3
TROUBLESHOOTING GUIDE
Warning: Subsequent steps require rotating parts and/or electrical circuits to be exposed. Stay clear if unit must be
running or disconnect and lock out or tag power source if contact must be made. Failure to observe these precautions
could result in severe bodily injury or loss of life.
Table 4 Troubleshooting
Symptom
Possible Cause
Solution
1) Loss of Torque
(Coasting)
Improper Switching Method
Brake Disc Worn
Brake Too Small
Excessive Cycle Rate (Disc Too Hot/Torque Fade)
Friction Surfaces Contaminated
Brake Worn Out (Frequent Adjustment)
If new brake appears to coast farther then desired, an alternate switching
method may be required, such as fast response circuit. Consult DODGE.
See Wear Adjustment Procedure-Maintenance Guide
Check Application
Reduce Cycle Rate & Check Application
Replace Friction Disc
Replace Friction Disc
2) Brake Not Releasing
Incorrect wiring
Improper input voltage
Open Circuit - Brake Wires damaged or Open Coil
Rectifier damaged
Requires Wear Adjustment
Verify wiring, see Table 3.
AC input voltage must be 10% of rated coil voltage
Check Brake Leads (B4 & B5) for Continuity. If open circuit, replace coil.
See Rectifier Checks - Maintenance guide (Page 2).
See Wear Adjustment procedure- Maintenance Guide (Page 1)
3) Motor Stalled
Brake Not Releasing
(See Symptom 2)
4) Excessive Housing
Temperature
8O°C (176°F) Maximum
Excessive Cycle Rate
High Ambient Temperature
Excessive Load Inertia
Brake Not Releasing
Excessively High Voltage
Reduce Cycle Rate
Reduce Cycle Rate and/or Load Inertia (Add External Cooling Fan)
Reduced Load Inertia
See symptom 2
Reduce voltage input to coil specifications
Figure 2 Internal Wiring Diagram
B5
(Red)
B4
(Blue)
B3
(Gray)
B1
(White)
B2
(Black)
D3
D2
D4
D1
-
+
Brake Coil
MOV
