J.P. Langston Brake RetrofitA detailed walkthrough of how Montalvo upgrades the capabilities of your Langston machine with a retrofit to Montalvo V Brakes
Langston Automotive Style Brakes and Langston Unwind Stands
First, verify your Langston machine number.
When ordering a Langston retrofit package your machine number is used to match brake bolt patterns and shaft types.
After receiving your V Brake(s), verify contents.
V Pistons & V PadsAir Fittings & ( 1/4) PipingAir InputV Brake PistonV300 Series brake spider assembly
To begin installation, attach fan cover mounting clips (3) to the back side of the spider plate.
Attach cover clips with supplied SHCS & Washers.Verify that the edge of the clip does not protrude past the edge of the spider plate before tightening. You can use your finger to verify that the edge of the clip is flush with the spider.
Edge of spiderEdge of clip
Additional brake package components
Brake with single air inputMounting Studs V300 SeriesHub & SpacerV300 Series Fan Cover1/2-13 UNC Hex Nuts, (3) per stud1/2-13 UNC Studs, (4) per brake
Input air lineJ P Langston friction moduleJ P Langston brake rotorJ.P. Langston Brake
Uninstall your Langston brake by loosening the set screws and removing the friction module mounting pins to remove the friction module assembly.
Set screwsMounting pinsJ P Langston friction module
Pull out the 4 friction module mounting pins.
Friction module mounting pin
Remove the 3 M12 SHCS from rotor hub using 10mm allen wrench.
Save all shims for use with the new brake.Check inside rotor hub and on the shaft end for additional shims
It is essential that all Shims are kept at their original position for use with your new V Brake.Remove all grease and dirt from the shimsDamaged or broken shims should be replaced with new ones of equal thickness
After rotor hub is removed use an allen wrench to remove mounting plate bolts.
Carefully pull the mounting plate from the spindle arm without allowing the shaft/core chuck to drop back from the side.
Clean grease and dirt from the mounting plate.Grease seal
Mark the mounting plate to identify the unwind position.Unwind Position
Prepare to remove and replace shaft seal, and then install new seals from mounting plate backside.Mounting Plate ShoulderSealPrepared mounting plate
Before installing seal into mounting plate, check that the seal lip spring has not popped out. Seal Lip SpringSeal
Install new seal using Federal-Mogul P/N 417269 4.875 x 6.250 x 0.500.
The next step is to mark the Mounting Plate Hole locations using the Montalvo Supplied Drill Jig
Place the drill jig over the mounting plate and align the jig so that the flat on the jig indexes to the flat on the mounting plate.Flat IndexDrill BushingsFlat IndexSeal IndexCounterbored SideNew SealFlat Index
Check to ensure each location to be punched is clear of existing mounting plate holes.
Remove jig and verify that punched locations clear mounting plate holes.1/4 Center Punch (4) LocationsVerified locations
Next, set up milling machine
Set machine for drilling and tapping 1/2-13 UNC holes, and drill holes for mounting studs (4 per plate).
Drill 27/64 Diameter (0.4219) thru (4) places
Note that thru holes are not close to existing mounting plate holes.
Clamp mounting plate to work surface and tap 1/2-13 UNC thru (4) places1/2-13 UNC tap, (4) places
Replace mounting plate/seal assembly and tighten bolts
Insert shims into new brake hub and align with clearance holesMontalvo brake hubShims saved from old brake
Place hub at shaft end and hold M12 SHCS bolts in place at hub counter bore
Insert and tighten 3 M12x45 SHCS bolts thru hub and spacer into shaft Note: Apply Pressure To The Back Side Of The Shaft While Tightening Bolts
Check shaft for rotation and axial movement
New seal may make rotation stiff until broken in.New grease sealPredrilled mounting plateSpacerHub
Install 4 1/2-13 UNC Studs with hex nut into mounting plate
Wait to tighten the hex nuts until after the brake has been put on.
3/4 to 1 thread into plateVisually insure stud end is behind hub shoulderHub shoulder
Thread a second 1/2-13 UNC nut on each stud before attaching the spider, and then slide Spider Assembly over the studs.Second set Of 1/2-13 UNC hex nuts installed behind spider assembly
Thread another 4 1/2-13 UNC hex nuts onto the stud ends to hold the spider in place
Make sure the friction pads are facing out.1/2-13 hex nutFriction padPiston assembly
Attach disc brake to hub over the index shoulder using 6 M8x35 SHCSMontalvo V300 Brake Disc
Tighten the 1/2-13 UNC hex nuts to the mounting plate.Hex nuts on either side of spider assemblyBe sure that stud does not contact brake disc
Adjust hex nuts until there is approximately 1/16 gap between friction pads and brake disc1/16 gapAdjust hex nut
Check pad-disc gap with 1/16 shim and tighten out hex nut where necessary
Verify 1/16 gap all of the way around the discOuter hex nut
Run a power cable for the fan cover and replace the air input line with a hose
Push input air line through cover into push lock fittingPush lock fittingBrake cover
Assembled V-308 Brake with fan coverPower to fanAir input to brakeFan power from control arm1/4 diameter air line
Run the fan power from each control arm
Note the air and power input orientation relative to the pick-up arm.Air and Power inputs
Langston Model 380 Corrugator With Montalvo V308 Brakes
Installation OverviewAfter removing old brake assembly:Remember To Keep Old Shims At Each Unwind StandIt Is Essential That All Shims Are Kept At Their Original Position For Use With The New Brake Remove Mounting PlateInstall New Seal In Mounting PlateUse Drill Jig To Align Mounting HolesUse Punch To Mark (4) LocationsDrill (4) Holes For Mounting StudsTap Holes For 1/2-13 UNCReplace Mounting PlateInsert SpacerMount New Brake Hub With Old Shims Tighten Hub While Supporting ShaftThread (4) Studs With Nuts Into Mounting PlateSlide V308 Spider Assembly Over Mounting StudsAttach Brake Disc To Hub Using (6) M8x35 SHCSVerify That Stud Does Not Contact Brake RotorAdjust For 1/16 Gap Around The Brake Assembly