parts book (pdf)

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


ASM463 Loaded Body for easy replacement


11

Master Valve Exploded Views

ASM463 Loaded Body for easy replacement



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:


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:


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:


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


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


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


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


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 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 #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

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