Stearns 35X Series Parts List

Important

Please read these instructions carefully before installing, operating,
or servicing your Stearns brake. Failure to comply with these
instructions could cause injury to personnel and/or damage to
property if the brake is installed or operated incorrectly. For
definition of limited warranty/liability, contact Rexnord Industries,
Inc.,

[phone].

Caution

1. Servicing shall be in compliance with applicable local safety
codes including Occupational Safety and Health Act (OSHA). All
wiring and electrical connections must comply with the National
Electric Code (NEC) and local electric codes in effect.

2. To prevent an electrical hazard, disconnect power source before
working on the brake. If power disconnect point is out of sight,
lock disconnect in the off position and tag to prevent accidental
application of power to system.

3. To avoid damage to internal power supply, hipot testing should
not exceed 1500 volts for one second. Brake coil leads must be
connected together.

4. Heat developed during normal operation (135°C) of the brake
may be hot enough to be painful or cause injury. Be careful
when touching exterior surfaces. Allow sufficient time for the
brake to cool before servicing.

5. After usage, the brake will contain burnt and degraded friction
material dust. This dust should be removed before servicing or
adjusting the brake.

DO NOT blow off dust using an air hose. It is important to avoid
dispersing dust into the air or inhaling it, as this may be
dangerous to your health.

a) Wear a filtered mask or a respirator while removing dust.
b) Use a vacuum cleaner or a soft brush to remove dust from

the brake. When brushing, avoid causing the dust to become
airborne. Collect the dust in a container, such as a bag,
which can be sealed off.

6. Maximum operating ambient temperature for these brakes
should not exceed 40°C (104° F).

I. Installation

Note 1: Position of hub should allow full engagement of friction
disc without interfering with the movement of the armature. Motor
shaft end float should not exceed .020”. Shaft runout should
be within .002” TIR. Motor mounting surface should be flat
and perpendicular to within .004” of motor shaft.

Note 2: Keep grease and oil from contacting friction surfaces.
Note 3: Hub should be a tight sliding fit. For shrink fit hub,

consult factory.

OEM’s and subsystem suppliers, please forward these
instructions with your components to the final user.

®

Armature Actuated Brakes

P/N 8-078-895-00

effective 8/5/04

Installation, Service and Parts List for
35X Series Armature Actuated Brakes

1. Place key in motor shaft.

2. Position hub per Table A.

3. Tighten set screws per Table B.

Bolt

Circle

EnglishMetric

9.00

11.00

11.00

1.60”40.5 mm

1.60”40.5 mm

35X-8
35X-9

Brake
Model

7.25

9.00

11.00

35X-7 1.50”

1.55”

38 mm

39.5 mm

32.5 Nm35X-7

7.25

9.00

11.00

Brake
Model

35X-9

35X-8

70.5 Nm

32.5 Nm

3/16”24 lb-ft

11.00 1/4”52 lb-ft

3/16”24 lb-ft

9.00

11.00

Metric

Hex

Wrench

English

Bolt

Circle

Table A(H2)

Table B

I. Installation

H2

1

2

3

2

Step 1

Note 1: It may be necessary to manually release the brake

to align the mounting register if the pressure plate has
shifted in shipment.

1. Insert O-ring in groove of register mounting face.

2. Position brake assembly over hub using care to align spline teeth,
and slide the assembly up against the motor register face.

3. Insert four (4) mounting bolts (5/8 - 11 x 1.25”) tighten to
manufacturers specifications using 1/2” hex wrench.

Note 2: Release air gap is factory set per Table D.
Verify air gap after mounting brake to motor.

3

2

Installation procedure continued on reverse side.

Remove 6 housing bolts (8mm hex wrench) lift housing
and gasket from brake assembly/mounting plate.

Step 2

Step 3 Mounting Instructions: 35X-7 and 35X-8

with 11.00” BC mounting.

ccw

Step 5 Leadwire Connection

Optional Conduit Box

1. Insert a 13mm socket through the access hole and engage the
release bolt.

2. Push down on the bolt while rotating the socket to engage the first
threads of the bolt.

3. Tighten the release bolts until snug against the brake frame.

4. Tighten the bolts (cw) to 19-23 Nm (14-17 ft-lb) by alternately
rotating each bolt 1/2 turn at a time.

1. Loosen NPT plug and four
(4) cover plate screws from
junction box and remove.

2. Route leadwires into
junction box and connect
conduit to box.

3. Connect wiring as shown
below for either the 9
terminal IP 56 or IP 65
conduit box assembly.

4. Replace junction box cover
and tighten screws to seal.

1. Replace gasket; align holes for housing bolts.

2. Place housing over brake making sure the manual release access
holes align with the release bolts.

3. Insert six (6) housing bolts and tighten to 11.2 Nm (100 in-lb).

Step 6

CAUTION: Be sure all internal wiring is clear of housing
flange before replacing housing.

II. Manual Release Engagement

Step 1

Step 2

Step 1

Loosen (ccw) release bolts until threads
are fully disengaged (about 10 turns).

Note: You will feel the bolt spring
loose when the threads become
disengaged.

Step 2

Replace access plugs.
Note: Ensure that gasket is securely located on the face of the plug.

Add a drop of Loctite 242, or equivalent, to the thread of the
plug and tighten to 28 lb-ft.

1 & 2

3 & 4

III Manual Release Disengagement

Installation continued

Remove access plugs from housing.

cw
x2

ccw

cw

ccw

x 2

5-08-0050-00
IP 56 Assembly

1. Remove the six mag body to adapter plate mounting bolts to
separate the adapter plate from the mag body.

2. Insert O-ring in groove of register mounting face.

3. Bolt adapter plate to motor register with four mounting bolts.
(1/2-13 x 1.25” for 7.25” and 9.00” BC and 5/8-11 x 1.25” for

11.00” BC.) Tighten to manufacturers specification using 3/8” hex
wrench for 7.25” and 9.00” BC mounting. Use 1/2” hex wrench for

11.00” BC mounting.

4. Align carrier disc onto mounted hub and slide it into place against
the mounting plate.

5. Position brake assembly over hub/carrier disc and slide up against
the pressure plate. Tighten mounting bolts per Table C.

Note: Release air gap is factory set per Table D. Verify air gap after
mounting brake to motor.

Step 4 Mounting Instructions: 35X-7 with 7.25” and 9.00” BC

Mounting, 35X-8 with 9.00” BC mounting and 35X-9
with 11.00” BC mounting

Mounting

Bolt Torque

14 lb-ft19 Nm

EnglishMetric

28 lb-ft38 Nm

28 lb-ft38 Nm

35X-7 196

Brake
Model

35X-9

35X-8

6 mm

278 8 mm

8 mm230

Hex

Wrench

Bolt

Circle

Table C

TERM BLOCK = LEADWIRES

Rexnord Corporation

8-078-760-00

1 = H1 YELLOW
2 = H2 YELLOW
3 = S1 RED-COMMON
4 = S2 WHITE - N.C
5 = S3 BLUE - N.O.
6 = B1 BLACK
7 = B2 BLACK
8 = 1 EMPTY
9 = 2 EMPTY

5-08-0051-00
IP 65 Assembly

TERM BLOCK = LEADWIRES

Rexnord Corporation

8-078-760-00

1 = H1 YELLOW
2 = H2 YELLOW
3 = L1 RED-COMMON
4 = L2 WHITE - N.C
5 = L3 BLUE - N.O.
6 = W1 RED-COMMON
7 = W2 WHITE - N.C
8 = W3 BLUE - N.O.
9 = B1 BLACK
10 = B2 BLACK

cw
x6

}

Optional
heater
leads

}

Optional
brake release
switch leads

}

Coil
leads

}

Optional
heater
leads

}

Coil
leads

}

Optional
brake release
switch leads

}

Optional
brake wear
switch leads

cw

x6