000] "0.080 2 2-101-028-195-2 DowEL Prt = 3/¢°X 1,75. LONG B.ogoo] 0.024 0 22az0-004-212-0, pree pic 3/2uer EXTERMAL 0 og] 0008, ua 22137-100-341-0, lrasien 1.00 Fuar as 2e.e000] 0070 ez $ag3c015-025-3 ISEACER/HEX HOT, 1"-8nC, STEEL 4.0000] 0.000 Fe 253-008-022. SPACER, 36H $68, 1/2" THICK s:000a] 2200 1 5-293-001-091-¢ lave, «eu 12586 a:0000) 471-000 NOTE! PLEASE STATE SERIAL MOMBER OF ONIT WHEN ORDERING SFARE PARTSAM36 Apr2008 Wichita Clutch Installation & Operation Manual 36 AquaMaKKsAM36 Apr2008 Notice These instructions serve as a general guideline for the installation and maintenance of Wichita AquaMaKKs water cooled brakes. Each Kopper Kool unit has an assembly drawing that is supplied from the factory that details any information specific to that brake. When ordering parts for Wichita products, be sure to always have the serial number available. This number is stamped on a brass tag riveted to the brake. In addition, it is stamped into the airtube holding plate on most units. CAUTION: ONLY QUALIFIED PERSONNEL SHOULD PERFORM MAINTENANCE ON THESE BRAKES. FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS PUBLICATION MAY RESULT IN SERIOUS INJURY. Wichita Clutch 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax &t 9685 www.wichitaclutch.comAM36 Apr2008 CONTENTS KK.1 INSTALLATION OF THE BRAKE..... KK.2 CLEARANCE & WEAR ADJUSTMENT... KK.3 LUBRICATION. KK.4. MAINTENANCE .. KK.4.1 REPLACEMENT OF THE AIRTUBE.. KK.4.2 REPLACEMENT OF FRICTION DISCS KK.5 RECOMMENDED SPARE PARTS .. PARTS LIST... ASSEMBLY DRAWING.. KK.6 BASIC OPERATION OF BRAKE UNIT... WARRANTY... KK.1 INSTALLATION OF THE BRAKE ‘THE FOLLOWING PROCEDURE IS FOR INSTALLING THE BRAKE BY DISASSEMBLING THE COMPONENTS OF THE BRAKE AND RE-STACKING THE COMPONENTS ON THE MOUNTED BACKPLATE AFTER INSTALLATION ONTO THE MOUNTING STRUCTURE, THE UNIT CAN BE INSTALLED ONTO THE MOUNTING STRUCTURE AS A COMPLETE UNIT. WHEN THE UNIT ARRIVES ON THE SHIPPING PALLET, PRESSURIZE THE AIR TUBE TO 50-60 PSI AND CAP OFF LEAVING TUBE INFLATED. THIS WILL FIX THE ALIGNMENT OF THE DRIVE PLATES IN POSITION WITH GEAR HUB TEETH. THE UNIT CAN BE THEN LIFTED UP OFF THE HUB. MOUNT HUB PER DRAWING ON THE SHAFT. ORIENT BRAKE UNIT INTO THE HORIZONTAL BY USING THE LIFTING HOLES IN THE BACK PLATE AND AIR TUBE HOLDING PLATE [ATHP] OR BY USING LIFTING STRAPS TO LIFT BRAKE UNIT. SLIDE COMPLETE UNIT ONTO GEAR HUB SO ‘THAT THE DRIVE PLATE GEAR TEETH SLIDE ONTO HUB. ONCE ALL OF THE DRIVE PLATES ARE ENGAGED TO THE HUB THE AIR PRESSURE CAN BE RELEASED TO ALLOW SMALL ADJUSTMENTS ROTATIONALLY TO MOUNT UNIT TO STRUCTURE, 1. The pilot on the mounting surface must be concentric with the shaft. This can be checked with a dial indicator. With the dial indicator on the shaft, place the indicator tip on the pilot of the mounting bracket and rotate the shaft. The indicator should not read more than .012” of an inch. See figure on following page. Wichita Clutch + 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www. wichitaclutch.comAM36 Apr2008 z With the dial indicator on the shaft, place the indicator tip on the face of the mounting surface and rotate the shaft. The indicator should not read more than .012” of an inch. 3. To mount the unit, use ten mounting holes as shown on print to install the backplate (2) to the mounting surface. The configuration of the mounting fasteners may vary depending on customized units. Mounting fasteners are not supplied with the brake. Wichita recommends the use of socket head cap screws, conforming to ASTM-AS74-97a, for mounting fasteners. USE OF MOUNTING FASTENERS OF INSUFFICIENT STRENGTH MAY CAUSE UNIT FAILURE RESULTING IN INJURY. 4. Position hub (5) on the shaft in relation to the unit as specified ‘on the print. Wichita Clutch * 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www.wichitaclutch.comAM36 -~ Apr2008 ‘CUSTOMER SUPPLIED MOUNTING BOLTS, 10 PLACES 3 EACH SIDE 2 EACH TOP AND BOTTOM. 5. Place the back water jacket with the copper wear plate facing away from the back plate and slide down the torque pins until it lays up against the back plate. 6. Water jackets shall be oriented to have the water inlet/outlet in the “up” and “down” position. 7. Place separator springs (3) on drive pins (14). Separator springs [6 each per drive plate] shall not be on the pins covered by the support columns. 8. _ Slide one drive plate assembly onto hub and back against water jacket (7). 9. Slide another water jacket (7) on the torque pins (14) with copper wear plate (71) facing the drive plate friction disk (61). _— Wichita Clutch * 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 9685 www.wichitaclutch.comAM36 Apr2008 10. If this is a 2 plate unit, slide another water jacket up onto the torque pins with the copper wear plate facing out away from the water jacket just installed. Slide the jacket down to lay shear against the previous jacket back to back. 11. Place separator springs (3) onto torque pins (14). Separator rings [6 each per drive plate] shall not be on the by the support columns. 12. Slide a second drive plate assembly onto hub and slide down against water jacket copper wear plate. 13. If this unit is a 3 plate unit, repeat steps 9-11. 14, The last water jacket installed should have the copper wear plate facing the drive plate friction disk (61). 15. Place pressure plate (10) mounting lugs up onto the torque pins and slide down to lay against the back side of the last water jacket. 16. Orient side covers [optional] (2 each)to slide into slots machined in the sides of the support columns and slide them all the way into the match groove on the back plate. 17. Orient top and bottom covers [optional] with long slot facing the back plate side of the unit and slide into position using mating slots in the support columns. Slide completely back into matching groove in back plate. Check that slots in the cover do not cover the water openings in the water jackets top and bottom. 18. Place Air Tube Holding Plate [ATHP] (with air tube installed as delivered from factory) with air tube facing the pressure plate onto torque pins. 19. Place the required amount of shims (12) under the ATHP and on top of the support columns. Use an ATHP mounting bolt to assist in positioning the stack of shims. The shim stack is segmented into four sections spanning between support columns. The thickness of the shim stack must be the same for all four ‘segments. 20. See Section KK.2 Clearance & Wear Adjustment for the required amount of travel of the water jacket closest to the air tube, Wichita Clutch ° 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www.wichitaclutch.comAM36 Apr2008 21. _ Install the remaining air tube holding plate mounting bolts (63) and torque to 650-750 Foot-pounds. Prior to installing bolts lubricate threads with anti-seize compound. 22. Install torque pin retention nut (15) and washers (42) to the tweleve torque pins. Torque to 300-350 foot-pounds. Use hand tools only to torque these nuts, NO IMPACT TOOLS SHALL BE USED. KK.2 CLEARANCE & WEAR ADJUSTMENT Clearance is required in the brake to assure full disengagement of the brake discs. Although brakes are correctly set before leaving our factory, the clearance should always be checked before the unit is put into operation. The recommended minimum clearances (front water jacket axial travel) are as follows. 136AM .09-.15 [inches] 236AM -12-.19 336AM -15-.22 436AM .19-,25 N MEASURE TRAVEL OF THIS WATER JACKET TO CHECK GAP CLEARANCE i 6g =A 3. The amount of torque output by the brake is affected by clearance in the brake. Maintaining the brake clearance at the minimum recommended clearance, will maintain catalog torque ratings. 4, The amount of clearance in the brake may be measured by applying and releasing the air from the airtube (11) and measuring the total axial Wichita Clutch 7 2800 Fisher Road, Wichita Falls, Texas 76302 ‘800-964-3262 Fax 800-999-9685 www.wichitaclutch.comAM36 Apr2008 movement of the pressure plate (10) or the closest water jacket (7) to the air tube. This distance should match the recommended clearances as stated previously. The brake is fully released when 0 air pressure is in the air tube. If clearance needs to be adjusted, this can be achieved by removing or adding the 0.D. shims (12) between Air Tube Holding Plate (13) and the 4 each support columns (9). Shims (12) are supplied in segments for easier installation. Shims are designed to be installed in stacks of segments to facilitate removal and maintain proper brake operation. To add or remove shims, loosen the nut (15) and washer (42) off of the drive pin (14). Loosen the 8 each ATHP mounting bolts (63) located adjacent to the torque pins. The shims are designed in with one slot and one hole in the ends of the shim. Lift the ATHP high enough to clear a shim thickness which is .06” minimum. Then add or remove shims to achieve the desired stack thickness. Repeat with the other shim stacks working all around the unit to maintain equal height of the shim stacks. . Install and tighten nut (15) and washer (42) onto the drive pin (14) and install and tighten the ATHP mounting bolts (63). ay ” a KK.3 LUBRICATION No lubrication is required, although a very light coat of Bostik Marine Grade Never-Seez compound may be applied to gear teeth of the hub. No ars or oil stances maybe allows me in contact with the friction material on the drive tes. This will alter the frictional ility of the drive plates and reduce the amount torque the brake unit can develop. Wichita Clutch * 2800 Fisher Road, Wichita Falls, Texas 76302 ‘800-964-3262 Fax 800-999-9685 www.wichitaclutch.comAM36 Apr2008 KK.4 MAINTENANCE KK.4.1 REPLACEMENT OF THE AIRTUBE 1. Shut off air pressure to brake and disconnect air hoses from the unit. 2, Remove fittings, or quick release valves, from airtube (11) inlets. 3. Remove Air tube holding plate mounting bolts (63), being careful to remove the four shim stacks (12). 4, Remove the torque pin retention nut (15) and washers (42). 5. Remove airtube holding plate (13) and airtube (11). 6, Remove old airtube (11) from airtube holding plate. 7. Install the new airtube (11) into airtube holding plate (13) aligning the inlets of the airtube (11) with the holes in the airtube holding plate (13). 8. Re-install ATHP onto torque pins and re-install the shim stacks, ATHP mounting bolts and torque pin retention nut and washers. . Reset or check the unit clearance as described in KK.2 CLEARANCE ‘ADJUSTMENT. 2° KK.4.2 REPLACEMENT OF FRICTION DISCS Friction discs should be replaced when the maximum clearance has been reached and all of wear shims have been removed. 1. Disconnect the air and water lines. 2. Remove the torque pin nut (15) and washers (42) and the 8 each ATHP mounting bolts (63), being careful to remove the four shim stacks. Remove ATHP with air tube as a subassembly. 3. Remove pressure plate (10) and water jacket assembly (7) and separator springs (3). 4. Remove drive plate assembly (6). 5. Remove the two water jacket assemblies (7), springs (3) and drive plate assemblies (6). Repeat as required on multi-plate units. 6. Remove friction material (61) from drive plate assembly by removing the bolts (62) on both sides of the drive plate. 7. Clean drive plate’s friction surface with cleaning solvent and wipe plate dry. Wichita Clutch ° 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www.wichitaclutch.comAM36 Apr2008 8. _ Install new friction discs to both sides of drive plate with bolts (62). Use of thread locker is preferred, but not mandatory. Torque bolts (62) to 9 ft-lbs. 9. Reinstall drive plate assemblies (6), springs (3), water jackets (7) in reverse order. 10. Reinstall pressure plate (10), and ATHP with air tube installed. 11. Replace shim stack (12) and secure ATHP mounting bolts and torque pin retention nuts and washer. 12. Check unit clearance per KK.2 KK.5 RECOMMENDED SPARE PARTS When ordering parts for Wichita products, be sure always to have the serial number available. This number is stamped on a brass tag riveted to the brake. In addition, it is stamped into the airtube holding plate on most units. 1. Stocking Spares Although spares are held in stock at Wichita and distributor warehouses, normal recommended spares should be held by the customer to greatly reduce costly downtime. 2, Parts List Due to the many variations obtainable in a basic type and size of clutch/brake, spare parts lists are issued for specific serial numbers. However, for general guidance, the normal recommended spares are as follows: A. Drive Plate/Friction Material (61) Drive plate/friction material should be replaced whenever it becomes excessively worn, contaminated, or no longer performs to Wichita Clutch '° 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www. wichitaclutch.comAM36 Apr2008 specifications. Drive plate/friction material should be kept clean, dry, and free from oil or grease, and stored flat to prevent warping. B. Airtube (11) Failures may occasionally occur if the airtube becomes excessively hot, saturated with oil or over expanded. Over expansion is usually a result of excessive wear. Store airtubes flat in a cool, dark place. KK Quick Release Valves (QRV) If quick release valves are installed to the air hoses, they should be disassembled and cleaned about every 6 months. TO DISASSEMBLE: -Hold valve body with a wrench and disconnect air hose. -Unscrew valve from airtube. -Place body of valve in a vice and remove end cap. Do not attempt to remove end cap while valve is fitted to airtube as valve may break at thread neck. Keep complete QRV replacement in stock. Wichita Clutch !! 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www.wichitaclutch.comAM36 Apr2008 PARTS LIST . Back Plate . Separator Spring . Hub . Drive Plate Assembly 61. Friction Disk 62. Button Head Cap Screw 7. Water Jacket Assembly 71. Copper Wear Plate 72. 1.D. O-ring 73. O.D. O-ring 9. Support Column 10. Pressure Plate 11. Air Tube Assembly 12. Shim Stack 13. Air Tube Holding Plate (ATHP) 14. Torque Pin 15. Torque Pin Retention Nut 42. Torque Pin Retention Washer 63. Air Tube Holding Plate mounting Bolt wr aun Representative parts list for unit, see Bill of Materials supplied with delivered unit for specific part numbers Wichita Clutch 1 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www.wichitaclutch.comAM36 Apr2008 = STPENSTON AquaMaKKs Cross-section Wichita Clutch '* 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www.wichitaclutch.com336AM SHOWN AM36 Apr2008 M20 x2, THREADS M24X3 THREADS 36 AquaMaKKs units use metric threads for the lifting provisions M20 x 2.5 threads at the top of the back plate and ATHP. M24 x 3 threads on the face of the ATHP M12 x 1.75 threads on face and edge of Friction Drive Plates M12 x 1.75 on Water Jacket Inlet/outlet adjacent to 1-/4NPT port Wichita Clutch 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www.wichitaclutch.comAM36 Apr2008 KK.6 BASIC UNIT OPERATION The Wichita Clutch AquaMaKKs brakes are pneumatically controlled, water cooled dynamic brake designed for continuous slip torque production. Air pressure is applied to the air tube and produces a clamp force between rotating drive plates with organic friction material which slides against copper alloy wear plates producing torque in direct relationship to the air pressure applied. Torque is produced on a straight line curve relative to input air pressure. Maximum air tube pressure is 130 psi [9 bar]. The heat generated by this friction producing torque is pulled away from the brake unit by cooling water flow thru the water jackets. A suitable brake cooling water system must be used and sufficient water flowing thru the brake to operate the brake unit. Contact Wichita Clutch Engineering for specific cooling system performance data that is required for your brake unit. Abso| imum water temperature out of the brake is 170 F. 236 requires minimum fresh water flow of 180 gpm 336 requires minimum fresh water flow of 225 gpm 436 requires minimum fresh water flow of 340 gom via tove ea f a High L eocicror esa Faupment Tertene Tork nee Wong | aa ia ox pm |] 1 a : 2 NSS | Boke | Huns 12 ao wionPresue | worsiman | TI | Shae \) ecules) y zs b= inet eae ene Wichita Clutch '° 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 19-9685 www.wichitaclutch.comAM36 Apr2008 Warranty Policy Wichita Clutch warrants all new products leaving the factory against defects in workmanship and material for a period of two (2) years after shipment, Replacement parts are also warranted as follows: standard tirtubes* — 3 years, all other standard replacement parts ~ 2 years. Adjustment under this watranty ‘vill be made after verification of defect ofthe part or produet by a factory representative. This warranty does not cover replacement or refurbishment of normal wear items unless such items are deemed by a factory representative to have flawed material or workmanship. Liability under the warranty shall extend only to the replacement or correction of any defective part or product as determined by Wiehita Clutch, and extends only to the intial purchaser and is not transferable or assignable without the ptior consent of Wichita Clute. This warranty shall not apply to any product that has been repaired or altered without the manufacturer's knowledge and consent. This warranty also does not cover damage or defects resulting from neglect, improper installation, improper maintenance or operation, or accidents. ‘This warranty is made in liew of all other warranties, expressed or implied, including but not limited to warranties of ‘merchantability or fitness for particular purpose, and there are no other warranties that extend beyond this expressed Warranty. Wichita Clutch’s obligation under this warranty is limited to repair or replacement of the defective part or produet and in no event shall Wichita Clutch be liable for consequential, indirect, ot incidental damages of any kind Incurred by reason of the manufacture, sale or use of any defective product Wichita Clutch reserves the right to discontinue models or to change specifications at any time without notice, No discontinuance or change shall create any liability on the part of Wichita Clutch in respect to its products in the hands of customers or products on order not incorporating such changes even though delivered afler any such change, Wichita Clutch '¢ 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685, www.wichil itch.AM36 Apr2008 Note: * Split air tubes are not intended for permanent installation and therefore are not covered under this warranty Wichita Clutch '7 2800 Fisher Road, Wichita Falls, Texas 76302 800-964-3262 Fax 800-999-9685 www. wichitaclutch.com