Series 56,000; 56,100; 56,200; 56,300; 56,400;

56,500; 56,600; 56,700; and 56,900

Mounting Face: NEMA 56C, 143TC and 145TC
Brake set and release times in milliseconds,
Engineering Specifications when brake and motor are switched separately
Maximum Solenoid Cycle Rate: 1 Thermal Capacity: 2 (for T1/T2 definitions, see page 101):

AC 36 cycles/min DC Horizontal 9 hp-sec/min (112 watts) Static

Coil Size Coil Strength T1 T2
10 cycles/min Vertical 6.5 hp-sec/min (80 watts) Torque lb-ft
1.5 - 25 4 3 25 14
1 M
 aximum solenoid cycle rate is based on ambient temperature of 72°F (22°C)
with 50% duty cycle.
Does not relate to brake cycle rate (see Thermal Capacity).
2 T
 hermal capacity rating is based on ambient temperature of 72°F (22°C),
stop time of one second or less, with no heat absorbed from motor. Refer to
Selection Procedure Section.

Series 56,000; 56,100; 56,300; Series 56,200; 56,400;

56,500; and 56,700 56,600; and 56,900 Ordering and Identification Information
Nominal
The following example and tables provide information
Nominal Coil
Number Coil 2 Static No. of
2
Inertia (WK ) for selecting the appropriate three-letter suffix when
Static Inertia (WK ) Size Coil
Torque of Size Coil Torque Friction ordering a Stearns Brake.
Strength 2
Friction Strength lb-ft discs lb-ft
lb-ft lb-ft
2 AC Example of a complete part number:
Discs AC (Nm) (kgm2 x 10-4)
(Nm) (kgm2 x 10-4) 1-056-034-00-BFF L
 ead wire position
3-6 (4-8) 2 4 3 .014 (5.88)
1.5-3 10 (14) 2 4 3 .014 (5.88) (internal and external,
1 4 3 .008 (3.36) Series
(2-4) left and right) standard
15 (20) 2 4 3 .014 (5.88)
6 (8) 1 4 3 .008 (3.36) Torque 230 Vac
20 (27) 3 4 3 .020 (8.40)
Enclosure
10 (14) 2 4 3 .014 (5.88) 25 (34) 3 4 3 .020 (8.40) 5/8 bore and
3/16 x 3/32 keyway
15 (20) 2 4 3 .014 (5.88) Hub Selection
20 (27) 3 4 3 .020 (8.40)
Bore Keyway**
Character
25 (34) 3 4 3 .020 (8.40) (in.) (in. x in.)

A* 5/8 1/8 x 1/16

B 5/8 3/16 x 3/32
Current Ratings (amperes) C 3/4 3/16 x 3/32
Voltage: 60 Hz Voltage: 50 Hz D 7/8 3/16 x 3/32
Solenoid Coil AC
Coil Size* Strength Current 115 200 230 400 460 575 110 220 380 E 1-1/8 1/4 x 1/8
F* 1-1/4 1/4 x 1/8
Inrush 4.6 2.5 2.3 1.2 1.0 .9 4.1 2.0 1.3
4 3 K 1/2 1/8 x 1/16
Holding .4 .2 .2 .1 .1 .08 .4 .2 .1
L* 1 1/4 x 1/8
N* 9/16 1/8 x 1/16
O* 11/16 3/16 x 3/32
P* 1-1/16 1/4 x 1/8
R* 13/16 3/16 x 3/32
S* 15/16 1/4 x 1/8
Z .460 pilot bore
M
 inimum bore is .500. Maximum allowable bore is 1.25
(maximum shaft length not to exceed end of hub).
For through-shaft applications, .875 is maximum

*These bores are non-standard.

**Keyseats made to ANSI B17.1 Standard.

Motor Frame Adapters: Series 56,000 through 56,600 Standard AC Voltage Ratings
WARNING! Before selecting an adapter to mount a brake on a larger motor frame, the
torque and thermal capacity required by the application should be determined as shown in Voltage Coil Wiring Configuration #1 Wiring Configuration #2
the “Selection Procedure” section. A larger motor may indicate a requirement for greater Character Type @60Hz @50Hz @60Hz @50Hz
thermal capacity than the brake is designed for. The brake selection must be matched to
the motor and application requirements, before use of an adapter is considered. B 115 96

Additional D 132 110

To Adapt AK Dim. Shaft Length
Brake Adapter E 200 167
to NEMA Reg. Brake Required
Enclosure Stock
Frame in. No. Torque F 1 230 192 N/A
1 Number in.
Size (mm) (mm) H 264 220
8.50 .94 L 456 380
-9 IP 23 1.5-15 5-55-5041-00
(215.90) (23.81)
182TC N 575 479
184TC 8.50 .94
213TC -9 IP 56 1.5-6 5-55-5041-00 O 264 220 132 110
(215.90) (23.81)
215TC
P 230 192 115 96
254TC 8.50 .94 2
-9 IP 23 20 & 25 5-55-5043-00
256TC (215.90) (23.81) Q 460 383 230 192
8.50 .94 R 400 333 200 167
-9 IP 56 10-25 5-55-5043-00
(215.90) (23.81)
Modifications are available - see SAB Modification Section.
1 56,300 Series have UL Type 1 enclosure. For adapter dimensions, see Technical Data. See page 9 for nominal coil voltage operating range.
12
Dimensional Drawings are on the pages following.
Series 56,000 (1-056-0XX-00) & BACK TO TABLE OF CONTENTS

Series 56,000-80 (1-056-0XX-80)

Mounting Face: NEMA 56C,
143TC and 145TC
4.5” AK, 5.88” AJ

Dimensions for estimating only.

Series 56,000 For installation purposes request certified prints.

Basic Model Number Enclosure: Lightweight Steel Housing, Aluminum Endplate

Nominal Static
Enclosure IP Rating: IP 23, 56
Torque lb-ft IP Rating
Type
(Nm) AC Enclosure Type: UL Type 1, UL Type 4x
Mounting: Fanguard mounted brakes requiring IP 56 protection
IP 23 UL Type 1 1-056-001-00 may require additional sealing measures beyond seals provided
1.5 (2) IP 56 UL Type 1 1-056-002-00 with the brake. Refer to Installation & Service Instruction sheets.
IP 56 UL Type 4x 1-056-004-00 Installation and Service: P/N 8-078-905-60
IP 23 UL Type 1 1-056-011-00 Parts List: P/N 8-078-906-00
3 (4) IP 56 UL Type 1 1-056-012-00 Modifications: Pages 54-63
IP 56 UL Type 4x 1-056-014-00
IP 23 UL Type 1 1-056-021-00 IP 23 Dimensions
6 (8) IP 56 UL Type 1 1-056-022-00 Dimensions in Inches
Nominal (Dimensions in Millimeters)
IP 56 UL Type 4x 1-056-024-00 Wt lbs
Static Torque
C Hub (Kg)
IP 23 UL Type 1 1-056-031-00 lb-ft (Nm) A AG G J
Width
10 (14) IP 56 UL Type 1 1-056-032-00 1.5 (2) 8 (3.6)
IP 56 UL Type 4x 1-056-034-00 3 (4) 8 (3.6)
IP 23 UL Type 1 1-056-041-00 4.06 .52 .81 1.23 .31
6 (8) 8 (3.6)
(103.1) (13.2) (20.6) (31.2) (7.9)
15 (20) IP 56 UL Type 1 1-056-042-00 10 (14) 8 (3.6)
IP 56 UL Type 4x 1-056-044-00 15 (20) 8 (3.6)
IP 23 UL Type 1 1-056-051-00 20 (27) 9 (4.0)
4.50 .52 1.18 1.66 .31
20 (27) IP 56 UL Type 1 1-056-052-00 25 (34) (114.3) (13.2) (30.0) (42.2) (7.9) 9 (4.0)
IP 56 UL Type 4x 1-056-054-00
IP 56 Dimensions
IP 23 UL Type 1 1-056-061-00

25 (34) IP 56 UL Type 1 1-056-062-00 Nominal Dimensions in Inches

Static (Dimensions in Millimeters) Wt lbs
IP 56 UL Type 4x 1-056-064-00 Torque lb-ft (Kg)
C Hub
(Nm) A AG G J
Width
Series 56,000-80* 1.5 (2) 8 (3.6)
4.06 .47 .81 1.21 .37
Basic Model Number 3 (4) (103.1) (11.9) (20.6) (30.7) (9.4) 8 (3.6)
Nominal Static Enclosure
IP Rating 6 (8) 8 (3.6)
Torque lb-ft (Nm) Type
AC 10 (14) 9 (4.0)

1.5 (2) IP 56 UL Type 1 1-056-002-80* 15 (20) 4.51 .59 1.18 1.66 .37 9 (4.0)
3 (4) IP 56 UL Type 1 1-056-012-80* 20 (27) (114.6) (15.0) (30.0) (42.2) (9.4) 9 (4.0)
6 (8) IP 56 UL Type 1 1-056-022-80* 25 (34) 9 (4.0)
10 (14) IP 56 UL Type 1 1-056-032-80*
15 (20) IP 56 UL Type 1 1-056-042-80*
20 (27) IP 56 UL Type 1 1-056-052-80*
25 (34) IP 56 UL Type 1 1-056-062-80*
* 56,000-80 Series includes a C-face gasket only, no
hub seal.
13
 ® P/N 8-078-906-00
Spring-Set Disc Brakes effective 05/16/2022

For Installation and Service Instructions

Parts List refer to sheet part number 8-078-905-60.
Instructions and parts list also available at

for 1-056-000 Series (rev. A & B) www.stearnsbrakes.com.

Manual Adjust Brakes

Tools required for installation and servicing:

3/8” hex wrench 5/16” nut driver
5/16” hex wrench 1/4” screwdriver
3/16” hex wrench 8” adjustable wrench

Typical Nameplate 2. Do not operate the brake in DO NOT BLOW OFF DUST using an air
atmospheres containing explosive hose. It is important to avoid dispersing
gases or dusts. dust into the air or inhaling it, as this may
3. To prevent an electrical hazard, be dangerous to your health.
disconnect power source before a. Wear a filtered mask or a respirator
working on the brake. If power while removing dust from the inside of
disconnect point is out of sight, lock a brake.
disconnect in the off position and tag b. Use a vacuum cleaner or a soft brush
to prevent accidental application of to remove dust from the brake. When
power. brushing, avoid causing the dust to
4. Make certain power source conforms become airborne. Collect the dust in
to the requirements specified on the a container, such as a bag, which can
brake nameplate. be sealed off.
5. Be careful when touching the
exterior of an operating brake. Allow
IMPORTANT sufficient time for brake to cool before
Please read these instructions carefully disassembly. Surfaces may be hot
before installing, operating, or servicing enough to be painful or cause injury.
your Stearns Brake. Failure to comply 6. Do not operate brake with housing
with these instructions could cause removed. All moving parts should be
injury to personnel and/or damage guarded.
to property if the brake is installed or
operated incorrectly. For definition of 7. Installation and servicing should be
limited warranty/liability, contact Rexnord performed only by qualified personnel
Industries, Inc., Stearns Division, familiar with the construction and
5150 International Dr., Cudahy, WI operation of the brake.
53110, (414) 272-1100. 8. For proper performance and
operation, only genuine Stearns
Caution parts should be used for repairs and
1. Installation and servicing must be replacements.
made in compliance with all local
9. After usage, the brake interior will
safety codes including Occupational
contain burnt and degraded friction
Safety and Health Act (OSHA). All
material dust. This dust must be
wiring and electrical connections must
removed before servicing or adjusting
comply with the National Electric
the brake.
Code (NEC) and local electric codes
in effect.

1
Information required when ordering replacement parts: • Enclosure Type is specified as follows:
• Give Part Number of parts or kits needed, Brake Model Number, • UL Type 1, IP 23 (formerly referred to as standard)
and Brake Serial Number. The Brake Model and Serial Number
may identify special brakes not covered by this parts list • UL Type 1, IP 56 (formerly referred to as DTWP dust-tight
waterproof)
• When ordering hubs, specify shaft diameter (hub bore) and
keyway. • UL Type 4X, IP 56 (formerly referred to as BISSC washdown)

(IP 23)

A (IP 56)
AA
A (IP 56)
4
3 (3A & 3B)

16 A
(IP 56) AA
2

Torque (lb-ft) 1.5 and 3 6 10 15 20 and 25

Enclosure Type 1 1
1-056-002-00 & -012-00 4X 1 1 4X 1 1 4X 1 1 4X 1 1 4X

1-056-004-00 & -014-00

1-056-051-00 & -061-00

1-056-052-00 & -062-00

1-056-054-00 & -064-00

1-056-001-00 & -011-00

Brake Model
TABLE 1
Number
Components of Standard AC Brake
1-056-021-00

1-056-022-00

1-056-024-00

1-056-031-00

1-056-032-00

1-056-034-00

1-056-041-00

1-056-042-00

1-056-044-00
Item Description Part Number 

A Hardware kit - UL Type 1, IP 23 5-66-1001-00 1 1 1 1 1

Hardware kit - UL Type 1, IP 56 5-66-1002-00 1 1 1 1 1
Hardware kit - UL Type 4X, IP 56 5-66-1003-00 1 1 1 1 1

AA Plug/Gasket kit UL Type 1, IP 56 5-63-0532-00 1 1 1 1

**Close couple UL Type 4X, IP 56 5-63-0533-00 1 1 1 1
UL Type 1, IP 56, 3 disc 5-63-0534-00 1
UL Type 4X, IP 56, 3 disc 5-63-0535-00 1

7 Housing & release knob kit ─ UL Type 1, IP 23 5-66-8756-00 1 1 1 1 1

Housing & release knob kit ─ UL Type 1, IP 56 5-66-8757-00 1 1 1 1 1
Housing & release knob kit ─ UL Type 4X, IP 56 5-66-8758-00 1 1 1 1 1

Not
Release knob kit 5-63-5503-00 1 1 1 1 1 1 1 1 1 1
Shown

3 Stationary disc kit (1 disc universal 5-66-8354-00 1 1 1 1 1 1 3 3 3

3 disc horizontal)
3A Stationary disc kit (2 disc universal) 5-66-8355-00 1 1 1 1 1 1
3B Stationary disc kit (3 disc universal) 5-66-8356-00 1 1 1

Not
Vertical spring kit (3 disc) 5-63-0525-00 1 1 1
Shown

4 Friction disc kit 5-66-8462-00 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3

4C Stabilizing clip (part of 5-66-8462-00) 2 2 2 2 2 2 * * * * * * * * *
DP Disc pack kit ─ 1 disc 5-66-8601-00 1 1 1 1 1 1
Disc pack kit ─ 2 disc 5-66-8602-00 1 1 1 1 1 1
Disc pack kit ─ 3 disc 5-66-8603-00 1 1 1

16 Hub and set screw assembly 5/8 bore 5-16-5150-00-01B 1 1 1 1

1 & 2 disc (UL Type 1, IP 23) 7/8 bore 5-16-5150-00-01D 1 1 1 1
1-1/8 bore 5-16-5150-00-01E 1 1 1 1

Hub and set screw assembly 5/8 bore 5-16-5151-00-01B 1 1 1 1

1 disc (UL Type 1, IP 56 and 7/8 bore 5-16-5151-00-01D 1 1 1 1
UL Type 4X, IP 56) 1-1/8 bore 5-16-5151-00-01E 1 1 1 1

Hub and set screw assembly 5/8 bore 1 1 1 1 1 1 1

5-16-5153-00-01B
3 disc (UL Type 1, IP 23) 7/8 bore 1 1 1 1 1 1 1
5-16-5153-00-01D
2 and 3 disc (UL Type 1, IP 1-1/8 bore 1 1 1 1 1 1 1
5-16-5153-00-01E
56 and UL Type 4X, IP 56)

2 Endplate and stationary disc 1 & 2 disc (UL Type 1, IP 23) 5-02-5031-00 1 1 1 1
assembly 3 disc (UL Type 1, IP 23) 5-02-5032-00 1
1 disc (UL Type 1, IP 56) 5-02-5033-00 1 1
2 & 3 disc (UL Type 1, IP 56) 5-02-5034-00 1 1 1
1 disc (UL Type 4X, IP 56) 5-02-5037-00 1 1
2 & 3 disc (UL Type 4X, IP 56) 5-02-5038-00 1 1 1

* Certain multiple friction disc model numbers require a single stabilizer clip (D1) added to each friction disc. If your brake has these clips, they must be
replaced when the friction disc is replaced. This clip is included as part of the friction disc kit 5-66-8462-00.

** Close coupled brakes are identified by an 8 in the 8th digit. Example: 1-056-XXX-8X.
2
 Support Plate Assembly

Torque (lb-ft) 1.5 & 3 6 10 15 20 25

Enclosure Type 1 4X 1 4X 1 4X 1 4X 1 4X 1 4X

5-42-5607-00-04

5-42-5607-00-14

5-42-5609-00-04

5-42-5609-00-14

5-42-5611-00-04

5-42-5611-00-14

5-42-5611-00-04

5-42-5611-00-14
5-42-5601-00-04

5-42-5601-00-14

5-42-5605-00-04

5-42-5605-00-14
Support Plate Assy.
TABLE 2 (Items 6 through 131
Components of Support Plate and Coil and Z)
Assembly
Solenoid and
Item Description Part Number
Coil Assembly
6 Bearing 8-006-501-00 1 1 1 1 1 1 1 1 1 1 1 1
8 Solenoid lever 8-008-504-05 1 1 1 1 1 1 1 1 1 1
8P Solenoid lever & pin assembly 8-008-506-00 1 1 1 1
8R Retaining ring 9-03-0057-00 1 1 1 1 1 1 1 1 1 1 1 1
8W Spacer 9-45-0168-00 2 2 2 2 2 2 2 2 2 2 2 2

11N Torque adjustment nut 9-40-3928-00 2 2 2 2 2 2 2 2 2 2 2 2

10 Wear adjustment screw 9-17-8420-00 2 2 2 2 2 2 2 2 2 2 2 2

11 Pressure spring 9-70-1215-00 2 2

Pressure spring 9-70-1523-00 2 2 2 2
Pressure spring 9-70-1524-00 2 2 2 2 2 2
11W Spring washer 9-46-0010-00 4 4 4 4 4 4 4 4 4 4

17 Lever arm and stop nut assy. 5-17-5011-00 1 1 1 1 1 1 1 1 1 1 1 1

26 Bearing pin 9-29-4826-00 1 1 1 1 1 1 1 1 1 1 1 1
29A Plunger stop 8-094-503-00 1 1 1 1 1 1 1 1 1 1 1 1

126 Support plate and spring 5-26-5019-00 1 1 1 1 1 1

stud assembly (2 housing studs)
Support plate and spring 5-26-5020-00 1 1 1 1 1 1
stud assembly (3 housing studs)

131 Pivot pin 9-29-4836-00 1 1 1 1 1 1 1 1

142S Mounting screws 9-25-9013-00 3 3 3 3 3 3 3 3 3 3 3 3

AC Brakes

Z No. 4 solenoid kit (rev A & B) 5-66-5042-00 1 1 1 1 1 1 1 1

(rev B) 5-96-5042-01 1 1 1 1 1 1 1 1

115/230 Vac 5-96-6479-59 1 1 1 1 1 1

Size 4 230/460 Vac 5-96-6479-70 1 1 1 1 1 1
Strength 3 115 Vac 5-96-6479-52 1 1 1 1 1 1
AC
Coil kit 230 Vac 5-96-6479-58 1 1 1 1 1 1
60 Hz 460 Vac 5-96-6479-68 1 1 1 1 1 1
575 Vac 5-96-6479-74 1 1 1 1 1 1

CC Brake release interlock switch (opt) 5-57-5526-00 1 1 1 1 1 1

 Optional Modification Kits
1.5, 3 10 & 20 &
Torque (lb-ft)
&6 15 25
Z
Brake Model

1-056-00X
1-056-01X
1-056-02X

1-056-03X
1-056-04X

1-056-05X
1-056-06X
TABLE 4 Number
AD
AC Catalog
Part
Mod Description
Number
Number

M4 Brass stationary disc 8-003-513-02 1 2 3

Space heater 115 Vac 5-27-2004-00 1 1 1

M13
230 Vac 5-27-2005-00 1 1 1
BD
M17 Terminal strip 5-63-0524-00 1 1 1

Vertical spring kit (2-disc) 5-63-0539-00 1

M21
(3 disc) 5-63-0525-00 1

Table 3
Contents of Kits and Assemblies

Item Kit Description

Hardware kit - UL Type 1, IP 23 (5-66-1001-00)

2 - Housing acorn nuts
2 - Conduit plugs

Hardware kit - UL Type 1, IP 56 (5-66-1002-00)

Hardware kit - UL Type 4X, IP 56 (5-66-1003-00)
A 3 - Housing nuts
3 - Housing nut gaskets
1 - Endplate oil seal
2 - Endplate hole plugs
1 - Housing to endplate “U” gasket
2 - Endplate conduit pipe plugs

Housing and release knob kit (5-66-875X-00)

1 - Housing and release knob assembly
7
2 or 3 - Housing nuts
3 - Housing nut gasket (NEMA 4 and 4X)

Stationary disc kit (5-66-8354-00)

3
1 - Stationary disc

Stationary disc kit (5-66-8355-00)

3A
2 - Stationary discs with springs

Stationary disc kit (5-66-8356-00)

3B
3 - Stationary discs with springs

Friction disc kit (5-66-8462-00)

4 1 - Friction disc
2 - Stabilizing clips

Disc pack kit (5-66-860X-00)

1, 2 or 3 - Friction disc(s)
DP 1, 2 or 3 - Stationary disc(s)
2 - Stabilizing clips (5-66-8601-00 only)
3, 6 or 9 - Stationary disc separator springs

Hub and screw assembly - all types, all bores (5-16-515X-00)

16 1 - Brake hub
2 - Set screws

No. 4 solenoid kit (5-66-5042-00) (5-96-5042-01)

1 - Plunger
1 - Solenoid link
Z 1 - Frame (including mounting bracket)
1 - Solenoid link cap screw
1 - Solenoid link nut
3 - Solenoid mounting screws

AC No. 4 AC coil kit (5-96-6479-XX) and

AD Coil / Top Plunger guide / Wire nut

Brake release interlock switch (5-57-5526-00)

1 - Microswitch
1 - Mounting bracket
2 - Bracket mounting screws
CC
2 - Switch mounting screws
2 - Lock washers
2 - Nuts
2 - Leadwire assembly

Electric Motor Wholesale, Inc.

[email protected]
(302) 653-1844
 ® P/N 8-078-905-60
Spring-Set Disc Brakes effective 05/16/2022
For replacement parts refer to sheets:

Installation and Service Instructions Series

1-056-000
Sheet Part No.
8-078-906-00
1-056-100 8-078-906-01
for 1-056-X00* Series (all revisions) 1-056-200
1-056-300
8-078-906-02
8-078-906-03
Manual Adjust Brakes 1-056-400
1-056-500
8-078-906-04
8-078-906-05
* This sheet includes Series 1-056,000; 1-056,100; 1-056,200; 1-056,300; 1-056,400; 1-056-600 8-078-906-06
1-056,500; 1-056,600 and 1-056,900. For other series consult factory 1-056-900 8-078-906-09
Also available at www.stearnsbrakes.com
1-056-100
1-056-600 a) Wear a filtered mask or a respirator while
1-056-000 removing dust from the inside of a brake.
1-056-400 b) Use a vacuum cleaner or a soft brush to
1-056-500 remove dust from the brake. When brush
ing, avoid causing the dust to become air-
1-056-200 borne. Collect the dust in a container, such
1-056-900 as a bag, which can be sealed off.
10. Caution! While the brake is equipped
with a manual release to allow manual
shaft rotation, the motor should not be
run with the manual release engaged,
Tools required for installation and servicing:
1-056-300 to avoid over-heating the friction disc(s).
0-300 lb-in torque wrench
3/8” hex wrench 5/16” nut driver General Description
5/16” hex wrench 1/4” screwdriver These series of brakes are spring-set,
3/16” hex wrench 8” adjustable wrench elec-trically released. They contain one or
more rotating friction discs (4) driven by a
hub (16) mounted on the motor or other
Typical Nameplate inspection authorities are responsible shaft.
for verifying and authorizing the use of Note: Fan-guard mounted brakes requir-
suitably designed and installed HazLoc ing IP 56 protection may require additional
equipment. When questions arise con- sealing measures beyond seals provided
sult local Authority Having Jurisdiction with this brake. Pressurized sprays aimed at
(AHJ). the fan and brake hub surfaces can result
3. To prevent an electrical hazard, discon- in fluid migration along the motor shaft and
nect power source before working on keyway, and into the brake. The use of an
the brake. If power disconnect point is appropri-ate sealant such as RTV or a for-
out of sight, lock disconnect in the off sheda seal is advised.
position and tag to prevent accidental
Operating Principle
application of power.
4. Make certain power source conforms to These series contain one or more friction
the requirements specified on the brake discs (4) assembled alternately between
nameplate. the endplate (2) friction surface, stationary
disc(s) (3) and pressure plate (also called
Please read these instructions carefully 5. Be careful when touching the exterior stationary disc) (3). The stationary disc(s)
before installing, operating, or servicing your of an operating brake. Allow sufficient are restrained from rotat-ing by being keyed
Stearns Brake. Failure to comply with these time for brake to cool before disassem- into the endplate. With the brake released,
instructions could cause injury to personnel bly. Surfaces may be hot enough to be all disc pack components are free to slide
and/or damage to property if the brake is painful or cause injury. axially and the friction disc(s) to rotate.
installed or operated incorrectly. For defi- 6. Do not operate brake with housing
nition of limited warranty/lia-bility, contact Brake release occurs when the solenoid coil
removed. All moving parts should be
Rexnord Industries, LLC, Stearns Division, is electrically energized, causing the sole-
guarded.
5150 S. International Dr., Cudahy, WI noid plunger to travel a specified distance
7. Installation and servicing should be and through a lever system, overcoming the
53110, (414) 272-1100.
performed only by qualified personnel pres-sure spring force. This action releases
Caution familiar with the construction and oper- the clamping force on the disc pack, thereby
1. Installation and servicing must be made ation of the brake. allow-ing the friction disc(s) and brake hub
in compliance with all local safety codes 8. For proper performance and operation, to rotate.
including Occupational Safety and only genuine Stearns parts should be Brake sets and torque is produced when
Health Act (OSHA). All wiring and elec- used for repairs and replacements. electric current to the solenoid coil is inter-
trical con-nections must comply with the 9. After usage, the brake interior will con- rupted, there-by collapsing the solenoid
National Electric Code (NEC) and local tain burnt and degraded friction material magnetic field. The solenoid plunger returns
electric codes in effect. dust. This dust must be removed before to its original de-ener-gized position allowing
2. Use of this brake in atmospheres servic-ing or adjusting the brake. the lever arm to move forward by virtue of
containing explosive gases and dusts DO NOT BLOW OFF DUST using an air the compressed torque springs. This action
must be in accordance with NEC arti- hose. It is important to avoid dispersing dust compresses the disc pack components
cle 501. This brake is not suitable for into the air or inhaling it, as this may be dan- which applies a retarding torque to the brake
use in certain atmospheres containing gerous to your health. hub and ultimately restores the brake to a
explosive gases and dusts. HazLoc spring-set static condition.
 BRAKE MOUNTING (Manual Adjust) 1-056-X00

1 Place hub on motor shaft. 2 Position hub on shaft as shown. 3 Tighten set screws to motor shaft.

.188”
(4.77mm)

4 Remove brake housing.

Housings vary by series number.

5 Slide endplate over hub noting position
of stabilizer clips, if used. (Refer to
Friction Disc Replacement, view 3 and
*Brakes under
20 lb-ft torque
rating, with
See page 1. IP-23 rating
3A.) Tighten mounting screws. only require two
3/8-16 mounting
bolts.
- Do not use
lock-washers
counter-clockwise with mounting
180-240 lb-in bolts
-For vertical
assembly of
20 & 25 lb-ft
brakes, refer to
page 3

6 AC coils are 50/60 Hz,

single phase rated. Power
supply to coil must not have
7 Replace brake housing and tighten to torque specified below:

Brake series Torque

current or frequency limiting 1-056-000 1-056-300
8-10 lb-in
1-056-400 1-056-500
output that is less then the 1-056-100 1-056-200
coil requirement. 12-14 lb-in
1-056-600 1-056-900
- Connect leadwires to
power source. Verify volt-
age rating* per nametag on
coil. clockwise
- Keep wiring away from
pinch points and moving

FRICTION DISC REPLACEMENT SERIES 1-056-X00

1 Remove support plate screws and

lift support from brake
3 Install new friction disc(s) and
stationary disc(s) as shown.
Note: Stabilizer clips should never be located over the set
screws of the hub.

Single disc brakes always use two stabilizer clips, locate at 90°
counter-clockwise from each other.

Double disc brakes typically will not require stabilizer clips,

how-ever there are some special modifications that will use
them.

Rev A & B may have these clips may have these clips located 1

2
per disc, and should never be positioned in line with each other.

Rev C will have only one clip, used on the inner-most disc. No
Remove and discard old friction disc. clip will be used on the outer-most disc.

Three disc brakes will never use stabilizer clips on friction discs

4 Reposition support plate on endplate and

tighten mounting screws to 55-58 lb-in.
clockwise

Note: Friction discs can wear to 1/2 their original thicknes, or .093”

2
 AIR GAP ADJUSTMENT 1-056-X00

1 2
As friction disc wear the air gap will increase. When plunger gets to the reset position, the air gap must be adjusted.
To increase air gap, turn both adjusting screws (10) counterclockwise. Use To decrease air gap, turn both adjusting
3/16 hex wrench, or flat screwdriver on older models. screws (10) clockwise.
56,X00 Series Air Gap (REV A & B)
Torque
Disc Torque Min/Max
1 1.5, 3 & 6 .38” - .69”
2 10 & 15 .45” - .69”
3 20 & 25 .50” - .69” clockwise

56,X00 Series Air Gap (REV C)

Disc Torque Min/Max
3, 6, 3/16 hex wrench 3/16 hex wrench
2 .45” - .69”
10 & 15 counter-clockwise
3 20 & 25 .50” - .69”
Maximum gap should not exceed .69”

COIL REPLACEMENT SERIES 1-056-X00

1 2 3
Remove housing and disconnect power and wiring to coil.
Insert screwdriver between support Lift plunger/solenoid Remove plunger guide.
plate and lever arm and pry forward. lever assembly
out of coil.

4 Discard coil.
5 A) Insert new coil. (Lead wires
in same position as old coil.)
B) Insert plunger guide.
6 A) Re-insert plunger into coil; drop
pivot pin into cradle of support plate.
B) Remove screwdriver.

A B
B

Reconnect coil and replace housing per installation instructions, page 2.

VERTICAL SPRING ASSEMBLY 1-056-X00

Vertical Brake Assembly Installation Procedure for 20 and Mount support plate and torque screws
25 lb-ft brakes if mounted vertical evenly to 55-58 lb-in.
Single disc brakes are universal mount and
do not require separator springs. Double to motor shaft (These brakes are
disc brakes are universal mount but require factory assembled for horizontal operation.)
separator springs which are preassembled Remove support plate by loosening the
to the stationary disc. These discs are three mounting screws. Remove stationary
inserted spring first into the brake. Refer to discs and friction discs.Using the spring
figure 5A below. kit provided with this brake, insert three
springs of identical color into each station-
ary disc hole. Springs are inserted from the Figure 5B
side opposite the indent mark (see Figure
5B). Stationary disc should be placed on a
clean flat surface with a clearance hole to
allow the tip of the spring to extend through
the bottom side of the stationary plate.
Using the 1/8” pin provided and a hammer,
drive the spring until the large coil diameter
Figure 5A bottoms out against the disc.
Reassemble the disc pack with the station-
ary discs in the proper arrangement shown
in Figure 5C.
Figure 5C

3
 TORQUE ADJUSTMENT
TABLE A
Torque Adjustment
Nominal Original Maximum % Torque
Brake is factory set for nominal rated static 11 11 Static Spring Counter- Reduction
torque which is maximum torque. Torque Torque Height clockwise per
may be decreased up to 50% for increased (lb-ft) (inches) Turns Turn
stopping times up to 2 second stop time. 1-1/2 1.56” ­- -
The torque on the 1-1/2 lb-ft brake may not 3 1.50”
be reduced. 10 6 1.47”
10
Turn both spring adjustment screws (11), 10 1.53” 7 7%
Figure 6, equal amounts counterclockwise 15 1.53”
to decrease torque. See Table A for torque Figure 6 20 1.53”
reduction permissible amounts. 25 1.47”

TROUBLESHOOTING
COIL FAILURE EXCESSIVE WEAR / OVERHEATING
SUPPLY VOLTAGE CAUSE SUPPLY VOLTAGE CORRECTION AIR GAP CAUSE AIR GAP CORRECTION
Low solenoid air gap Reset air gap (refer to Air Gap
Line voltage >110% of coil rating Reduce voltage or replace with
Adjustment)
proper rated coil
Disc pack dragging Inspect endplate, hub and discs for
AC input on a DC coil Replace rectifier or replace with dirt, burrs, wiring and other sources
proper rated coil. of interference preventing disc “float”
Excessive voltage drop during Increase current rating of power CYCLE RATE CAUSE CYCLE RATE CORRECTION
inrush time supply. Brake “jogging” exceeding coil Reduce cycle rate or consider
WIRING CAUSE WIRING CORRECTION cycle rate alternate control method
Leadwires interfering with plunger Reroute wiring away from plunger Reduce cycle rate, use alternate
Thermal capacity is being
pull-in and other moving components. control method or increase brake
exceeded
size
Excessive voltage drop during Increase leadwires size from power
inrush time supply ALIGNMENT CAUSE ALIGNMENT CORRECTION
Coil leadwire shorted to ground Replace coil or leadwire and protect Broke endplate not concentric to Motor register must be within
with wire sleeving motor C-Face .004” on concentricity.

SOLENOID ASSEMBLY
SOLENOID ASSEMBLY CAUSE Motor shaft runout is excessive Must be within .002”; runout;
CORRECTION
consult motor manufacturer
Plunger not seating flush against Loosen solenoid mounting screws
solenoid frame and reposition frame to allow full Brake is being operated on a Vertical separator springs must be
face contact incline greater than 15° above or used to prevent discs from
below horizontal becoming cocked
Plunger cocked in coil preventing Realign solenoid frame
pull-in WORN PARTS CAUSE WORN PARTS CORRECTION
Excessive solenoid/plunger wear Replace solenoid assembly Friction disc excessively worn Replace friction discs.
at mating surface (disc can wear to 1/2 original
thickness or .093”)
Broken shading coils Replace solenoid assembly
Endplate, stationary disc or Replace warped or worn component
WORN PARTS CAUSE WORN PARTS CORRECTION pressure plate warped
Excessive wear of solenoid link Replace link arm and link bolt; also Linkages and/or pivot pins worn Replace all worn components
arm and/or shoulder bolt inspect plunger thru-hole for
Motor shaft endfloat excessive Endfloat must not exceed .020”;
elongation
consult motor manufacturer
Plunger guides worn down and Replace guides
HUB CAUSE HUB CORRECTION
interfering with plunger
movement Burr on hub interfering with disc File off burr
“float”
APPLICATION CAUSE APPLICATION CORRECTION
Machinery cycle rate is exceeding Reduce brake cycle rate or use Set screw backed out and Retighten set screw; use Loctite®
brake rating alternate control method interfering with disc 242 to help secure
High ambient temperature Use Class H rated coil and /or find MISCELLANEOUS MISCELLANEOUS
(>110%) and thermal load alternate method of cooling brake Solenoid plunger not pulling Check line voltage (±10% of
exceeding coil insulation rating completely nameplate rating) or replace worn
Brake coil wired with windings of Wire coil to dedicated power source solenoid assembly
an Inverter motor or other with instantaneous coil rated voltage Wiring is restricting disc pack Reroute wiring
voltage/current limiting device movement
MISCELLANEOUS CAUSE MISCELLANEOUS CORRECTION Excessive stop time Increase brake size/torque or use
(2 seconds or greater) alternate control method
Replace with proper spring or refer
Wrong or over tightened torque
to Installation section for proper Reduce cycle rate or use alternate
High Ambient temperature
spring height method of cooling
(in excess of 110°F)
Excessive air gap Reset, refer to Installation Section 4
Rexnord Industries, LLC, Stearns Division, 5150 S. International Dr., Cudahy, WI 53110, (414) 272-1100 Fax: (414) 277-4364 www.stearnsbrakes.com