FDEOR

FDMOR

Operations &
Maintenance Manual
Premium EZ Flexx Bricking Machines
August 2011 REV.5
 SUMMARY OF OUR MISSION
The most important issue in todays world of kiln maintenance is SAFETY. This guide will introduce
the most advanced equipment available for safe and efficient rotary kiln bricking maintenance procedures.
We believe it will give you some concepts and ideas on how to reduce some risk of the demanding tasks of
removing and relining rotary kilns along with increasing productivity.

Quality rotary kiln refractory maintenance revolves around easy access, rapid tear out, and efficient
installation. If any part of this circle is missing, youre losing valuable days of production. At Bricking Solutions,
our goal is to minimize kiln downtime by creating products that improve the safety, speed, and quality of every
step in your maintenance process. With the Bricking Solutions maintenance system, your kiln is back on line
quicker and turning profits longer.

We take pride in designing, engineering and building everything we sell. We do everything possible to make
sure our products are the best in the industry. All our products meet and exceed the following criteria:

1) Increase safety, productivity, and efficiency;

2) Added, tangible time savings;
3) Measurable return on customers investment.

By maintaining close relationships with installers, contractors, plant designers, and refractory
manufacturers, we adapt our products as their needs evolve. These efforts help us to constantly improve our
bricking system and your refractory maintenance process. We are committed to listening to our customers
while striving to make their jobs easier and safer. Bricking Solutions refractory maintenance products can be
found in the cement, lime, pulp and paper, steel, incineration, and chemical industries of over 70 countries.
Each product is unique to that customers needs; each is offered with in-depth consultation and training; and
each one is backed with a customized parts inventory.

On the following pages you will find an operational and maintenance manual that discusses the advantages
of using our product line with special focus on the bricking machine you purchased. It will help you quickly
understand the principles of the machine and how to reap the rewards of a safe, fast, and efficient brick
installation as well as some proven concepts on kiln maintenance and access.

Bricking Solutions has contacted many experts in the field of kiln maintenance and asked them to contribute
their ideas and concepts. Further, we would like to encourage anyone who reads this guide to contact us with
their ideas. Our goal is to convey ideas we and many others have used with great success. Please contact us
with any questions or ideas at TOLL FREE: 800-621-7856, TELEPHONE: 360-794-1277, FAX: 360-805-2521,
or E-MAIL: info@brickingsolutions.com.

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 Thank you for choosing a Bricking Solutions bricking machine! We know if used correctly it will
increase your work productivity. This operations and maintenance manual contains descriptions and
instructions for your specific bricking machine custom designed for your particular kiln. Keep the
operations and maintenance manual as well as the assembly and disassembly guide protected and
available for your operators for future reference.
Note Before Using A Bricking Machine

It is the responsibility of the owner/employer to ensure that the masons can assemble and use
the machine safely. Before starting the machine assembly, both the supervisor and masons must
read and understand the operations and maintenance manual or have a Bricking Solutions trained
technician assist your team for a smoother start. Within this manual, we will cover:

1. Safety instructions to prevent personal injury and damage to the machine.

2. What the machine is intended for and what it is not equipped to deal with.

3. How to use and operate the bricking machine.

4. Basic maintenance, troubleshooting, and repair of bricking machine components.

MANUFACTURERS CONDITIONS

Bricking Solutions reserves the right to change the specifications and instructions of the machines
without prior warning. The machine must NOT be modified or repaired without written permission
from Bricking Solutions. The owner takes responsibility if the machine is modified after delivery from
Bricking Solutions and without written permission from Bricking Solutions. Modification may cause
new risks to the masons, machine, and surrounding area, i.e. a reduction in rigidity or defective
protection. It is the responsibility of the owner to specify the modifications to be carried out and to
contact Bricking Solutions for approval before starting any such modification. Please call us toll free
at 800.621.7856 or at 360.794.1277 to speak with a factory trained technician.

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 BRICKING SOLUTIONS WARRANTY CONDITIONS

The warranty will only apply if the equipment is used and maintained according to the safety
and maintenance instructions given in the operations and maintenance manual as well as the
assembly/disassembly guide.

Irrespective of local guarantee requirements and unless otherwise agreed, Bricking Solutions
guarantee period for new standard products is 12 months from the date of first installation use or
maximum 18 months after the date of shipment from Bricking Solutions, whichever comes first.
To claim warranty, the parts in question must be sent to Bricking Solutions.

Bricking Solutions liability to a customer for any claim related to product defects shall be limited
to the refund of the purchase price or replacement of the defective part. In cases where gross
negligence or faulty design is the cause, Bricking Solutions will also reimburse the freight, import
duties, and labor cost.

Bricking Solutions obligation shall not apply to parts which are not Bricking Solutions originally
supplied parts, nor cover any product which has been subjected to accident, alternation, abuse,
misuse, or normal wear and tear.

Bricking Solutions liability does not cover defects, which are caused by faulty handling, faulty
maintenance, faulty repair, problems related to dirt/water/particles in the system or poor electric
power or air supply.

Bricking Solutions guarantee period for spare parts is 12 months from date of installation or
maximum 18 months from date of shipment, whichever comes first.

Bricking Solutions will dismantle the defective part and install the new part only if this operation
requires special knowledge. If such special knowledge is not required, Bricking Solutions has
fulfilled its obligation in respect of the defect when the repaired or replaced part has been
delivered to the customer.

Bricking Solutions liability does not cover normal wear and tear, damage, or breakdowns caused
by lack of maintenance or improper handling of any products.

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 INDEMNITY, WAIVER OF LIABILITY,
& ASSUMPTION OF RISK

Bricking Solutions is a manufacturer of bricking machines and associated equipment used for
refractory maintenance in rotary kilns. Bricking Solutions equipment is for commercial use only and
is intended for a sophisticated user who already has thorough and complete knowledge and expertise
with equipment used for refractory maintenance, working in dangerous environments (indoors and
outdoors), equipment, working with hydraulic and mechanical tools, federal state and local safety
laws and regulations, and in work in environments classed as confined space.
Buyers of Bricking Solutions equipment shall not rely on Bricking Solutions skills or judgment to
select, provide, or recommend appropriate equipment or training for the use of Bricking Solutions
equipment. The information and training that Bricking Solutions provides is of a broad general nature
and is not a complete or comprehensive guide to the equipment. The information Bricking Solutions
provides is not a substitute or replacement for appropriate training in equipment operation, and it
is not a substitute or replacement for the manuals, warnings, and instructions supplied by Bricking
Solutions.
The purchasers and uses of Bricking Solutions equipment knowingly and voluntarily assume
all risk associated with the equipment and with the information and training provided by Bricking
Solutions, including but not limited to the risk of property damage, economic harm, bodily injury,
and death. As part of the agreement to purchase and/or use Bricking Solutions equipment and/or
training, the purchasers and users of Bricking Solutions equipment and Bricking Solutions training
agree to release Bricking Solutions and its officers, directors, employees, agents, and assigns for all
claims of any kind or nature (including, without limitation, property damage, bodily harm, economic
harm, and death) arising out of the information or training provided by Bricking Solutions. The
purchasers and users of Bricking Solutions equipment and Bricking Solutions training also agree
to indemnify, defend, and hold harmless Bricking Solutions and its officers, directors, employees,
agents, and assigns from any and all claims.

DISCLAIMERS:
Bricking Solutions hereby expressly disclaims all warranties of the fitness of the information and
training it provides for a particular purpose and expressly disclaims all warranties of merchantability,
express and implied. Bricking Solutions also hereby expressly disclaims all warranties, express and
implied, that may arise from the course of dealing or usage of trade. There are no warranties which
extend beyond the description on the face hereof. The information and training provided by Bricking
Solutions is as is, and with all faults as those terms are used in the Uniform Commercial Code.

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 ENGINEERS CERTIFICATION OF
MANUFACTURING STANDARDS

6
ENGINEERING CERTIFICATION OF ANTI-FALL GUARDS

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 INSPECTION & REPAIR OF
ALUMINUM FABRICATION WELDS
11/2/2006

INSPECTION & REPAIR OF ALUMINUM FABRICATION WELDS

In response to the question from Lafarge on how to inspect and repair our aluminum bricking machine frames please
consider the following:

1) First be very careful and do not expect Aluminum to react like steel. They are two different animals and
aluminum though as strong as steel is 3 times as flexible. Therefore the design, fabrication, welding and
repair of aluminum structures can be very challenging.
2) Welding and inspection should be in accordance to AWSD1.2 -2003 an internationally recognized and used
standard. Welding and Inspection should be done by a certified welder or under the supervision of a certified
inspector guided by the AWS standards.
3) Inspection:
a. Unlike steel, aluminum welds cannot be inspected with a mag-flux process. A die penetrate process
can be utilized. Care should be taken to clean the area thoroughly before applying the chemicals
used in this process. Any cracks or defects (inclusions, contaminants, etc.) will be highlighted in red.
b. Visual inspection by an experienced or certified welder is another option. The inspector looks for
obvious cracks or heat distortions. Craters at the beginning of or ending of a weld can be inspected
for stress cracks. Cracks with in the crater are ok; cracks extending outward from the crater indicate
a defect. Visual separation between the weld material and base material is another indication of a
defect and can often be found at the beginning or end of a weld.
4) Repair
a. As a rule of thumb conservative aluminum experts will recommend that you do not repair aluminum
defects. They recommend that the defected piece be discarded. The reason being that the heat of
a repair welding procedure tends to reduce the strength of the aluminum in the area of repair (for
example a structure with a 3:1 Safety Factor may be reduced to a 2:1 Safety Factor or lower)
b. If the repair is decided upon, the type of aluminum to be repaired (6061-T6) must be determined
perhaps by contacting the original manufacturer.
i. Then determine the correct filler material.
ii. Then prep for repair use new cutting wheels or abrasive wheels to avoid contamination of
the repair area by wheels that may have been used on other materials. This will reduce the
chance of porosity or inclusions. Also remove all traces of paint of other residue. Degrease
the surface to be repaired with Baltane or an equivalent solvent.
iii. Always remove the old weld. Never weld new filler over an old weld.
iv. Always start the repair weld ahead of and continue past the area to be repaired to avoid new
cracks.
v. If the structure is fabricated from tubular material avoid welding across the face of the tube
except at designed joints where the effects of welding across the face have been taken into
account. Weld tubes on edges as welding across the face weakens the tube.
vi. Inspect visually per AWS when the repair is completed.

This dissertation is meant to be a guideline only and any repair or inspection should be done in accordance to the
standards of AWSD1.2-2003 by someone certified or at least familiar with these standards.

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 SAFETY INSTRUCTIONS
Management, production, engineering, purchasing, maintenance, and operations departments should be brought
together to devise a maintenance program. If the plant is using an outside contractor they should also be advised of the
schedule and plans for the outage. A plan should always address the long term needs of material, equipment, and labor.
These long lead items can be critical if not handled properly and the plant may have to compromise due to short term
planning.

Management needs to address many problems, assign an appropriate budget, and empower the individuals
to implement the necessary changes to correct these problems. The continued education of personnel will increase
productivity and safety. Gathering all the information and researching how to increase kiln production will better prepare
the plant to find sound solutions. It is important to understand what is the best equipment and material available due to the
capital intensity of hundreds of thousands of dollars in refractory being used annually in the relining of the kiln.

Organizing the burn floor

Once the shutdown begins the kiln will need a cooling down period of 12 to 24 hours. Cool down time varies with kiln
diameters, amount of coating, draft control, and kiln length. During this period, it is important to begin staging the materials
and double checking supplies.

Safe & efficient kiln access

We have discovered many plants have limited access into the kiln. These small doors and burn floors lend to many
disadvantages and slow down the job of bringing the kiln back on line quickly. A large access into the kiln will allow for the
use of a forklift for transporting pallets of brick, a loader for removal of rubble, and easier access for the bricking machine.
With the hood door open and the burn pipe rolled back, a kiln ramp can be installed.

Safe inspection of brick

Theres no way of knowing what kind a job lays ahead when you open the kiln. The inside of a kiln during
an outage is a hostile and dangerous environment. When cooling down, coating, brick and kiln shells cools at
different rates. This causes separation and cracks causing coating to fall without any warning. Theres a great
risk when going into a kiln for inspection, but with a safety inspection cage, those risks are greatly reduced.

Removal of coating and brick

This is a very dangerous task because coating build up can be very unstable and unpredictable. Coating
thickness will vary from kiln to kiln. Utilizing an access ramp Brokk demolition machines provide safer, more
precise, and quicker refractory tear out than other methods.

Removal of debris and mucking the kiln

The Muck-It Buckets radiused bottom was custom made to allow full surface contact the hardened radiused
front edge helps to penetrate rubble decreasing machine and operator impact making it the most efficient and
safest method for removing debris.

Planning for new refractory installation begins

It is critical to install the brick perpendicular to the axis of the kiln. If the bricks are not placed in the proper
alignment, the chance for premature brick failure will greatly increase. Producing a continuous laser light
parallel to the kilns axis intercepted by a rotating penta-prism device, the Radialign refracts the laser line
perpendicular onto the kiln shells circumference. Points along the kiln can then be marked and used as exact
references for brick installation as well as setting a new nose ring.

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Suppling brick to the masons
Transporting brick on a pallet not only speeds up refractory installation, but also avoids potential injury
and fatigue to workers as well as possible individual brick damage. The Port-A-Trac modular system allows
the transport a full pallet of brick or two into the kiln and under the bricking machine platform. Best used for
smaller kilns or when there is no fork truck access under the bricking machine. This eliminates the need for
prestocking the kilns and allows tops and bottoms to be installed simultaneously for faster and higher quality
installation.

Another way to supply brick to the masons

Transportation of material into and out of a rotary kiln or furnace is critical to the speed of a maintenance
operation. Conveyor systems reduces worker fatigue. Made of lightweight aluminum with hydraulic drive
motors, conveyor sections are easily handled and assembled. The conveyor eliminates the need to drive
mobile equipment over new or old brick, reducing chances of damage to good brick due to vibration or weight
of the vehicle.

GENERAL

The following safety instructions cover those matters that are absolutely essential to know and follow when working
with a Bricking Solutions machine and equipment. Before using the machine, we strongly recommend both the supervisor
and masons must read and understand the entire Bricking Solutions manual or seek OEM training.

IN THE EVENT OF AN ACCIDENT

The employer has the responsibility of making a plan, and training all operators, to deal with an accident situation.

Do not resort to panic. React quickly and effectively to save lives and only then to prevent material damage.

Learn First Aid. You could save lives!

Create a checklist for actions in event of an accident

Get an overview of what has happened, if anyone is hurt and if anyone is still in the area of the accident.

Alert the emergency services as soon as possible.

Be prepared to supply detailed information.

Give First Aid

Appoint someone/several people with good local knowledge to meet the emergency service vehicles, unlock doors
and show the way for the emergency service personnel.

Ensure that any casualties are accompanied to hospital

Secure the scene of the accident

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 Contact supervisors

Contact subordinates

Establish the cause of the accident, write and file a report with the proper authorities

Take action to prevent future accidents

Always inform Bricking Solutions of accidents whether the machine was directly involved or not.

RESPONSIBILITIY OF SUPERVISORS AND MASONS

Ensuring that National and local laws, safety regulations, precautions and other instructions are followed when the
machine is used. This may include special protective equipment.

That the masons have the relevant training and experience to carry out the duties safely. This can be achieved
through product training by experienced Bricking Solutions personnel, using good judgement, reviewing manuals, and
supervising personnel.

That no one is permitted to enter the kiln without the correct training and protection. There is a risk of accident and
injury.

That the machine is only used for the intended purpose.

That the machine is used in a safe manner.

That the masons are informed of the nature of the kiln and machine.

That personnel with access to the kiln are aware of and have access to protective equipment.

Ensure that there is enough personnel to cover shifts and kiln down time with equipment training.

Report all accidents and safety incidents

REQUIREMENTS OF THE MASONS

The masons must learn the function, characteristics and limitations of the machine or other equipment under safe
conditions.

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 ASSEMBLY SAFETY RISKS

Use common sense to avoid incidents and accidents.

The masons must stop using the machine or equipment in the event of a hazardous situation. Ensure that the
machine or equipment cannot be used by mistake and inform the supervisors. The machine must not be used until the
safety hazard has been removed.

or
The masons must not be under the influence of alcohol, narcotics Locate andelse
anything inventory
whichall
maytools, hardware,
affect reaction&times
spareor
parts in stock. Do not use any unauthorized
Locate & read the assembly manual supplied with hardware or parts not supplied by manufacture.
the machine and understand its full instruction.

If previously used, clean all components of mortar

or buildup missed during disassembly.

Take notes on any missing hardware and damaged

parts needing replacement or needing repair.

Take the necessary action for the above by

ordering or replacing parts.

Use the Color Coding System found in the

assembly manual and machine labels when
assembling the machine to unsure proper setup.

Important to stage components in proper order to ensure they enter the kiln sequentially and facing the correct
direction. In the kiln looking toward burn floor at components entering kiln, the green and yellow markings should be
advancing toward assembly area.

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 judgement.

The masons must use personal protection equipment (PPE) appropriate to the work.

The masons must ensure that the machine or equipment cannot be used by unauthorized personnel.

PROTECTIVE EQUIPMENT

The masons and supervisor must evaluate what protective equipment is required. The following equipment is only an
example. The following is recommended as basic protection:

Eye Protection

Hard hat

Ear Protection

Thick overalls

Protective gloves

Safety footwear

Meet your company requirements

RISK FACTORS BEFORE AND DURING OPERATIONS

The identification and prevention of any risks and of defining the relevant risks, before and during operations, is the
responsibility of the operational supervisors and the masons. Experience of working with the machine, safety precautions
are important for ensuring that work is carried out without exposing personnel or equipment to risk.

The following is a summary of possible risk factors. The aim is to introduce the supervisors and masons to a way
of thinking which anticipates risk factors so that they can identify possible risks and take any precautions necessary to
prevent injury or damage.

Personal injury can be avoided by strict awareness of the risk.

Risk of personal injury. Never carry out repairs on the machine without the necessary training. Call for technical
support or service.

Only trained service personnel may carry out work. Personal protective equipment (PPE) and the appropriate safety

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 Use caution when installing arch if you do not have a customized fork
truck bracket to install the arch. Components can be assembled in
pieces on the machine.

Use extreme care when installing the arch. Carelessness could result
in damage to master valve, lubricator filter, emergency shut off valve
or check valve causing the cylinders not to work properly.

Install manufacturer fall guard up and down kiln.

Optional heavy duty fall guard shown Standard fall guard shown

equipment to mechanically secure machine components must be used during maintenance or

service.

A complete understanding of all maintenance, repair, and assembly manuals.

All repairs are to be done by Bricking Solutions unless approved by manufacturer. Special
aluminum alloys require specific weld filler material or possible failure may occur. Call for
technical services immediately - 360.794.1277.

Risk of allergic reaction. Repeated skin contact with chemicals such as the lubricator or grease
can cause allergic reaction. Avoid skin contact. Use protective equipment.

The machine should be inspected at least 2 to 3 months prior to each use in the kiln. This should
be accomplished by the people responsible for the bricking machine and the installation of the brick.
It is important to go through the machine and inspect it, making sure it is in top working order. One
way to ensure this is to fully assemble the machine at the plant. Apply air to the machine testing each
pneumatic and hydraulic function.

Use clean & spacious location, undercover if possible.

All castor wheels must be perpendicular to the frame (parallel to kiln axis) to allow the frame

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 OPERATION OF THE MACHINE

MOVING OR ADJUSTING THE MACHINE RISKS

There is a risk of dropping the machine because of
incorrect lifting method or incorrect lift. Check that the
fork lift is approved for the weight of the machine.
When lifting the machine for adjustment or
transporting be sure everything thing is secure, use
arch trolley pin locks, tie off arch trolley to avoid
damage or personal injury. Make sure all brick, tools
and personnel are off of the machine and be sure
personnel are clear from machine area. Leg jacks on
all four sides takes the fork lift out of the kiln when
adjusting or moving an adjustable machine.

Personnel should NEVER be on or near the machine

while its being moved by a fork lift. This could result in
serious injury or death.

When adjusting the arch height using the hydraulic

jacks or screw jacks be careful of pinch points.

Before moving the arch visually inspect the path of

travel for any obstructions and have them removed.
Then verbally announce ALL CLEAR DECK to
prevent injuries during the movement of the arches.

Personnel on kiln floor need to verify that everything

is out of castors path to allow for easy movement.

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WHILE WORKING / OPERATING MACHINE
Do not operate the machine until all machine
hardware is tightened. Overloading, improper
assembly, or alterations to the platform frames
may cause serious injury. Always check
tightness of fastners before each shift.
Do not reinforce the deck system unless you
have approval from Bricking Solutions.
Always distribute weight evenly on the machine.
Risk of personal injury to masons or other
personnel from falling objects. Incorrect
operations or an unexpected brick or tools
falling can cause serious injury. Never stand
beneath were the masons are working.
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Never overload the machine. Maximum live
load on the 14 ft deck is 10,000 lbs (4,544kg)
or an optional 17 ft deck is 15,000 lbs (6803kg).
Overloading may result in damage to machine
or serious injury. Verify your machines load
limit. Older machines were rated at 6,000 lbs.
maximum.
Do not assume that if you reinforce the frames
you will be able to load more weight onto the
machine. Doing so may result in serious injury
or machine damage or failure.
Key mason should always be aware of pinch
points on cylinder heads and jacks and call
CLEAR HANDS before cylinder movement.
All personnel need to be aware of head
clearance on and below the machine, the load
limit, all safety features, and correct access.
 STICKER WARNINGS ON MACHINE

Do not load the machine until castors are parallel to kiln

axis. This could result in damage to the frame.
Personnel, brick or equipment should NEVER be on
or near the machine while its being moved. This could
result in damage to the machine, serious injury or death.
There are many areas during
the set up of the machine
where your fingers can get
pinched. Please be aware
of your hands and other
personnels hands while setting
up the equipment.

Do not assume that if you reinforce the platform

frames you will be able to load more weight onto the
machine. Doing so may result to serious injury.

Do not use any other method of repair

than the kit number listed.

This is a crutial component for the

machine to work. Always keep this kit on
hand.
Use the Color Coding System found in the
assembly manual when assembling the
machine to unsure proper setup. Its very
important to stage components in proper order
to ensure they enter the kiln sequentially and
facing the correct direction.
Read manual

To order new or old warning sign stickers, please contact our Parts & Service Department at 360.794.1277,
via Fax at 360-805-0602, or email Seth@brickingsolutions.com
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 ANATOMY OF A FLAT DECK EZ FLEXX

The Bricking Solutions bricking machine is used for the sole purpose of re bricking kilns and ladles.The
bricking machine includes:
1. Double Adjustable Aluminum Arch 10. Dual 3-Way Master Valves & Lubricator-Filter
2. Arch Trolley Cart (Cantilever) 11. Pneumatic Cylinder
3. Decking, standard 4M long or recommended 12. Hydraulic Jacks for FDEOR (bottle jacks for FDMOR)
optional 5.2M long deck 13. Long Jack
4. End Frames 14. Cut Away Center Section
5. Rail 15. Screw Jacks
6. Ladder 16. Spacers
7. Castors with intregral kick brakes 17. Hinge Connections
8. Anti Fall Guards 18. Leg Jacks
9. Lights 19. Second Castor Position

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17

12 8

2
16

18

18 15 7
 13
10
11
9
8
6 2
1

5
4

17
14

13

8 12
1
8

15
3

4
6
19
18
7
19

Kiln Diameter Range (FDEOR)
Kiln Diameter Range (FDMOR)
Load Capacity
Deck size
Adjustable Frame(s) (FDEOR)
Frame(s) (FDMOR)
Arch Design (FDEOR)
Arch Design (FDMOR)
3-Way Master Valves
Cylinder Maintenance
Cylinder & Bumper Protection
Top Deck
Machine Castors
Time Required to Assemble
Safety Check Valves
Arch Movement (FDEOR)
Arch Movement (FDMOR)
Brick Lining Installation
Productivity
Keying Access
Keying Tools included with
machine
Tool Access
Minimum Air Pressure
Maximum Air Pressure
Minimum Air Volume
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PREMIUM MACHINE SPECIFICATIONS
Any - usually 3.5 to 6 meters, fully adjustable
Any fixed size 3M thru 7.6M with limited adjustment for kiln distortion and varying brick ID
6,803 kg (15,000 lbs) (any size machine), 3:1 safety factor
Standard 5.2 M (17 ft)
Allows adjustment for a range of kiln sizes (optional 8 ton 20 stroke hydraulic leg jacks
on two or all four frame legs) Fabricated of 6061 T6 Aluminum
Not adjustable. Fabricated from 6061 T6 Aluminum.
Segmented double arch adjusts for different size kilns and kiln distortions with extreme
ease of adjustment
Hinges on arch allow for minor kiln distortion adjustments
of maximum 8-10 inches (20-25 cm)
Cylinders on both arches can be independently operated and/or are simultaneously
controlled 3-Way Master Valve
Quick-connect fittings and exposed cylinders allow for cylinder change out in under 20
minutes or cylinder bypass during an outage
Cylinders remain flush with solid brick shelf on the arch until deployed
Perf-O-Grip, Non-skid, light weight, aluminum deck. Expanded flat work area with
ergonomic stair step design incorporated into mobile work platform
Polyurethane double wheel castors to protect new brick bed with foot brake and lock pin
2 hours with minimal experienced crew
Automatic to temporarily insure a loss of plant air pressure does not result in loss of
cylinder pressure
4M/13 FT moves along a rail system center mounted to a trolley on the deck parallel to
kiln, standard two 3 ton 20 stroke hydraulic jacks mounted on the base of the arch trolley
4M/13 FT moves along a rail system center mounted to a trolley on the deck parallel to
kiln
1 meter per hour under ideal conditions
Cut out center section in front arch to allow easy access to key section for hands and
tools
Pneumatically operated finger-tip controlled hydraulic spreader jack and shim driver -
both standard
Built in storage shelves- standard
6.33 kg/sq. cm. (6.21 bar) (90 psi)
8.33 kg/sq. cm. (8.27 bar) (120 psi)
.28 cubic meters per minute/ 10 cubic feet per minute
 PRE - USE MACHINE MAINTENANCE

BEFORE WORK
There is a risk of damage caused by insufficient machine maintenance and inspection. The machine must
be maintained in a condition which does not expose the masons or other personnel to danger or accidental
damage. Daily checks when in use and regular service must be carried out according to the Bricking Solutions
instructions. The machine must be kept clean. The signs and stickers must be visible and legible. Any faults
must be remedied. Avoid using the machine until the fault has been remedied.

1 - 2 MONTHS BEOFRE PLANNED OUTAGE MAINTENANCE AND SERVICE
A pre outage inspection is the best way to have a successful
outage. Review the Pre Use Inspection Checklist on page to ensure
machine is in good working order prior to use.

Pre assemble machine in a dry clean area before outage

Hook machine to plant air
Test all moving parts, hardware and pneumatics
Make note of all components needing replacement
Order parts

The maintenance to the Master Valve and Lubricator-Filter are key

items. If these systems are not working the machine will not function.
Refer to the Maintenance, Troubleshooting, and Repair section for
a maintenance schedule that will reduce kiln down time, keep your
machine in proper working order, and reduce the risk of accidents or
injuries or unnecessary down time.

Field service by Bricking Solutions factory trained technician can be scheduled for a site visit to your
plant for service and training. Contact Bricking Solutions or your local Bricking Solutions Representative
(to locate your representative, visit our Agent Network at www.brickingsolutions.com) to schedule one at
your site 1-360-805-1277 or 800-621-7856. If you have any questions about your machine, parts, or
components, call technical service.

As each bricking machine is custom

designed to meet the needs of each
unique kiln, please make certain to refer
to your individual machines Assembly/
Disassembly Guide for more detailed
illustrations and instructions.

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MACHINE REQUIREMENTS

Minimum air pressure 6.328 kg/sq.cm 90 psi

Maximum air pressure 8.440 kg/sq.cm 120 psi
Air volume .28 cubic meters per minute or 10 cubic feet per minute
Electrical source for lights only

HOOKING UP AND TESTING AIR SUPPLY TO MACHINE

Before plugging in any air device, make sure there is no dirt, debris, or water
in the lines. When hooking up the air supply, make sure to bleed the air from the
compressor & air line to remove any unwanted debris and water. The machine
requires a minimum of 90 psi (6.21 bar) and a maximum of 120 psi (8.27 bar). CHICAGO FITTING

Attach plant air or compressor using Chicago fitting with safety pin. The fittings can be found attached to
the lubricator unit on the down kiln arch. Make sure all hands are clear of cylinders by using a warning call,
Clear Hands. Turn on the plant air and check the pressure gauge making sure the pressure is properly set
between 90-120 psi (6.21-8.27 bar). The air pressure can be adjusted by pulling down and turning the valve
stem on the air regulator located between the filter and lubricator unit. Check lubricator for correct setting -
2-4 drops per cycle of master valve. Turn knob to adjust drops

To prevent pinched
fingers and injury when
activating the master
valve up or down, make a
verbal announcement to
clear hands.

TESTING CYLINDERS 3-WAY MASTER VALVES AND LUBRICATOR-FILTER

The Master Valve and Lubricator-Filter system are the two most important components of our bricking
machines, known as the Heart and Lung of the machine. Never run the pneumatic system without the
lubricator working properly as this will shorten the life of the pneumatic cylinders, long jack, and shim driver
significantly. Without preventative maintenance and basic repair knowledge, their failure can result in a work
cessation. Always keep spares available.

22
 CHECK VALVE IS REQUIRED. The Check Valve will stop cylinder
from retracting if the plant air is lost. This will temporarily prevent the
cylinders from loosing air and keep brick from falling and preventing
injury. Note the air shut off valve next to the regulator can be pushed
down at anytime and will stop the flow of air to and from the pneumatic
system without turning off the air supply at the compressor. Warning call
Clear Hands. Test the pneumatic systems by activating each master
valve two to three times per arch. Extend each cylinder individually by
activating the cylinder handles.

Check the reservoir on the lubricator and make sure it is full of air tool
oil every 8-12 hours or at the beginning of each shift. Keep all hoses and
cords off the kiln floor.

Turn red knob, the shut off

valve next to the regulator to stop the flow of air to and from the
pneumatic system without turning off air supply (doing such will not
compromise air pressure to extended cylinders due to placement of
safety check valve).

Do not extend or retract cylinders when air is off. If machine air pressure drops below 80 psi, remove
unkeyed brick until air is reconnected. Make certain everyone working with the machine knows the location
of the shut off valve in case of an emergency. Prevent pinched fingers & injuries when activating the master
valve up or down by verbally announcing CLEAR HANDS.

Make sure everyone working with the machine

knows the location of the shut off valve in case
of an emergency.

23
 PRE USE INSPECTION CHECKLIST

AREAS TO
PRE USE CHECKLIST
INSPECT

Inspect welds for cracks, stress, and distortions before each use. Any machine 5 years or
older should be dye pen tested every year. Ensure all warning labels, color coding labels, and
Machine frames
capacity labels are visible and in good condition. All ID/OD tubes (legs, out riggers, trolley posts,
etc.) are inspected for stress, cracks, and distortions.

Decking Decking should be free from debris build up. Free from distortions.

Check castor base for cracks. Be sure the tread is in good condition. Check all pins, locks, and
Machine castors brakes for good working conditions. Castors should be free of debris to ensure they rotate freely.
Oil castors well.

Leg Hydraulic Jacks

Be sure jacks are well oiled. Raise and lower jack several times to ensure it does not jam.
(8 ton)

All panels should be checked for cracks, stress, and distortions. All ledges should be fairly
Arches
straight and free from major gouges. All hinges should be in good working order.
Arch Hydraulic Jacks
Be sure jacks are well oiled. Raise and lower the ram several times to ensure it does not jam.
(2 or 3 ton)
Arch & Leg Support
Make sure jacks are not bent. Handles should rotate freely.
Screw Jacks
Be sure all cylinders are in good working order, retract freely, and free from leaks. Cylinders
Cylinders & Rubber should be cycled 3 to 5 times prior to use. Handles should be free from damage and distortions.
Bumpers All bumpers should be free from major gouges from shims and be in good condition. All air lines
must be cleaned and free from debris and water.

Be sure Petcock valve (bleeder valve) is in good working condition. Lubricator Filter should be
Master Valves &
filled properly with oil and cycling oil correctly. Check Lubricator Filter for leaks. Master Valves
Lubricator Filter
must be in good working order and free from leaks.

Lights In good working order. No frayed cords.

Spacer
In good working order. Be sure all are well oiled. Aluminum bolt should not be bent.
Assemblies
All heads and shanks are free from damage. Lubricate gun before use. Make certain all air lines
Shim Driver Gun
are clear of debris. Be sure all fittings are free from leaks and damage.

Hoses and fittings should be free from leaks, damage, and debris. Gauges should work properly.
Keying Jack Finger top control or trundle foot pump should be in good working order. Swivel feet should be
free from cracks and damage.

Check rails, trolleys, arch connect adjustment plates, trolley posts, and additional steps for
cracks, stress, and distortions. Rail tracks should be free from major gouges. Trolley wheels
Arch Trolley Systems
should be in good condition. Trolley locks, brakes, and lock out pins should be visible and in
good working condition.

Fall Guards Up and down kiln fall guards are free from damage and meet local and state requirements.

Ladder Make certain ladders are present. Check for cracks and distortions.

24
 AVOID HEART FAILURE & LUNG COLLAPSE

The Master Valve and Lubricator-Filter system are the two most
important components on our bricking machine. They are what we
would call the Heart and Lung of our bricking machines. They keep
the machine breathing and pumping so the brick can be installed safely,
fast, and efficiently. Without preventative maintenance and basic repair
knowledge, their failure or collapse can eat away precious time and
company profits causing you to stop dead in the refractory zone.
The HEART of our machine is a set of two 3-Way Master Valves.
Positioned on the down kiln and up kiln arches, the 3-way air valves allow
for rapid advancement up the kiln by engaging or releasing cylinders
simultaneously or individually without resetting. I think most would agree it is better for this set of valves to be holding up
the brick rather than doing it by hand. Keeping the HEART pumping and knowing the signs of a heart failure will reduce
or even eliminate dead time.
The first step is to keep the following replacement parts in stock: Master Valve repair
kits (ASM461), A loaded Master Valve body (MV441), A complete Master Valve assembly
(ASM465).
Having any one of these as a spare part on your inventory shelf will do nothing but
save your company lost profits if the heart of the system should fail. The second step is
to know the warning signs and what to troubleshoot. As outlined in our Maintenance and
Repair Guide, the reaction of the cylinders is the key. If they extend too slow, you need
to check the Master Valve and replace the necessary components. A possible plugged or
almost plugged muffler could cause the cylinders to act sluggish. Muffler replacement is
recommended rather than attempting to clean them.
The LUNGS of our bricking machine is the Lubricator-Filter system. Without this
system maintaining clean dry air and continual lubrication to the pneumatic system, the life
of the bricking machine would be short lived. Keeping those LUNGS breathing smoothly
and recognizing the signs of a lung collapse shortens the time ticking away on the outage
time clock.
The most important replacement part to keep in stock is a complete Lubricator-Filter
system (ASM500). If a problem arises, you can replace the complete system to save time and then repair the problem by
keeping the following replacement parts in stock for a collapse:
Emergency Shut Off Valve (AF457), Filter (AF100), Regulator for setting machine air pressure (AR200), Lubricator
(AL100), heck Valve (CV004) (NOTE: the check valve is a safety feature that should not be removed from the machine).
Take a look at your spare parts and consider these items as essential tools needed for you to safely, efficiently, and
productively complete refractory installation next time you prepare to set up your machine. Component adjustments
during the pre-outage evaluation can significantly reduce down time.
Using a small flat head screw driver the adjustment screw located at the top of the lubricator can be turned to
adjust the oil flow. To increase the flow turn the screw clockwise and to decrease it make a counter clockwise turn.
The air regulator can also be adjusted by pulling the adjustment knob down, setting the gauge to the recommended
pressure setting on the up kiln arch and then pushing
the knob in to lock it into place. Any leakage around
the lubricator or filter is warning signs of possible lung
collapse. Loss of air pressure is the key to problems
with the regulator. Damaged seals between all
components can also cause air leaks. If either occurs,
those parts need to be replaced before installation
can continue. It is also important to not over work
your lungs. This can occur with too much lubrication.
Balance is very important. Make certain the lubricator
is set for 2-4 drops per cycle of Master Valve.

25
 MACHINE ASSEMBLY INSIDE THE KILN

STAGING THE MACHINE FOR ASSEMBLY INSIDE THE KILN

Follow the color coding system. Line up all left hand components on the left side of the burn floor (blue/
yellow). Line up all the right hand components on the right hand side of the burn floor (red/green). An average
size machine should take 4-5 men about 45 to 60 minutes to assemble.

It is important to stage the machine in the

proper order to ensure the components enter
the kiln in sequence and facing the correct
direction. Remember to follow the color code
system

MACHINE ASSEMBLY INSIDE KILN

Install suitable length of brick, at least 26 feet (8M) on the bottom bedding of the kiln and up to a height of
two bricks above center line.

Follow the color coding system. Bring in the yellow/green upkiln frame, preferably utilizing a Fork Truck
Bracket.

Hold the frame in place and bring in the green trolley rail girder and loosely install bolts to frame.

26
 Lean first trolley rail hooked to frame on floor.

Bring in the yellow trolley rail girder in and loosely install bolts to frame.

Bring in blue/red downkiln frame as near to rails as possible.

Lift rails up while moving frame closer and loosely bolt rails to downkiln
frame.

Install center support to rails upkiln and loosely bolt to frame and rails.

Install center support to rails downkiln and loosely bolt to frame and rails.

Quality Assurance worker(s) proceed to tighten all bolts on frame and rails.

Quality Control worker(s) verify all bolts on

frame and rails are tightened.

Decking is color coded and lettered and should be installed first to either
side of trolley rails using B, C, D, E decking first.

Install fall guard brackets on upkiln frame.

Install post on upkiln side for fall guard.

Install rail poles for fall guard and if utilizing optional lift gate, install
center panels.

Complete decking installation to edge of frames and bolt decking into

place loosely.

Quality Assurance worker(s) proceeds to tighten all bolts on decking.

Quality Control worker(s) verify all bolts on decking are tightened.

If utilizing optional lift gate, install side panels and swing gates to fall guard on upkiln

Install ladder to upkiln frame.

Prepare arch for loading onto deck of machine by removing screw jacks and
let arch hang down.

27
 Attach to fork truck bracket and lift off of arch tolley cart posts

Secure safety chains and set arch aside

Use fork truck to move arch trolley cart onto deck rails until wheels contact rails.

Roll off fork truck forks onto the deck and set breaking system on trolley cart

Attach fork truck bracket to arch and secure safety chains

Move arch to arch trolley cart to assemble to arch

trolley cart posts

Release from fork truck bracket and release breaking system

Move cart to mid deck

Install downkiln fall protection

Install screw jacks

Assembly complete

Hook up and test air supply to machine.

Test cylinders, three-way Master Valves, and Lubricator-Filter

ARCH ASSEMBLY INSIDE KILN WITHOUT A FORK TRUCK BRACKET

Disassemble arch sections (which are connected for shipping purposes).

Disconnect panel sections by removing spacer assemblies from the

downkiln arches. Spacer assemblies are connected to the downkiln
arch by one long bolt and one short bolt.

Lay arch panels on the ground with cylinders and connecting pneumatic
system facing up. Be cautious of the lubricator-filter.

The cylinder handles are facing down so protect them from bending by
supporting with wooden wedge. The arch will lay flat - support by a top strap
of arch, and wedge block under arch bottom.

28
 OPERATING THE BRICKING MACHINE

Assemble upkiln arches

Top panel contains the can or keying void and holds the 10 ton
keying jack.

On either side of keying section contains a solid row of cylinders.

First connect the air supply blocks, then connect panels with
mounting hardware.

Assemble downkiln arches.

Top panel or keying panel contains a solid row of cylinders and has neutral labels placed over the air
cylinder handles.

On enither side of keying section connect panels containing spaced row of cylinders.

First, connect the air supply blocks, then connect panels with mounting hardware.

Mount the upkiln arch (arch with keying void or can section).

Pick up the arch with cylinders facing up and carry flat. Imagine a large
C laying flat. Often workers will want to carry the arch standing upright with
the result of the workers in the center not able to reach the arch, so most of
the load is taken on by the workers on the arch ends.

Lead into the kiln with base of the arch that will mount to the left side base
plate (base plate B). Imagine a large C
carried flat - the top of the C being the part
of the arch that leads into the kiln and will be placed on the left hand
base plate (B base plate).

Pass the arch, still leading with the top of the C, up to the workers on
top of the deck. Be sure there are enough workers to support the arch
as it is passed up.

As most of the arch is passed onto the

deck, begin to slowly rotate the arch so that
the bases of the arch are positioned on the
arch trolley rails (the arch trolley cart should
be moved upkiln, out of the way). The arch
should be passed onto the top deck, laying
flat with cylinders facing up, the top panel
with keying void pointed upkiln, and the arch
bases resting on the arch trolley rails.

Stand the arch upright onto the arch trolley rails so the cylinders
handles will face up kiln.
29
 Roll the arch trolley cart to the arch, then lift the arch onto the arch trolley cart posts and fasten, one
side at a time.

Roll the arch trolley cart with mounted arch upkiln and out of the way for the next arch.

Mount the downkiln arch.

Transport downkiln arch in same manner, laying flat with cylinders facing up.
Be cautious of the lubricator-filter.

Pass arch up to top deck, rotate into proper position and stand arch upright.

Roll arch trolley cart to arch, lift downkiln arch onto arch trolley cart posts
next to upkiln arch, one side at a time.

Mount downkiln arch to upkiln arch by connecting spacer assemblies.

ADJUSTING ARCH HEIGHT FDMOR / FDEOR

When the bricking machine assembly is complete, roll the bricking machine toward the down kiln end of the
new brick.

Apply foot brake on castors and locking devices on castors.

Place the arch trolley system on top of trolley rails at the

down kiln end of the deck at the desired position ready to install the first row
of brick.

The distance between the top of the arch and the kiln should be adjusted
to the height of the brick being installed plus a maximum of 75% cylinder
stroke.

Use 3 ton hydraulic jack (FDEOR) or 2 ton bottle jacks (FDMOR) to

adjust the height of the arch.

Then use screw jack to adjust arch wings towards or away from kiln sides.

Close the valve at the base of the jack and insert the jack handle into the
jacking knuckle.

30
 Pump the jack handle until the pressure is relieved from the j-bolt which holds the
stabilizer post in position.
g
Pull out the j- bolt on trolley post to free up the stabilizer post
and allow for adjustment up or down.

Adjust the arch to the proper clearance, locate hole in the stabilizer post and slide
the j bolt into the post.
g

ADJUSTING THE DISTANCE BETWEEN THE TWO ARCHES

Locate the four spacer assembly screws located on the down kiln side of the
down kiln arch.

Adjust the distance center to center

measure between rubber pads to the brick
size being used for installation.

Using the speed wrench from the machines

tool box, begin rotating the adjustment screws
evenly in small increments.

Avoid damaging the spacers by adjusting each spacer little by little

from one side to the other until you reach the correct distance between arches.

INSTALLING THE FIRST RING

Position the frames as close to old brick work or castable as possible

and secure using castor brakes and locks.

The crew then positions the arch in bricking position and locks it into
place with a bottom cylinder on each side.

The mason will rest the brick on the top of the arch ledge and push the
brick tight against the retaining ring and the brick next to it.

The mason will then activate the cylinder handle raising the cylinder and forcing the bricks cold face
against the kiln shell.

Use a raw hide hammer to tap the brick in place making sure all the angles are uniform and the bricks cold
face is tight against the kiln shell. Continue this process moving up toward the key zone.

31
USING HYDRAULIC JACK TO MOVE ARCH

Watch the hydraulic pressure gauge on the left side of the intake arch. Proper
jacking pressure is between 4500 and 6000 psi and the suggested maximum
pressure should never be exceeded as friction between brick and shell can cause
damage to the brickwork, especially when bricking Spinella type basic bricks.

Always, but especially if the brickwork is installed with mortared joints, place the
jack relatively near the back of the brick, i.e. near the previously keyed ring. This
is to avoid that mortar is pressed out of the joints on the uphill side. If this occurs,
there will be problems to fit the key brick, as the width on the downhill side will be narrower than on the
uphill side.

Observe that the only purpose with the hydraulic jack is to hold
the bricks in place while the cylinders are lowered by the Master
Valve so the arches can be moved one row forward. That jacking
pressure shall be enough to hold the bricks safely in place but not
so high that damage to the bricks occurs. Jacking pressure has no
influence over final installation quality. Quality is always determined
by the skill of the masons working the rig.

Once both wing masons have brought the brick up to the top, the key mason will install the hydraulic long
jack.

Watch the pneumatic cylinder rods; they can be damaged over time by being subjected to the jacking
force. This flexing may bend the rods (only when they are overextended), but most of the damage is done
to the rubber O-ring at the top of the cylinder. The rod will be forced into the O-ring and will pinch the O-ring
against the cylinder base wearing the O-ring out and causing the cylinder to leak needing to be replaced.

The long jack has two rectangular swivel feet at either end of the jack.

The swivel feet must be rotated to be perpendicular to the kiln shell. Raise the jack up until the swivel feet
rest against the kiln shell and the swivel feet are centered on both ends of the brick to be jacked.

Apply pressure to the jack.

Activate the finger tip valve found on the jack cylinder. Jack until the proper hydraulic pressure is reached
using the gauge or preset pump.

32
SHIMMING THE NEWLY KEYED RING

Use a pneumatic shim driver gun with steel shank and shim driver head. The shim driver
head has a recess running the length of its face allowing for the shim to rest securely inside the recess.

Place the shim up toward the kiln shell and use a hammer to start the
shim; once it is inserted, use the shim driver gun. Apply consistent
ample pressure to the gun, pointing toward the brick and angled
slightly up towards the shell.

Squeeze the trigger on the shim driver gun and as the shim slides in
between the brick, move the gun upward towards the kiln shell so it is
parallel to the top of the shell. Continue this until the shim driver head
contacts the brick. Finish driving the shim with a hammer.

MOVING THE ARCH

Locate the master valve handle on both up kiln and down kiln arch and announce ALL CLEAR. Push
inward or pull outward so all the cylinders will drop at once. The hydraulic jack will support the un-keyed
row.

Now move the arch one row of brick towards the up kiln end of the kiln by
pulling each side of the arch and rolling the Arch Tolley Cart on the rail system
one brick row up kiln.

Place the down kiln arch under the un-

keyed row of brick making sure it is centered. Now
neutralize the air cylinders on the up kiln arch directly
under the hydraulic jack by moving the cylinder
handle to the middle of its rotation. This will keep the
cylinders from rising up and into the long jack.

Activate the master valve on

the down kiln arch, all the cylinders will raise at the same time
except the neutralized ones. Now the down kiln arch will support
the un-keyed bricks.

33
 Release the hydraulic long jack by activating the finger tip release button. Set the long jack in its stowed
position. The up kiln arch is now free of brick and is ready for the wing masons to begin bricking up towards
the center again. The down kiln arch is supporting the un-keyed row of brick and is ready for the key mason
to install the last bricks and key out the row.

Having the wing masons begin bricking on the open up kiln arch,
while they are doing this, the key mason is using the neutralized cylinders
to install the remaining key zone brick with the down kiln arch.

Repeat the process until the Arch Trolley Cart has traveled to the
end of the work deck.

KEY BRICKS CUTTING OR NOMINAL KEY BRICKS

Keying speed with depend not only on the skill of the masons, but also on the type of bricking being
installed. If RKB is used, there are ways to speed up the keying as the key brick must be cut according to the
available remaining space. Half size bricks may be cut in advance to avoid waiting time for cut bricks needed
in when keying out. VDZ sizes are the most complicated to key because neither the cold nor hot face measure
is adequte to determine brick combination. A cheat sheet can be prepared in advance as follows:

1. Mark a keying section corresponding to 10 full size bricks and using a cold face diameter. Place the
10 bricks in proper combination. First and last brick must be as near to 90 degress to the imaginary shell
as possible. Mark combination on paper.
2. Combine standard and key bricks until you find the correct combination to correspond with the 10 full size
bricks minus 2mm and mark on paper.
3. As in #2, combine standard and key bricks until you find the correct combination to correspond to the 10
full size bricks minus 4mm and mark on paper.
4. Continue until you reach the combination for 9 full size plus 2mm. Mark all on paper, color code, and make
available to the keying masons.

The process above is a tedious job requiring patience and first class bricking skills. It will only work if there
are two types of prefabricated key bricks available.
When ISO sizes are used, before keying the first ring, mark 1030mm down from the top of the kiln on each
side, corresponding to 10 standard bricks for each wing mason. Check how the 1030mm mark relates to full
size or to whatever size key bricks are available. If mortar is used, add a few mm to the 1030 to compensate
for the motar joints. Check how the installed brickwork relates to the 1030mm mark and how it relates to
available key bricks. Use this to establish a cold face keying pattern. Once the first ring is keyed, this pattern
can be used for subsequent rings, if the masons are able to follow the cold face line.

34
ROTATION OF THE KILN

The bricking machine must be completely emptied of brick ancillary equipment and personnel.

Lower arches to keep from catching and damaging brick work or machine parts. Arch trolley lock out pin
must be in place.

The castors must be rotated and locked perpendicular to

the kiln axis.

The machine must be visually watched during kiln rotation

to prevent overturning as its center of gravity is high.

The arches can be laid down on the deck, but be careful

not to damage master valves or filter.

MOVING BRICKING MACHINE IN KILN

FOR EACH MOVE OR ADJUSTMENT YOU MUST ALWAYS SECURE ARCH TROLLEY. Using arch
trolley brake and arch trolley lock device (if applicable) position arch trolley on opposite end of machine to be
adjusted. Lock or secure trolley to fixed component of machine using rope or cable so trolley wont be able to
advance during move or adjustment, for safety of men and machine. Think safety!

MOVING BRICKING MACHINE IN KILN OVER NEW REFRACTORY

SECURE ARCH TROLLEY

Key out the last row of brick and lower arch with the hydraulic jacks to insure clearance. Unload brick and
make certain tools and equipment are safely stored so they wont fall during the machine move.

All personnel must be off machine. Verify arch is tied off and not able to move and that all leads for air
and electric are long enough for the required move.

Gather the personnel required for the move and check that the machine wheel path is clean and clear
of obstructions and that the ladder is elevated as to not damage new brick or the ladder. Position your
personnel facing in the direction of travel, release the brakes and in unison push slowly into the next
refractory installation zone.

Verify the new position is correct and then reset the caster brakes.

Release arch trolley and roll to new starting location. Restock the machine with brick and tools.

MOVING BRICKING MACHINE IN KILN OVER OLD REFRACTORY

SECURE ARCH TROLLEY
Key out the last row of brick and lower arch with the hydraulic jacks to insure clearance. Unload brick and
make certain tools and equipment are safely stored so they wont fall during machine move.

35
 All personnel must be off machine. Verify arch is tied off and not able to move and that all leads for air and
electric are long enough for the required move.

Gather personnel required for the move, more effort is required to provide clean and clear wheel path. This
may require the aid of forklift using tips of forks against top of frame tube or fork truck bracket. Push slowly
and consistently to move machine into work area. Make certain machine wheel path is clear of obstructions
so wheels will roll on advancing machine. Dont allow binding of wheels or damage may occur.

Verify the new position is correct and then reset the caster brakes.

Release arch trolley and roll to new starting location. Restock the machine with brick and tools.

MOVING BRICKING MACHINE IN KILN OVER RETAINING RING

SECURE ARCH TROLLEY
Key out the last row of brick and lower arch with the hydraulic jacks to insure clearance. Unload brick and
make certain tools and equipment are safely stored so they wont fall during machine move.

All personnel must be off machine. Verify arch is tied off and not able to move and that all leads for air and
electric are long enough for the required move.

Slowly move machine toward retaining ring. Using wood wedges, place the wedge against retaining ring
so caster will roll up and over retaining ring slowly. Aid of a forklift and fork truck bracket may be required
to make this transition. Place the tips of forks against the top of frame tube. Push slowly and consistently
to move the machine into the work area. Make certain machines wheel path is clear of obstructions so
wheels will roll on advancing machine. Dont allow binding of wheels or damage may occur.

Verify the new position is correct and then reset the caster brakes.

Release arch trolley and roll to new starting location. Restock the machine with brick and tools.

IF UTILIZING FORK TRUCK BRACKET

Fasten bracket to fork truck.

Bring bracket and machine frames together and raise until tight
contact has been made.

Install fork truck bracket chains over frame.

Release castor brakes.

All personnel should be standing well clear of the machine.

Assign a few spotters to watch and inform lead person to hold movement in event of interference and to
advise when to resume machine move.

Slowly move machine to predetermined position.

36
 Reset castor brakes.

Remove fork truck bracket chains from frame.

Lower or reposition ladder.

Restock machine, release arch, and comence with brick installation

IF MANUALLY MOVING MACHINE

Gather all personnel and assemble all members along down kiln side of both machine frames

Assign one man to conduct move and be responsible for releasing castor brakes and resetting same
when move is complete.

Lift off tie off ladder or remove.

Release castor brakes.
Following the directions from the lead person, slowly and steadily move the machine to the
predetermined position.
Assign a few spotters to watch and inform lead person to hold movement in event of interference
and to advise when to resume machine move.
Once machine has reached predetermined position, reset castor brakes.
Check all hardware for tightness.
Lower or reposition ladder.
Restock machine, release arch, and comence with brick installation.

BRICKING THROUGH CONICAL SECTIONS

The bricking machine can be used for bricking through conical section within the diameter range for
which it is manufactured. A few considerations and good preparation will save much time and problems
during the installation job. Unless the difference in diameter is minimal, bricking should always be made
from the large diameter towards the small, and the bricking should always be completed in the large
diameter before bricking the cone. On the other hand, bricking should never be completed in the smaller
diameter until the conical section is completed.
The best way to prepare for bricking of conical section is to mark both the large (inside brick)
diameter and the small (shell diameter) on the floor before starting. Consider the length of the conical
section to determine if the platform length is enough to brick the section without moving the bricking
machine. If platform length is sufficient for bricking the complete section, do as follows:
Lay the frame on the floor, considering the large diameter, then the other frame, considering the
smaller diameter. Calculate at what height respective platform legs shall be set, this is to grant that the
platform is as level as possible. Mark legs or take note. Doublecheck correct platform height by marking
the SID of the small diameter inside the BID of the large diameter. Once in the kiln the job will be both
safer and faster if the frame heights are as near exact as possible.
Add height of the trolley, mark on the ground over the frame. Check head room in both diameters.
Present the arch in the large diameter. Consider using 75% of cylinder stroke and having the arch
elevated as much as possible on the hydraulic jack. Take notes.
Thereafter, present the arch in the small diameter. Mark very carefully the level of the deck. Consider
using minimal cylinder stroke and having the arch as low as possible on the hydraulic jacks. There will

37
 be space for the same arch configuration as long as the bottom part of the arch sits over the deck level.
If the arch hits the deck, it will be necessary to eliminate one segment on each side of the arch during
the job.
Once installed in the kiln, start bricking from the large to the narrow diameter. Be aware that a cone
section many times will make it impossible to use all the planking, and that there is an increased risk for
the side masons due to the gap between the brickwork and the deck.
Brick up the cone, let the arch go down on the jacks if you run out of cylinder stroke on the upper
part of the arch. If you run out of stroke on the lower side of the arch, it will be necessary to adjust the
arch segments, use the screw jacks after loosening the hinge bolts. In the case you need to remove
segments, move the arch upwards to the unbricked area where better space will be available for
adjusting the arch, remove the corresponding segments. Before you start bricking again, check that all
the hose connections are tight and without leaks and in correct placement - back to back; front to front.
Remember always to secure the arch when making adjustments. Remember also, that the platform
will not always be completely level when working through a cone, more of force might be required to
move the arch once a ring is completed, or even to hold it in place once the jack is applied and the
trolley ready to be moved. A good additional safety precaution is to keep the arch secured all the time to
eliminate the risk it rolls should cylinders be lowered .
In a cone section longer than the platform it will be necessary not only to follow the procedure
described above, but also to move the complete bricking machine. As the machine will move from
a large diameter to a more narrow, both scaffold frames will need to be lowered, how much can be
determined in advance using the same preparative procedure as described above, presenting both
scaffolds and arches on the ground. Remember never to adjust scaffold legs unless the arch is secured.
1st step is to adjust scaffold legs to the lower position, 2nd step to make all the adjustments necessary
to the arch. Once this is completed, move the machine into the unbricked area.
Kilns are always bricked from discharge side to feed side, with the exception of cones, which,
as a principle, always should be bricked from the large to the narrow side. Observe the following, if
the narrow diameter is on the discharge side: It is never necessary to turn the bricking machine. It is
sufficient to turn the trolley and the arch around on the platform, then continue bricking as described
previously. Remember that it is always easier to complete the job if the narrow diameter is unbricked
and the large diameter is completed prior to the cone section.

THE A-B-CS OF BRICKING THRU TRANSITION (CONICAL/TAPER) FOR FDMOR &

FDEOR
(Please refer to the following pages for the ABCs diagram)

Always make safety your teams first priority

When using a fork lift to elevate the machine, or adjust the legs, the main frame is the only area
contact can be made to assist in this type of maneuver. Always secure the frames to the fork truck
bracket to avoid slipping or loss of control. Always secure the Arch Trolley Cart with all trolley locking
devices before attempting any movement.
Using 2 ton bottle jacks or 3 ton hydraulic jacks mounted from the base of the arch trolley post, you
can use the jack handle to raise or lower the arch to achieve desired clearance from brick to top of
arch.
The screw jacks on the arch wing panels are also used to adjust arch wing panels for your kilns
diameter.
Optional 8 ton cylinders on the legs replace the need of the fork lift for adjustment, this is a highly
38 recommend option.
Before starting to adjust the machine or lowering the arch to its lowest position for the required conical
taper transition section, complete the following:

Secure arch trolley with all arch trolley locking devices so it cannot roll during machine adjustment.
Once this is done have crew remove any tools left on machine to avoid fall hazards during machine
re-positioning.
All brick and crew must be removed from machine deck before the machine is ever moved
The machine castor brakes must be set during the machine use and/or leg adjustment process.

DISSASSEMBLY AND STORAGE INSTRUCTIONS

!! UNLOAD ALL BRICK, TOOLS, AND EQUIPTMENT FIRST!!
Store all components and hardware in a clean dry area. Preferably away from dust.
Reverse assembly steps to dismantle machine and take note of any repairs or damage to the
machine.
Store hydraulic equipment with the other spare parts and components, they should be cleaned and
stored.
Thoroughly clean machine from mortar or build up.
Verify all required hardware has been located and stored.
To extend the machines life, store in a clean and dry location away from heat. Maintenance to
machine at end of use is highly recommended for longer lifetime of use.
Find a permanent location for machine and all components in a clean, dry, and away from dust and
heat, if possible.
Remove the arch screw jacks and place into storage
Support the arch using the Fork Truck Bracket or man power and remove hardware.
Store arches assembled, in upright position.
Clean arches and cylinder shafts of all mortar at the end of each outage (highly recommended).
Open air line bleeder valve at bottom of each arch and after waste has been evacuated close
bleeder to keep dust and debris out of system during storage. Remove the arch trolley cart and
secure it to the fork truck. Place into storage
Remove up and down kiln fall protection and lights. Place into storage
Remove the planking. Place into storage
Remove the center plank support. Place into storage
Remove all hardware from down kiln trolley rail to down kiln frame. Before you loosen, have the
personnel support the frame during hardware removal.
Lift the trolley rails enough for down kiln frame to be removed. Let the trolley rail sit gently on kiln
bottom.
Remove all hardware from up kiln trolley rail to up kiln frame. Have the personnel support frames
and trolley rails during hardware removal.
Lift and remove the trolley rails to the burn floor
Clean all machine components and hardware before storage
Make notes of any issues or repairs required

39
 DIAGRAM A
LEG JACKS & SCREWS JACKS

To adjust work platform, raise or

lower leg jacks
The bolt in the leg must be removed
for adjustments
Up kiln leg jacks are necessary when
a fork lift has no access to the up kiln
side of the machine

Easier to adjust for various kiln or

brick sizes

Adjust screw jacks for leg strength

and added leg support

WARNING:
TROLLEY LOCK MUST BE IN PLACE

40
 DIAGRAM B
ARCH TROLLEY DECK ADJUSTMENT

Adjust key and wing masons deck

height by raising deck with anticipated
trolley deck in place to appropriate
height to achieve easiest refractory
installation and correct head clearance
in work area

Trolley steps are easily removed

and reinstalled for key masons head
clearance requirements

Machine decks have many different

configurations. All built for your
specific kiln needs. Refer to your
manual drawing for your specific
arrangement.

Trolley lock must be in place before

adjusting the machine

WARNING:
TROLLEY LOCK MUST BE IN PLACE

41
 DIAGRAM C
ARCH WING ADJUSTMENTS

EOR center panel wing hardware

must be loosened to adjust arch.
After arch is set, Retighten arch
hardware
Slotted arch adjustment guides
move panels in for smaller
diameters and move panels out for
larger diameters

For larger diameters, raise the 3

ton trolley jacks

Lower 3 ton trolley jacks for small

diameters

Color coded screw jacks adjust

the arch wing panels

WARNING:
TROLLEY LOCK MUST BE IN PLACE

42
43
 MAINTENANCE,
TROUBLESHOOTING, &
REPAIR

44
 MAINTENANCE SCHEDULE
AREAS TO
PRE OUTAGE
CHECK
Air Supply free of dirt, debris, water
in lines; bleed air from
compressor & air line
Master Valve / test 2-3 times; run each
Pneumatic cylinder individually; use
Cylinders & Hoses silicone spray on cylinder
rods; check hoses for leaks,
cracks, fatigue
Lubricator Filter adjust air flow; adjust oil
System & flow 2-4 drops per cycle of
Shut off Valve master valve; shut off valve
functioning properly
Castor Wheels free of stress or fractures
brakes working properly
apply grease for proper
lubrication of bearings
Frames free of cracks or bends
all hardware tight
Rails free of sagging or alignment
deformities
Arch Trolley Cart all hardware tight; cart,
stabilizer post, adjustment
plate free of fatigue, cracks,
damage; mover cart stop in
place
Bottle Jack, 3 ton, reservoir full with clean
& 8 ton Hydraulic hydraulic jack oil; shaft fee of
Jacks damage; jack shaft lubricated
with hydraulic oil
Lights all working properly
Arches all hardware tight; free of
damage
Rubber Bumpers all in place and all hardware
tight
Spacer lubricate bearing; lubricate
Assemblies aluminum threads with dry
graphic spray/not bent
Shim Driver Gun working properly - add airtool
oil to air whip then test
function
Long Jack working properly
AFTER EACH SHIFT
repeat per outage checks
repeat per outage checks
lubricator reservoir full
of air tool oil; functioning
properly; shut off valve
functioning properly
check braking system &
castor position
free of cracks or bends
all hardware tight
all hardware tight (each
move); free of sagging or
alignment deformities
all hardware tight (each
move); cart & stabilizer
post free of fatigue,
cracks, damage
clean exposed shaft &
check mounting hardware
all hardware tight; free of
damage
all in place and clean with
no build up
check arch spacing and
adjust as needed
lubricate 2-3 times per
shift; lubricate shank and
quick disconnect with
silicone
keep hydraulic fluid full
AFTER USE
normal maintenanc should be
followed
use silicone spray on cylinder
rods; check hoses for leaks,
cracks, fatigue
Lubricator filter functioning
properly; replace filter every
other outage or excessively
dirty; shut off valve
functioning properly
free of stress or fractures
brakes working properly
apply grease for proper
lubrication of bearings
free of cracks or bends
free of sagging or alignment
deformities
cart & stabilizer post free of
fatigue, cracks, damage
clean & retract cylinder to
protect shaft
free of damage
rotate bumpers for even
ware; replace if large gouges
are present
lubricate bearing; lubricate
aluminum threads with dry
graphic spray
add oil to air whip and
distribute oil thru gun to
ensure working properly
working properly
45
PARTS ON HAND AT ALL TIMES
Master Valve repair kits (ASM461) OR A complete Master Valve assembly (ASM465) - depending on
experience, call technical services
A loaded Master Valve body (MV441)
Emergency Shut Off Valve (AF457)
Filter (AF100)
Lubricator (AL100)
Check Valve (CV004)
Lubricator-Filter system (ASM500)
Cylinder Repair Kit (ASM453)
Two (2) spare cylinders

CASTOR WHEELS
MAINTENANCE
Check castor body for any stress and replace if fractures exist.
Grease should be applied before each usage to ensure proper lubrication to the
bearings.
Verify breaking system available

TROUBLESHOOTING
If the wheels do not respond after a greasing, bearings are damaged and the
wheel needs to be replaced.

REPAIR
The wheels have a zirk grease fitting found just outside the axel hub.
When replacing the wheels, make sure the washers are returned to their proper position and locked.

CASTOR ROTATION All four castors must be

TROUBLESHOOTING locked parallel to the kiln
If the castors become difficult to rotate, clean the debris and axis while the bricking
fill with grease. machine is in use.

REPAIR
Grease
If there are cracks in the base, the entire castor must be replaced.

CASTOR ROTATION LOCK PIN & LOCKOUT ON CASTOR BEFORE JANUARY 2008
MAINTENANCE
The lock pin helps keep the castor in a set position.
There are four positions on the castor, each at 90 degrees.
The lock pin can freeze into position.
Separating the two castor pieces will allow the lock pin to be removed.
First, drive the roll pin out of the lock pin with a hammer and punch.
Once this has been removed, the lock pin will slide out of its housing.
Inspect the spring for damage and replace if necessary.
The lock pin is plated and can be subject to corrosion.
Sand the pin clean or replace.
Lubricate the housing and reassemble.
46 New castors as of January 2008
FRAMES
MAINTENANCE
Check all frame components for cracks and bends at the beginning
of each shift. If found, report damage to supervisor.
Check hardware tightness at the beginning of each shift.
Use only ASME Grade 5 hardware or equivalent for assembly.

REPAIR
Replace if bowed, twisted, or sagging.
All repairs are to be done by the manufacturer.
Do not reinforce the deck system unless you have notified
the manufacturer. Overloading, improper
Do not assume that if you reinforce the deck frames you will assembly, or alteration
be able to load more weight onto the machine. of the frames can
cause serious injury to
personnel.
RAILS
MAINTENANCE
The aluminum rails on the machine need to be kept clean of any
debris since the wheels of the trolley cart will be rolling over the rail
tracks.
A wire brush can be used to clean the rails clear of debris.
Check all hardware tightness at the beginning of each shift.
The rails should be inspected for any sagging or distortions. If
noticed, inform manufacturer.

REPAIR
If the rails sag when not under load more than / 17mm, they need to be replaced.

ARCH TROLLEY
MAINTENANCE
Check all hardware tightness at the beginning of each shift and all components in place.
Check the cart, stabilizer post, and base plate for any fatigue, cracks, or damage at the beginning of each
shift.
Make certain the arch trolley cart stop is in place at the down kiln end before use.
Replace arch adjustment plates if bent or sagging.
Be sure all safety devices are in working order and free from
damage.

REPAIR
The arch trolley wheels are made of steel.
By removing the axle, the wheels can be lifted free and
examined.
The bushing may be worn and in need of replacement or
require cleaning or lubrication.
Replace any wheel that has a damaged V-groove.
If wheel wont turn, the axle may be pitted or worn and need
to be replaced or cleaned.

47
2 TON BOTTLE JACK
MAINTENANCE
To fill the bottle jack, remove the rubber plug on the side of the jack half way up
the barrel.
With the ram down, fill the reservoir with clean hydraulic jack oil until the oil is
level with the bottom of the fill hole.
Make sure the shaft of the jack has not been damaged.
Lubricate the threaded portion of the jack shaft with hydraulic oil.
To prime the bottle jack, open the valve stem and pump handle
5-6 times to release air from under the ram.
Release the valve and then turn to closed position.

3 OR 8 TON HYDRAULIC JACKS

MAINTENANCE
To fill the jack, remove the rubber plug on the side of the jack half The bottle jack and
way up the barrel. hydraulic jack are
With the ram down, fill the reservoir with clean hydraulic jack oil not to hold the arch
until the oil is level with the bottom of the fill hole. into position. They
are only to be used
Make sure the shaft of the jack has not been damaged.
to raise the arch so
To prime the bottle jack, open the valve stem and pump handle
a pin can be placed
5-6 times to release air from under the ram. into the stabilizer
Release the valve and then turn to closed position. post.

LIGHTS
MAINTENANCE
The quartz lights are a 300w, 110v (220v), 60hz quartz light.
Do not touch the bulbs when installing them as oil will damage bulb; cover the
bulbs with paper or cloth and then install.
Keep the glass cover clean and angle the light by adjusting it toward the top of the
kiln shell.

ALUMINUM ARCHES
MAINTENANCE
Check arch at the beginning of each shift.
Check all hardware tightness at the beginning of each shift.
Use only ASME Grade 5 hardware or equivalent for assembly.

PNEUMATIC CYLINDERS
MAINTENANCE
The use of silicone spray or similar light weight lubricant on the
cylinder rods may also help in keeping the rod and o-ring lubricated.
Replace the cylinder and make sure all the hose fittings and
hardware are secure.
Replace quick connects if cracked or leaking.
Replace hoses if cracked, damaged, or if leaking.

48
TROUBLESHOOTING
The air cylinders have a repairable valve located on the bottom of the cylinder.
Replace the valve if the cylinder begins to leak at the bottom or the handle is
difficult to rotate. A cylinder repair kit is available through our parts department
(ASM453).
If the cylinder leaks in other areas, it will need to be replaced.

REPAIR
Disconnect air supply to machine.
Rotate the cylinder handle and remove until the roll pin on the backside of the
cylinder valve lines up with the slot on the valve body.
Use the spring compressor tool, provided in the tool box to compress the spring
freeing up the pressure on the pin.
Use a small diameter punch to push the pin out of the shaft and release
pressure on the tool.
Slide the shaft and washer out of the valve body.
Remove the plastic rotor and spring out of the inside valve body.
Inspect the interior of the valve body, clean any debris that may be inside, and
replace any necessary parts.
If removing the cylinder from the arch, the four cap screws that hold the cylinder
to the arch must be removed.
Loosen the set screw that holds the handle onto the cylinder and pull off the
handle from the cylinder.
The four air hoses attached to the cylinder will
need to be removed. It is important to replace leaking
Take the cap screws and handle off of the cylinders right away since the
cylinders on either side of the cylinder in need of bad cylinders will suck dust into
repair (for old cylinder style). the pneumatic system and create
Reassemble the cylinder. wear in other cylinders.

CYLINDER CHANGE BEGINNING IN 2005

The cylinder shaft; which has in the past been 3/8 is now 1/2. This change was
due to supply issues, our confidence remains in the 3/8 shaft cylinders that are still
employed. This change will begin to affect replacement parts in 2006 however and
that is the reason for this information piece.
For ADJUSTABLE machines, the change will be transparent, except for assuring
customers that the two sizes of shafts will be compatible with each other and the
1/2 shaft cylinders will fit the machines. Assembly of the bumper to the cylinder will
not change and all of the old bumpers and bumper hardware will fit on to the larger
shaft. The other noticeable difference for adjustable machine cylinders is that the
top of the shaft will be threaded, in addition to being slotted.
Cylinder orders for MOR & POR, the Fixed-sized machines, will get cylinders
with the shaft. The shaft will be slotted and have a hole drilled in it; the shaft will
also have 1/2 threads. It will be necessary to drill out the U bumper (A) to 29/64
and tap the hole to 1/2 - 20 threads per inch (National Fine Thread) and drill the
anti-turn U clip (B) from 3/8 to 1/2. Another option would be to replace all three
Cylinder shaft Cylinder at the same time. Bricking Solutions will have drills & taps available at cost to
with threads and shaft with help make sure customers have the tools to get the job done.
slot slot only
NEW OLD 49
FDEOR AND FDMOR RUBBER CYLINDER BUMPERS
MAINTENANCE
Keep the rods clean of any material build up.
Lubricate the rods before each use and prior to storage with silicone
lubricant.

REPAIR
The rubber cylinder bumper can be removed by unscrewing the 10/32
cap screw on the back center of the bumper.
Remove the old bumper and install the new bumper.
Reinsert the cap screw and tighten firmly.
Replace the steel rod by removing the e-clip from the top of the rod.
Slide the rod out and replace with the new rod and reinstall the e-clip.

MASTER VALVE
TROUBLESHOOTING
If clyinder response becomes slow to extend or retract, mufflers need
to be replaced. Over time they will slowly begin to plug themselves.
Replacing them with new mufflers will correct the issue.

REPAIR
Be certain always to have a complete Master Valve assembly in stock.
To repair the Master Valve, retract all cylinders and/or unkeyed brick.
Bleed the air off the machine by either opening the petcock valves at
the bottom of the arch or running the other master valve up & down until
the air in the system has been purged.
Remove Master Valve knob.
Remove Master Valve body (if able) or complete unit from machine and take it to a clean, well lit area for
repair.
Disassembly main components: pull spool out of body, remove the 4 cap screws that hold body to base
(carefully as there are 3 o-rings between these 2 pieces).
Remove the o-rings and discard.
Remove the 4 cap screws from end caps to gain access to center seals.
Within the body are 6 center seals. Remove these and discard them (hook tool is the best way to
accomplish this). Do this carefully so scaring of body interior is avoided. ALWAYS remove and replace all
6 seals when making this repair.
Open the master repair kit.
Lubricate the center seals and the interior of the valve body with petroleum jelly or o-ring lubricant.
Slide the seal into the body using both hands and use fingers to seat the seals into the seal cavity.
Start at the middle and work the seals out to each end.
Once all seals are in place, look into the valve & make sure they are all resting in the proper position.
Lubricate the spool and slide the spool back into the body.
Push and pull the spool many times to confirm the seals are seating properly.
Locate the three o-rings and seat into the o-ring cavity and lubricate o-rings.
Place the body on top of the base and thread the screws back into the base and tighten firmly.
Reinstall Master Valve on machine and reconnect all air lines and any other items removed prior to making
this repair.

50
 Recheck connections then re-install air to machine. Be certain all team
members of clear of any cylinder movement.
Cycle the Master Valve a couple of times to verify correct function.

LUBRICATING THE FILTER

MAINTENANCE
Fill oil reservoir with air tool oil to level marked on reservoir bowl.
Adjust oil flow to two to four (2-4) drops per cycle of master valve.
Adjust air flow and pressure as desired.
Machine operation pressure is 90-120 psi required

MANIFOLD BLEEDER PETCOCK

MAINTENANCE
Bleeder petcock are located at the end of each pneumatic hose run at the
bottom of each arch.
These valves should always be closed while in operation and always kept
open during storage.

TROUBLESHOOTING
If the valve is leaky, it may need to be tightened or the rubber o-ring will need
to be replaced

PNEUMATIC HOSES
MAINTENANCE
Bleed all hoses at the beginning of each shift.
Check all hoses for leaks and fatigue.
Always have spare lengths of hose available.

TROUBLESHOOTING
They will become brittle if exposed to heat for long periods of time, and will begin to crack and eventually
begin to leak.

SPACER ASSEMBLIES
MAINTENANCE
The spacer assemblies should be assembled using three small bolts and one long bolt.
The long bolt will act as a stop for the Anti-turn Lever.
Be certain long bolt wont come through bearing and bust anti-turn lever off.
The spacer assemblies bearings will need to be lubricated before each outage.
The bearing flange has a zirk fitting for installing grease.
The aluminum threads on the assembly should
be lubricated with a dry graphic spray.
Do not use a lubricant that will attract dust or ANTI-TURN
dirt. Keep threads clean. LEVER

TROUBLESHOOTING
If the aluminum threads get damaged they
must be replaced.

51
REPAIR
Unbolt the two bearing flanges with a wrench found in the tool box and remove the spacer assembly.
Notice the one end of the threaded bolt is pressed into the bearing flange.
Rest this bearing flange on top of an open vice.
Use a large flat punch and drive the threaded bolt out of the flange.
Un-thread the bolt out of the other bearing flange.
Thread in the new bolt.
Tighten the vice around the new bolt (soft jaws or wood can be used so as not to damage the bolt); put the
flange on top of new bolt and strike with a large rubber mallet.
A little lubricant may assist the bolt to slide into flange.
Reinstall on the arch when completed.
Use the same procedure for replacing damaged anti-turn lever and bearings.
Always keep bearings lubricated and when adjusting the spacer assemblies, try to adjust all four evenly so
not to bind the bolts.

SHIM DRIVER GUN

MAINTENANCE
The shim driver gun should be lubricated 2-3 times per shift by
inserting 3-4 drops of air tool oil into the air hook-up nipple located on
the handle of the gun.
Also lubricate the shank housing and quick disconnect with silicone or
similar light weight lubricant; otherwise the housing retainer can break
and the housing will fall off.
A spare gun should always be on hand along with the shim driver
shanks and shim driver heads.
After completing each job, and damaged guns should be sent out for
repair.

TROUBLESHOOTING
The shim driver gun utilizes a flapper style valve.
Dirty or wet air will sometimes cause this valve to stick.

REPAIR
To free this valve, add three drops of oil to air inloet, connect
air supply and while depressing level bang nose of gun
against a soft piece of wood to try to dislodge valve.
Shank and head must be installed to free flapper style
valve.
Never use a damaged shank
or shim head they can
KEYING JACK ASSEMBLY fragment and cause injury.
Pushing the trumpet valve operates the extension Always wear eye protection.
of the long jack, by pumping hydraulic fluid from the
hydraulic pump to the cylinder, and the jack extends.
NEVER fully extend cylinder, damage may occur.
Pushing the other valve releases the pressure to the jack by allowing air to run down the air hose to an air
cylinder or piston, which pushes down on the release valve.
This air cylinder works in a plunger fashion, pressing down on the release valve of the hydraulic pump.
This is located under an aluminum block, which is clamped to the blue hydraulic pump.
52
MAINTENANCE
For any air appliance, keep the supply
hose capped to prevent dirt from
entering the system.
Thread all components tightly.
Check QC fittings and replace if
cracked.
Check hoses and reset or replace if
damaged.
It is critical to stock a complete long
jack unit since the keying process
relies on the long jack.
It is important to keep the hydraulic
fluid full at all times and cylinders must
be fully retracted.
To fill the pump with fluid, unthread the
end cap at the rear of the pump and fill
with hydraulic fluid.
Keep the swivel feet tightly threaded
since they are tapered pipe threads or
damage will occur.
Replace the swivel feet if they are damaged, otherwise they may fracture and cause injury.
Keep the extension tightly threaded since they are tapered pipe threads or damage may occur.
Replace the extensions if damaged.
The long jack pressure should be determined by the installer or refractory provider.

TROUBLESHOOTING
If the cylinder slows, check the pump for the proper fluid levels.
If there is not enough air pressure, check to make certain air pressure at the long jack is gauged between
90-120 psi (6.21-8.27 bar).
If there is enough air pressure and it still doesnt work, debris may be in the air plunger located on the
inside of the aluminum block; follow instructions below to repair.

REPAIR
To clean the air plunger, remove the aluminum blocks from the hydraulic pump.
Remove the spring and piston and clean out debris.
Clean and apply petroleum jelly or O-ring lube to lubricate.
Reassemble.
To adjust the pressure on the hydraulic pump, follow the hydraulic line from the pump to the 10-ton cylinder
to a nut extending from the pump just below the aluminum block
In the center of the nut is a plastic plug
Pop out the small plastic plug using a blade
Find an Allen head screw behind the plastic plug, this is the hydraulic setting of the pump
The screw should be backed off 1/8th of a turn or so
To set the pressure, place the long jack cylinder in a fixture so the pressure can be jacked up.
If you are able to do this in the kiln, you can jack up the pressure in a keying void of the brick being
installed.

53
 Pump the jack up to the pressure determined by the installer.
This will decrease the amount of pressure of the hydraulic pump and the pressure on the release valve
so the air piston will be able to push down and activate the release valve, which in turn will release the
pressure on the 10-ton cylinder.

54
 CONTENTS

Summary Of Our Mission2 Moving Bricking Machine In Kiln Over Old Refractory32
Welcome To The Bricking Solutions Family3 Moving Bricking Machine In Kiln Over Retaining Ring33
Bricking Solutions Warranty Conditions4 If Utilizing Fork Truck Bracket33
Indemnity, Waiver Of Liability, & Assumption Of Risk5 If Manually Moving Machine 33
Engineers Certification Of Manufacturing Standards6 The A-B-Cs Of Bricking Thru Transition (Conical/Taper) For
Engineering Certification Of Anti-Fall Guards7 FDEOR & FDMOR35
Inspection & Repair Of Aluminum Fabrication Welds8 Diagram ALeg Jacks & Screws Jacks36
Safety Instructions9 Diagram BArch Trolley Deck Adjustment37
General9 Diagram CArch Wing Adjustments38
In The Event Of An Accident9 Dissassembly And Storage Instructions39
Responsibilitiy Of Supervisors And Masons9 Maintenance, Troubleshooting, & Repair40
Requirements Of The Masons9 Maintenance Schedule41
Protective Equipment10 Castor Wheels 42
Risk Factors Before And During Operations10 Castor Rotation42
Assembly Safety Risks10 Castor Rotation Lock Pin & Lockout On Castor Before
Moving Or Adjusting The Machine Risks11 January 200842
While Working / Operating Machine12 Frames43
Sticker Warnings On Machine13 Rails43
Kiln Maintenance: More Than Rebricking14 Arch Trolley43
Organizing The Burn Floor 14 2 Ton Bottle Jack44
Safe & Efficient Kiln Access14 3 Or 8 Ton Hydraulic Jacks44
Safe Inspection Of Brick 15 Lights44
Removal Of Coating And Brick 15 Aluminum Arches44
Removal Of Debris And Mucking The Kiln15 Pneumatic Cylinders44
Planning For New Refractory Installation Begins16 Cylinder Change Beginning In 200545
Suppling Brick To The Masons16 Fdeor And Fdmor Rubber Cylinder Bumpers 46
Another Way To Supply Brick To The Masons16 Master Valve 46
Planning, Pre-Staging, & Training 17 Lubricating The Filter 47
Anatomy Of A Flat Deck Easy Flex18 Manifold Bleeder Petcock47
FDEOR Machine Specifications20 Pneumatic Hoses47
FDMOR Machine Specifications21 Spacer Assemblies47
Pre Use Machine Set Up22 Shim Driver Gun48
Before Work22 Keying Jack Assembly48
Pre Outage Maintenance And Service22
Machine Requirements22
Preparing For Pre Use Machine Assembly 22
Hooking Up And Testing Air Supply To Machine24
Testing Cylinders 3-Way Master Valves And Lubricator-
Filter24
Pre Use Inspection Checklist 25
Avoid Heart Failure & Lung Collapse26
Staging The Machine For Assembly Inside The Kiln 27
Machine Assembly Inside The Kiln 27
Adjusting Arch Height Fdmor / Fdeor29
Installing The First Ring30
Using Hydraulic Jack To Move Arch 30
Operating The Bricking Machine 30
Shimming The Newly Keyed Ring31
Moving The Arch31
Key Bricks Cutting Or Nominal Key Bricks 31
Rotation Of The Kiln32
Moving Bricking Machine In Kiln32
Moving Bricking Machine In Kiln Over New
Refractory32 55
 1144 Village Way | Monroe, Washington 98272 | USA
360.794.1277 | 800.621.7856 | FAX 360.805.2521
E-mail: info@brickingsolutions.com | www.brickingsolutions.com