J.P. Langston Brake Retrofit

A 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 Pads

Air Fittings & (Ø 1/4”) Piping

Air Input

V Brake Piston

V300 Series brake spider assembly

V308

To begin installation, attach fan cover mounting clips (3) to the back side of

the spider plate.

Mounting clips

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 spider

Edge of clip

Additional brake package components

Brake with single air inputMounting Studs – V300 Series

Hub & SpacerV300 Series Fan Cover

1/2-13 UNC Hex Nuts, (3) per stud

1/2-13 UNC Studs, (4) per brake

Input air line

J P Langston friction module

J P Langston brake rotor

J.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 screws

Mounting pins

J 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 shims

Damaged 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 Shoulder Seal

Prepared mounting plate

Before installing seal into mounting plate, check that the ‘seal lip spring’

has not popped out.

Seal Lip Spring

Seal

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 Index

Drill Bushings

Flat Index

Seal Index

Counterbored Side

New Seal

Flat 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.

Ø1/4” Center Punch (4) Locations

Verified locations

Next, set up milling machineSet 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) places

1/2-13 UNC tap, (4) places

Replace mounting plate/seal assembly and tighten bolts

Insert spacer

Insert shims into new brake hub and align with clearance holes

Montalvo brake hub

Shims 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 plate

Spacer Hub

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 plate

Visually insure stud end is behind hub shoulder

Hub 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

placeMake sure the friction pads are facing out.

1/2-13 hex nutFriction pad Piston assembly

Attach disc brake to hub over the index shoulder using 6 M8x35 SHCS

Montalvo V300 Brake Disc

Tighten the 1/2-13 UNC hex nuts to the mounting plate.

Hex nuts on either side of spider assembly

Be sure that stud does not contact brake disc

Adjust hex nuts until there is approximately 1/16” gap between

friction pads and brake disc

1/16” gap

Adjust hex nut

Check pad-disc gap with 1/16” shim and tighten out hex nut where

necessaryVerify 1/16” gap all of the way around the disc

Outer hex nut

Run a power cable for the fan cover and replace the air input line with a Ø

¼” hose

Push Ø ¼” input air line through cover into push lock fitting

Push lock fitting

Brake cover

Assembled V-308 Brake with fan cover

Power to fan Air input to brake

Fan power from control arm

Ø1/4” 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

Done.Langston Model 380 Corrugator With Montalvo V308 Brakes

Installation OverviewAfter removing old brake assembly:•Remember To Keep Old Shims At Each Unwind Stand•It Is Essential That All Shims Are Kept At Their Original Position For Use With The New Brake •Remove Mounting Plate•Install New Seal In Mounting Plate•Use Drill Jig To Align Mounting Holes•Use Punch To Mark (4) Locations•Drill (4) Holes For Mounting Studs•Tap Holes For 1/2-13 UNC•Replace Mounting Plate•Insert Spacer•Mount New Brake Hub With Old Shims •Tighten Hub While Supporting Shaft•Thread (4) Studs With Nuts Into Mounting Plate•Slide V308 Spider Assembly Over Mounting Studs•Attach Brake Disc To Hub Using (6) M8x35 SHCS•Verify That Stud Does Not Contact Brake Rotor•Adjust For 1/16” Gap Around The Brake Assembly