brake cable and lever systems - wescon...

WESCON CONTROLS

BRAKE CABLE AND LEVER SYSTEMS

2

WESCON'S BRAKE CABLES, LEVERS AND KITS

Brake Cables Wescon brake cables are designed to allow high loads to be carried with low compressive defl ection. This provides safe and effi cient performance of your brake system.

Custom Brake Cables Wescon's engineers can customize a brake cable to fi t your application. From hard to reach locations to harsh environmental conditions, Wescon can build a brake lever control system to meet your requirements.

Over-Center Brake Levers Wescon has available nine different models of over-center brake levers to fi t your application. Our levers offer a welded construction with a durable matte black, powder coat fi nnish to prevent corrosion.

Ratcheting Brake Lever Wescon's ratcheting brake levers allow progressive tension adjustments when applying the brake and a push button release for disengaging.

Brake Lever with Electric Switch Wescon has developed the ability to install a magnetic electric switch in any of our over-center brake lever models. This switch is environmentally sealed and can be easily installed by Wescon or the customer.

Connection Hardware Kits Wescon offers connection kit hardware to join your brake lever and cable. Our zinc cobalt plated components prevent corrosion which means a reliable brake cable system.

3

Wescon Brake Cables

Conduit Inner-Core CONSTRUCTION The conduit construction is a Bowden Flat Wire design, made from spring steel wire. This type of construction is extremely effective in providing high loading with low compressive defl ection in brake cable control assemblies. It is designed to combine fl exibility, for ease of routing during installation, with the performance requirements of a safe and reliable brake cable system.

LINER The liner of our Standard Series Brake Cable is made from High Density Polyethylene (HDPE), especially formulated to minimize friction for maximum effi ciency. Our Premium Series Brake Cable features a self-lubricating Nylon liner for use in high temperature applications.

COVERING Our special formulated conduit coverings seal out environmental contaminants and dirt while resisting abrasions and common solvents. Our Standard Series Brake Conduit features a HDPE covering, while our Premium Series .125 dia. Brake Conduit features a Nylon covering for high temperature applications.

FITTINGS A variety of conduit fi ttings are available to satisfy most requirements. Special fi ttings are available upon request. All fi ttings are zinc-cobalt plated steel exceeding a 96-hour salt spray corrosion resistance test and swaged to the conduit resulting in a highly secure installation. The fi ttings incorporate internal seals to inhibit entry of dirt and contaminants into the cable. These specially designed seals provide a smooth sliding wear surface for the Inner Core, resulting in a highly effi cient, long life brake cable.

CONSTRUCTION On the .125 and .156 diameter series brake cables the inner core is manufactured with pre-formed high-tensile 1 x 19 galvanized steel strand and covered with a highly effi cient self-lubricating nylon jacket. In the covering process the nylon jacket is pressurized onto the strand providing a unifi ed con-struction with improved effi ciency and reduced wear of the inner core. This design results in a fl exible, easily operated control assembly with low defl ection and increased cycle life. On the .187 diameter series brake cable the inner core is a bare 1 x 37 galvanized steel strand.

FITTINGS A variety of end fi ttings such as clevises, slug fi ttings and end rods are available. All fi ttings are zinc cobalt plated with yellow chromate for additional corrosion protection and swaged to the inner core to hold the specifi ed load of the cable assembly.

LUBRICATION The inner-core is lubricated with a specially formulated lubricant and is factory installed for years of effi cient and maintenance-free operation. As an alternative for demanding applications, Wescon has developed a proprietary lube, especially formulated for antifreeze protection, which is available at additional cost.

NOTE: Brake Cable Installation ConsiderationsThe following steps should be taken when installing brake cable assemblies:1) A sketch of the proposed installation will help Wescon Engineering select the proper control for your needs. A Wescon engineering drawing will be made. The design will then be approved by you and a sample will be provided for you to check for proper fi t in the application to complete the design process.2) Conduit fi ttings should be securely fastened to a structural member or rigid support.3) In order to reduce operational load due to friction of the inner member within the conduit, remember to keep the degrees of bend in the routing of the cable to a minimum.4) Assemblies over 6 feet should be supported at vari- ous points along the length of the conduit to minimize vibration induced failures at the conduit/fi tting junction.

HDPE or Nylon LinerLow Friction, Maximum Effi ciency

Specially Formulated

Lubricant

Flat Wire "Bowden" ConduitFlexibility with Low Compressive Defl ection

HDPE or Nylon CoverSeals Out ContaminantsResists Abrasion

Nylon Covered CorePressurized Unifi ed Construction for Long Life(.125 & .156 Dia Series Only)

Internal SealsSeal Out ContaminantsProvides Wear Surface

Conduit FittingsZinc Cobalt Plated for High Corrosion Protection

Core FittingZinc Cobalt Plated

4

Core

Conduit:Liner with Steel FlatWire Jacket, Plastic CoveredLiner

.187 Dia. Series Brake Cables

Minimum bend radius: 5 inchesProof loaded 100% to 1200 lbs.


* H.D.P.E. = High Density Polyethylene




** For Applications up to 300° F

Wescon Brake Cables

ConduitCore

Cover Liner

Standard H.D.P.E.* H.D.P.E.* .125 (1/8) Dia-1x19 Galvanized CableNylon Covered to .156 (5/32) DiaPremium ** Nylon Nylon

ConduitCore

Cover Liner

Standard H.D.P.E.* H.D.P.E.* .156 (5/32) Dia-1x19 Galvanized CableNylon Covered to .187 (3/16) Dia

ConduitCore

Cover Liner

Standard H.D.P.E.* H.D.P.E.* .187 (3/16) Dia-1x37 Galvanized Cable

5

Company Name: ________________________________ Contact Person: _______________________________________

Phone : _____________________________ Fax: ________________________________ E-Mail: __________________________

Which Cable Series Fits your Application? (See page 4) .125 Series .156 Series .187 Series

Which Type? Standard Premium

Will cable be used with a brake lever? Yes No If Yes, model number (See pages 11-19 & 22-28) _______________

What will be your Part Number? Cable Assy __________________________ Brake Lever ______________________________

Optional Accessories? (See page 7) Jam Nut Retaining Ring Compression Spring Boots

Cable FittingPart No.

Cable FittingPart No.

Conduit FittingPart No.

Conduit FittingPart No.

Fill in your requirements and fax to Wescon at 316-942-5114or visit our web-site www.wesconproducts.com

Brake Cable Worksheet

Assy Utilizing U-Bolt Type Conduit FittingSee page 8

Assy Utilizing Clamp Type Conduit FittingSee page 8

Assy Utilizing Retaining Ring Type Conduit FittingSee page 8

Assy Utilizing Snap-In Type Conduit FittingSee page 8-9

Assy Utilizing Threaded Conduit FittingSee page 8

Cable Eye FittingSee page 7

Cable Slug FittingSee page 7

Cable End RodSee page 6

Clevis (Straight)See page 6

Clevis (Closed)See page 6

Control Length ± "A" Fully Ext. ±.18

Control Length (Inches) "A"

Up to 24.00 ± .12

24.01to 60.00 ± .18

60.01 to 120.00 ± .25

120.01 to 240.00 ± .50

Above 240.00 ± 1.00

6

Threaded End Rod

"A"

"B"

Thread

Core

"B"

"A"

Clevis (Closed) .125/.156/.187 Series

"C"

5/16 Dia Threaded End Rod

"D"

Clevis Pin Dia

Clevis (Straight) .125/.156/.187 Series

"B" "A"

"D"

Slug Fitting

"C" Clevis Pin Dia

Slug Fitting

Cable Fittings

Type I

Type II

.32/.33 .50/.51

PartNumber Type "A" "B" "C" "D" Cable End

TypeClevis Pin

Dia22-2121-01 I .21/.27 .41/.42 1.44 .65 Slug Fitting 5/1622-2121-04 I .22/.28 .51/.52 2.38 .75 5/16 Dia Thd. Rod 5/1622-2121-05 I .22/.28 .51/.52 1.75 .75 5/16 Dia Thd. Rod 3/822-2121-06 I .16/.22 .51/.52 1.88 .75 5/16 Dia Thd. Rod 5/1622-2121-07 I .22/.28 .38/.39 1.88 .75 Slug Fitting 3/822-2121-08 I .16/.22 .38/.39 1.56 .75 Slug Fitting 3/822-2121-09 I .22/.28 .51/.52 1.75 .75 Slug Fitting 5/1622-2121-10 I .20/.28 .51/.52 2.38 .75 Slug Fitting 3/822-2121-11 I .26/.28 .51/.52 1.45 .75 Slug Fitting 5/1622-2121-13 II .21/.27 .41/.42 1.44 .65 Slug Fitting 5/1622-2121-14 I .28/.34 .51/.52 2.38 .75 Slug Fitting 3/822-2121-16 I .25/.29 .41/.42 1.44 .65 Slug Fitting 1/4

PartNumber "A" "B" "C" "D" Cable End

TypeClevis Pin

Dia22-2122-01 .38/.45 .39/.40 1.62 .62 Slug Fitting 5/1622-2122-02 .38/.45 .39/.40 2.00 .62 Slug Fitting 5/1622-2122-07 .49/.56 .51/.52 1.62 .62 Slug Fitting 5/1622-2122-08 .49/.56 .51/.52 1.94 .75 Slug Fitting 3/822-2122-09 .49/.56 .51/.52 2.50 .75 5/16 Dia Thd. Rod 5/1622-2122-10 .49/.56 .51/.52 2.50 .75 5/16 Dia Thd. Rod 3/822-2122-11 .49/.56 .51/.52 1.94 .75 Slug Fitting 5/1622-2122-18 .49/.56 .51/.52 1.94 .75 Slug Fitting 1/222-2122-19 .55/.59 .57/.58 .94 .75 Slug Fitting 1/222-2122-21 .49/.56 .51/.52 1.62 .62 5/16 Dia Thd. Rod 5/1622-2122-26 .65/.69 .63/.67 .68 .62 Slug Fitting 5/1622-2122-27 .71/.79 .72/.75 1.94 .75 Slug Fitting 3/8

.125 Series

PartNumber

CoreSize "A" "B" Thread

21-1052-47 .125 Dia 2.62 1.50 3/8-24 UNF-2A21-1052-11 .125 Dia 3.62 2.25 5/16-24 UNF-2A21-1052-12 .125 Dia 4.62 3.25 5/16-24 UNF-2A21-1052-13 .125 Dia 2.75 1.50 1/4-28 UNF-2A21-1052-14 .125 Dia 2.50 1.50 5/16-24 UNF-2A21-1052-20 .125 Dia 5.00 2.50 1/4-20 UNC-2A

.156 Series

PartNumber


21-1052-26 .156 Dia 2.00 1.00 3/8-24 UNF-2A21-1052-27 .156 Dia 2.50 1.50 3/8-24 UNF-2A21-1052-28 .156 Dia 3.00 2.00 3/8-24 UNF-2A21-1052-29 .156 Dia 3.25 2.25 3/8-24 UNF-2A

.187 Series

PartNumber


21-1052-35 .187 Dia 2.00 1.00 3/8-24 UNF-2A21-1052-36 .187 Dia 2.50 1.50 3/8-24 UNF-2A21-1052-37 .187 Dia 3.00 2.00 3/8-24 UNF-2A21-1052-38 .187 Dia 3.25 2.25 3/8-24 UNF-2A21-1052-39 .187 Dia 2.00 1.00 5/16-24 UNF-2A21-1052-40 .187 Dia 2.50 1.50 5/16-24 UNF-2A21-1052-41 .187 Dia 3.25 2.25 5/16-24 UNF-2A21-1052-42 .187 Dia 4.00 3.00 5/16-24 UNF-2A21-1052-31 .156 Dia 2.50 1.50 5/16-24 UNF-2A21-1052-32 .156 Dia 3.25 2.25 5/16-24 UNF-2A

7

Cable Fittings

Cable Eye Fitting Cable Swage Fitting

Conduit Fitting Accessories

Jam Nut

.31

9/16-12 UNC-2B

.87 Hex

NOTE: Use with Retaining Ring Conduit Fitting (See page 8)

Retaining Ring

O.D. ±.005

Active Coils

Free Length ±.12

Compression Spring(26-6332 Series)

Many standard springs are available for your application. Contact Wescon for details.

Flexible Boot - Ethylene Propylene (EPDM)(03-0003 Series)

For additional protection and in severe applications, where moisture and debris are major concerns, fl exible boots are available to prevent foreign materials and moisture from entering the cable, providing superior performance and longer life.

"B"(After

Swaging)

"C"

1.00

"A"Dia

.245

Core

Type I

"A"

"B" Dia

Core

Type III"A"

"B" Dia

Type IV"A"

"B" Dia

Type VI"A"

"B" Dia

Type VII"A"

"B" Dia

Full Sph. R

Full Sph. R

Full Sph. R

.125 Series

PartNumber

CoreSize "A" "B" "C"

21-1108-13 .125 Dia .500 1.93 .7521-1108-18 .125 Dia .329 1.93 .7521-1108-19 .125 Dia .329 1.50 .7521-1108-24 .125 Dia .475 1.50 .75

.156 Series

PartNumber


21-1108-17 .156 Dia .500 1.93 .7521-1108-28 .156 Dia .323 1.93 .5621-1108-29 .156 Dia .386 1.93 .75

.187 Series

PartNumber


21-1108-06 .187 Dia .265 1.93 .7521-1108-07 .187 Dia .329 1.93 .7521-1108-08 .187 Dia .386 1.93 .75

.125 Dia Bare/Covered Cable

PartNumber

CoreSize "A" "B" Dia

(Approx.) Type

21-1086-28 .125 Dia .50 5/16 VI21-1086-30 .125 Dia .50 3/8 VII21-1086-37 .125 Dia .50 3/8 VI21-1086-50 .125 Dia 1.28 11/32 IV

.156 Dia Bare Cable

PartNumber


(Approx.) Type

21-1086-39 .156 Dia .87 3/8 VI

.187 Dia Bare Cable

PartNumber


(Approx.) Type

21-1086-05 .187 Dia .87 3/8 I21-1086-35 .187 Dia .87 3/8 III

.125 and .187 Series

Part Number80-0006-72

.125 and .187 Series

Part Number80-0033-09

8

9/16-12 UNC-2A

Threaded Conduit Fitting

“A”

.125 Series

18-0034-0110" Backing Plate

18-0034-0212" Backing Plate

38° Conduit Fitting

.50 Dia

2.56

38°

.134 - With Retaining Ring

.165 - With Retaining Ring Removed

Retaining Ring

U-Bolt Conduit Fitting

1.37.36

.50 Dia

.38 Dia

.17 R

2.39

.44

.62 Dia

.38 Dia.17 R

.125 Series21-2410-01Standard Fitting

.156/.187 Series21-2410-02Standard Fitting

.88

Conduit Fittings

Retaining Ring Conduit Fitting

.50Dia

.50

.56 Dia

.23/.24 Grip

1.37

.12/.13 Grip

Clamp Type Conduit Fitting

2.431.00

.62 Dia

.50 Dia

1.50.75

.50 Dia

.50 Dia

.125 Series21-2406-01Standard Fitting


“B”

.125 Series21-2404-02, -07Standard Fitting

.156/.187 Series21-2404-05, -06Standard Fitting

.50

.56 Dia (-02)

.50 Dia (-07)

1.37

.19 Grip (-02)

.28 Grip (-07)

Retaining Ring / Boot Conduit Fitting.125 Series21-2404-15Standard Fitting


.56 Dia

.69

.55 Dia

1.37

.19 Grip

.69Dia .69 Dia

.72

.56 Dia

1.50

.24 Grip.13 Grip

21-2404-01Standard Fitting

.78

1.43

.24 Grip (-05)

.28 Grip (-06)

.55 Dia

.13 Grip (-05)

.19 Grip (-06)

.50Dia

.125 Series

Part Number "A" "B" "C"21-2405-01 2.37 1.50 .56 Dia

.156/.187 Series

Part Number "A" "B" "C"21-2405-02 2.43 1.50 .62 Dia21-2405-03 2.93 2.00 .62 Dia

“C”

9

Snap-In Conduit Fitting

.50 Dia

Conduit Fittings

.125 Series18-0014-07.12/.18 Grip.57/.58 Dia Mounting Hole

.125 Series18-0024-01.12/.18 Grip.62 Dia Mounting Hole

.156/.187 Series18-0024-03.12/.18 Grip.62 Dia Mounting Hole

.781.50

.68 Dia

.721.56

.156/.187 Series18-0024-02.12/.18 Grip.57/.58 Dia Mounting Hole

EqualizerPart Number - 02-1600-89 .47 Dia. Hole

for 3/8 Dia Slug Fitting(2 Places)

.36 Dia. Holefor 5/16 Dia Threaded Rod

.87

2.004.00

1.06 .811.62

.33 Dia Holefor 5/16 Dia Clevis Pin(4 Places)

.39 Dia Holefor 3/8 Dia Clevis Pin(2 Places)

Typical Applications and Recommended Components

21-1086-30 (.125 Series w/.125 Dia Cable)21-1086-39 (.156 Series w/.156 Dia Cable)21-1086-35 (.187 Series w/.187 Dia Cable)

3/8 Dia Clevis Pin21-1108-26 (.125 Series w/.125 Dia Cable)21-1108-29 (.156 Series w/.156 Dia Cable)21-1108-08 (.187 Series w/.187 Dia Cable)

21-1108-18 (.125 Series w/.125 Dia Cable)21-1108-28 (.156 Series w/.156 Dia Cable)21-1108-07 (.187 Series w/.187 Dia Cable)

Brake Cable Equalizer

5/16 Dia Threaded End Rod(See page 6 for options)

5/16 Dia Clevis Pin

10

NOTE: Electric Switch option is available on all over-center brake levers (see page 30)

XXX

1 = With Hardware Kit2 = Without Hardware Kit3 = Installed Electric Switch with Hardware Kit4 = Installed Electric Switch without Hardware Kit

Design Options:

Over-Center Brake Lever Part Number CodesFor Over-Center Brake Levers Shown on Pages 11-19

Designation forBrake Lever

19

Knob Cover:

1 = Without Orange Knob Cover4 = With Orange Knob Cover

X X X

Model Number:

200 (see page 11)201 (see page 12)202 (see page 13)203 (see page 14)204 (see page 15)

Over-Center Brake Levers

0 = Standard Lever3 = Long Lever

205 (see page 16)206 (see page 17)207 (see page 18)208 (see page 19)

Flange Mount Brake Lever with Single CableModel 202 (Pg. 13), Model 206 (Pg. 17),

Model 208 (Pg. 19)

Flange Mount Brake Lever with Dual CableModel 205 (Pg. 16)

Side Mount Brake Lever with Single CableModel 200 (Pg. 11), Model 201(Pg. 12), Model 203 (Pg. 14), Model 207 (Pg. 18)

Side Mount Brake Lever with Dual CableModel 204 (Pg. 15)

11

Model 200 Over-Center Brake Lever

1.15 (29.2)

All dimensions are inches (mm)

• Side mount to cowling, instrument panel, seat riser or frame installation.

• Use clamp-type conduit fi ttings (See page 8) on the end of the cable that attaches to the brake lever.

• 2.5 inches (64mm) wide side plates with three alternate positions for attaching one brake cable assembly.

• Electric switch option (See page 30)

Typical Applications and Features

Dimensions 3.11 and 4.11 depict lengths when lever is in "OFF" position. The 2.11 dimension will not allow the lever to be put in full "OFF" position. This will reduce the net travel of the lever. These dimensions should be used to calculate cable assembly length.

21-2406-01 (.125)21-2406-03 (.156 & .187)

Hole for 5/16 (7.9) Dia Pin

22-2121-01 (.125)22-2121-09 (.156 & .187)21-1086-28 (.125)21-1086-39 (.156)21-1086-05 (.187)

4.11 (104.4)3.11 (79.0)2.11 (53.6)

-A-

(6) Holes for 5/16 (7.9) Dia Bolt, Both Plates

.50 (12.7)

-A-

2.50 (63.5)

Adjusting Nut

1.25 (31.7) Dia

5.00 (127.0)

4.14 (105.2)2.46 (62.5)

8.20 (208.3) Standard Lever12.12 (307.8) Long Lever

1.66 (42.2) 2.50(63.5)6.75 (171.4)

8.25 (209.5)

(2) Holes for 3/8 (9.5)Dia Bolt, Both Plates

1.00 (25.4)(Typ)

1.50 (38.1)

.91(23.1)

.12 (3.0)

01-5001-23 Hardware Kit(Items listed in parentheses not included in kit)

(Top Side Plate)(Pivot Nut)

Flat WasherHair Pin

Cotter Pin5/16-18 Jam Nut (2)

Spacer (2)

Clamp

(Clamp Fitting)

Spacer

(Bottom Side Plate)

(Pivot Nut)Clevis Pin

5/16-18 Bolt (2)

(Linkage)

(Brake Lever)

(Clevis)

Recommended components for mounting brake cable with this brake lever assembly

NOTE:

Electric Magnetic Switch Option

(Pivot Fastener)

Spacer (2)

12


1.15 (29.2)

.12 (3.0)

.91 (23.1)

4.66 (118.4)

2.50(63.5)

1.66(42.2)

5.00 (127.0)

1.25 (31.7)

2.46 (62.5)

4.14 (105.2)

Adjusting Nut

1.25 (31.7) Dia

2.50 (63.5)

-A-



21-1086-28 (.125)21-1086-39 (.156)21-1086-05 (.187)

22-2121-01 (.125)22-2121-09 (.156 & .187)

-A-

Cotter PinHair Pin

Flat Washer

(Mounting Nuts)

(Pivot Nut)

(Top Side Plate)

(Brake Lever)

(Linkage)

(Clevis)

(Clamp Fitting)

Spacer (2)

(Bottom Side Plate)

(Pivot Nut)

(Mounting Bolt)

Clevis Pin

(Mounting Bolt)



• Conduit support supplied by customer external to the brake lever.

• 2.5 inches (64mm) wide side plates for one brake cable assembly.

• Electric Switch Option (See page 30)


Customer Specifi ed (consult your Wescon representativefor standard fi ttings)

Customer to provide conduit fi tting support

01-5000-19 Hardware Kit for 5/16 bolts01-1902-01 Hardware Kit for 3/8 bolts(Items listed in parentheses not included in kit)




(Pivot Fastener)

13


Typical Applications and FeaturesAll dimensions are inches (mm)

• Flange mount for bulkhead, fl oor or island (dog house) installation.


• 2.5 inches (64mm) wide side plates with one position for attaching one brake cable assembly.

• The rigid frame maintains alignment of clevis pin guideslots for improved life of both the pin and side plates.


Dimension 2.58 (65.5) depicts length when lever is in "OFF" position. These dimensions should be used to calculate cable assembly length.

-A-

.50 (12.7)

6.22 (158.0)

6.84 (173.7)

.12 (3.0)1.15 (29.2)

.91 (23.1)

3.31(84.1)

Adjusting Nut

2.46 (62.5)

2.50 (63.5)

4.14 (105.2)

5.00 (127.0)

1.25 (31.7) Dia

(4) Holes for5/16 (7.9) Dia Bolt

.75 (19.0)

1.50 (38.1).50 (12.7)

2.31(58.7)

1.25 (31.7)

21-2406-01 (.125)21-2406-03 (.156 & .187)2.58 (65.5)

21-1086-28 (.125)21-1086-39 (.156)21-1086-05 (.187)

22-2121-01 (.125)22-2121-09 (.156 & .187)

-A-


.50 (12.7)


1.50 (38.1)

01-5001-01 Hardware Kit(Items Listed in Parentheses not included in Kit)

5/16-18 Jam Nut (2)

Cotter Pin

Hair PinFlat Washer(Pivot Nut)

(Top Side Plate) Spacer (2)

Clamp

(Clevis)

(Clamp Fitting)

Spacer

(Linkage)

(Brake Lever)

(Bottom Side Plate)


5/16-18 Bolt (2)



NOTE:


(Pivot Fastener)

14





• 1.5 inches (38mm) wide side plates with single position for attaching one brake cable assembly.



.12 (3.0)

1.15 (29.2)

.91 (23.1)

Adjusting Nut

4.14 (105.2)

2.46 (62.5)

5.00 (127.0)

1.25 (31.7) Dia

1.56(39.6)

7.96 (202.2)

3.22 (81.8) 4.00 (101.6)

4.00 (101.6) (4) Holes for 5/16 (7.9)Dia Bolt, Both Plates

-A-

.33 (8.4)

1.50 (38.1)


22-2121-01 (.125)22-2121-09 (.156 & .187)21-1086-28 (.125)21-1086-39 (.156)21-1086-05 (.187)

21-2406-01 (.125)21-2406-03 (.156 & .187)

3.46 (87.9)

-A-

Dimension 3.46 (87.9) depicts length when lever is in "OFF" position. These dimensions are used to calculate cable assembly length.


Cotter Pin

Hair Pin

Flat Washer

(Top Side Plate)(Pivot Nut)

5/16-18 Jam Nut

(Linkage)(Brake Lever) Spacer

(Clamp Fitting)

Clamp

(Clevis)5/16-18 Bolt

(Pivot Nut)

(Bottom Side Plate)Clevis Pin



NOTE:


Spacer

(Pivot Fastener)

15





• 2.5 inches (64mm) wide side plates with single position for attaching two brake cable assemblies.

• When considering load requirements, the load on the lever assembly will be the sum of the load in each cable.



.91 (23.1)

1.15 (29.2)

.12 (3.0)

2.46 (62.5)

5.00 (127.0)

4.14 (105.2)

-A-Adjusting Nut

1.25 (31.7) Dia

8.50 (215.9)8.03 (204.0)

5.16 (131.1)6.91 (175.5)

2.50 (63.5)


Dimension 2.80 (71.1) depicts length when lever is in "OFF position. These dimensions are used to calculate cable assembly length.

21-2406-01 (.125)21-2406-03 (.156 & .187)

21-1108-19 (.125)21-1108-28 (.156)21-1108-07 (.187)


2.80 (71.1)

-A-


5/16-18 Jam NutCotter Pin (3)Hair Pin (3)

Flat Washer(Pivot Nut)

(Top Side Plate)

Connecting Link (2)

Clamp (2)

Spacer

(Clamp Fitting)

(Linkage)(Brake Lever)

Clevis Pin (2)

(Bottom Side Plate)


5/16-18 Bolt

(Cable Eye)



NOTE:


(Pivot Fastener)

Spacer

16






• 2.5 inches (64mm) wide side plates with single position for attaching two brake cable assemblies.

• When considering load requirements, the load on the lever assembly will be the sum of the load in each cable.


2.46 (62.5)

-A-.12 (3.0)

2.41 (61.2).91 (23.1)

Hole for 5/16 (7.9)Dia Bolt, Both Plates

4.14 (105.2)

1.50(38.1)

1.81 (45.7)

(6) Holes for 5/16 (7.9) Dia Bolt

6.89 (175.0)8.62 (218.9)

5.00 (127.0)

1.25 (31.7) Dia

Adjusting Nut


21-1108-19 (.125)21-1108-28 (.156)21-1108-07 (.187)

21-2406-01 (.125)21-2406-03 (.156 & .187)

2.80 (71.1)

-A-



5/16-18 Jam NutCotter Pin (3)

Hair Pin (3)Flat Washer(Pivot Nut)

(Top Side Plate)

Connecting Link (2)

Clamp (2)

(Clamp Fitting)

Spacer

(Cable Eye)

(Linkage)

(Brake Lever)

Clevis Pin (2)

(Bottom Side Plate)

(Pivot Nut) Clevis Pin

5/16-18 Bolt

2.50 (63.5)



NOTE:


(Pivot Fastener)

17







21-2406-01 (.125)21-2406-03 (.156 & .187)

21-1086-28 (.125)21-1086-39 (.156)21-1086-05 (.187)

22-2121-01 (.125)22-2121-09 (.156 & .187)

2.58 (65.5)

-A-



9°

.12 (3.0)

3.41 (86.6)

1.15(29.2)


(4) Holes for 5/16 (7.9)Dia Bolts

.91 (23.1)

4.14 (105.2)

2.46 (62.5)

1.25 (31.7) Dia

5.00 (127.0)

1.50(38.1)

6.22 (158.0)

6.82 (173.2)

2.50 (63.5)

.52 (13.2)

.50 (12.7)

2.31 (58.7)

-A-

Adjusting Knob

1.50(38.1)



8.20(208.3) Standard Lever12.12 (307.8) Long Lever


NOTE:

5/16-18 Jam Nut (2)

Cotter PinHair Pin

Flat Washer(Pivot Nut)

Spacer (2)

Clamp

(Clevis)

(Clamp Fitting)

Spacer

5/16-18 Bolt (2)

Clevis Pin(Pivot Nut)

(Bottom Side Plate)

(Linkage)

(Top Side Plate)

(Brake Lever)


(Pivot Fastener)

18

1.17 (29.7)

4.14 (105.2)

2.46 (62.5)

5.00 (127.0)

1.50 (38.1)

1.25 (31.7) Dia

Adjusting Knob

3.22 (81.8) 4.00 (101.6)

8.10 (205.7)


.31 (7.9)

-A-


-A-

22-2121-01 (.125)22-2121-09 (.156 & .187)21-1086-28 (.125)21-1086-39 (.156)21-1086-05 (.187)

18-0014-07 (.125)18-0024-02 (.156 & .187)

3.95 (100.3)




• Use snap-in type conduit fi ttings (See page 8-9) on the end of the cable that attaches to the brake lever.





(Mounting Nuts)Cotter PinHair Pin

Flat Washer

(Pivot Nut)

(Top Side Plate)

(Linkage)

(Brake Lever)

Spacer (2)

(Clevis)

(Snap-In Fitting)

(Bottom Side Plate)

(Pivot Nut) (Mounting Bolt)

Clevis Pin

(Mounting Bolt)



NOTE:

.57/.58 Dia



(Pivot Fastener)

19

All dimension are inch (mm)

• Flange mount for bulkhead, fl oor or island (doghouse) installation.




.52 (13.2)

Adjusting Nut

4.14 (105.2)

.12 (3.0)

1.15(29.2)

3.41(86.6)

2.46 (62.5)

5.00 (127.0)

1.25 (31.7) Dia

.91(23.1)

-A-

2.50 (63.5)

1.50(38.1)

6.22 (158.0)

6.82 (173.2)

(2) Holes for 5/16 (7.9)Dia Bolts, Both Plates

9° (4) Holes for 5/16 (7.9)Dia Bolts

2.3 (58.4)

1.50(38.1)

22-2121-01 (.125)22-2121-09 (.156 & .187)

21-1086-28 (.125)21-1086-39 (.156)21-1086-05 (.187)


-A-

2.58 (65.5)


21-2406-01 (.125)21-2406-03 (.156 & .187)






NOTE:

5/16-18 Jam Nut (2)

Cotter PinHair Pin

Flat Washer

(Pivot Nut)

(Top Side Plate) Spacer (2)

Clamp

(Clevis)

(Clamp Fitting)

Spacer

(Linkage)

(Brake Lever)

(Bottom Side Plate)


5/16-18 Bolt (2)


(Pivot Fastener)

20

Model 302 (Page 22) Model 316 (Page 23) Model 320 (Page 24)

Model 330 (Page 25) Model 335 (Page 26) Model 340 (Page 27)

Ratcheting Brake Levers

Model 360 (Page 28) Accessories (Page 29)

21

Ratcheting Brake Lever Part Number CodesFor Ratcheting Brake Levers Shown on Pages 22-28

Designation forBrake Lever Control

Length Code:0 = Standard3 = Long5 = X-Long

Model Number:302 (see page 22)316 (see page 23)320 (see page 24)330 (see page 25)335 (see page 26)340 (see page 27)360 (see page 28)

Button Color:2 = Red3 = Black

Leg Orientation: (Not Applicable for Model 316)1 = Type 12 = Type 23 = Type 34 = Type 45 = Type 56 = Type 6

Design Options:1 = W/ Hardware Kit2 = W/O Hardware Kit3 = W/ Electric Limit Switch and Hardware Kit4 = W/ Electric Limit Switch W/O Hardware Kit

XXX19 X

NOTE: Electric Limit Switch option is available on ratcheting brake levers (see page 29)

Ratcheting Brake Levers

X X X

22

Model 302 Ratcheting Brake Lever

Ratcheting Brake LeverModel 302Typical Applications and Features


• CableTravel = (A) 2.47 (B) 3.37

• Lever Rotation = 63° max.

• Lever Ratio = (A) 4.5 to 1 (B) 3.3 to 1

• Hardware Kit 01-1902-03

12.55 (318.8)

3.23 (82.0)

2.36(60.0)

4.20 (106.7)

.17 (4.2)

.80 (20.3)

10°

1.38 (35.0)

.323 Dia(8.20)

.56 (14.2)

4M8-1.25 HHCS

23


• Flange mount for lift trucks, golf carts, utility vehicles, lawn and garden tractors, stand alone trailer park brakes.

• CableTravel = 1.57 inches. (39.9mm)

• Lever Rotation = 45° max.

• Lever Ratio = 4 to 1


• Electric Limit Switch 80-4004-07 (See page 30)

2.70(68.6)


.55(14.0)

3.80 (96.5)

2.66 (67.5)

1.89 (48.1).28 (7.0)

.81(20.6)

.63 (15.9).69 x .38 Slot

(17.5 x 9.5 slot)(4 Places)

.32 Dia (8.2)

Electric Limit Switch (Optional)(Normally Open Grounding Switch)

10.61 (269.5)

1.00(25.5)

1.12(28.5)

12.23 (310.7)


24




• CableTravel = 1.57 Inches (39.9 mm)

• Lever Rotation = 45° Max

• Lever Ratio = Standard 4.0 to 1 X-Long 5.1 to 1


13.36 (339.3)

1.13(28.7)

1.96(49.8)

.32 Dia(8.1)

25

Ratcheting Brake LeverModel 330 (L.H.)Typical Applications and Features


• Cable Travel = 1.11 Inches. (28.2mm)

• Lever Rotation = 57° Max.

• Lever Ratio = Standard 6.2 to 1 Long 7.2 to 1 X-Long 8.3 to 1

• Electric Limit Switch Kit Option 01-1902-05 (See page 29)

• Cable Connection Kit 01-1902-04 (See page 29)

.33 (8.4)

4.13(104.9)

.33 Dia(8.4)

.61 (15.5)

12.38 (314.5) 19-0330-XXX Standard14.00 (355.6) 19-3330-XXX Long15.50 (393.7) 19-5330-XXX X-Long


Switch Optional(See Design Options)

3.21(81.5)

.38 Dia(9.7)

.71(18.0)

1.18 (30.0)

4.13 (104.9)

.71(18.0)

3.21 (81.5)

1.14 (29.0)

This illustration for Type 1 for straight mounting fl anges only

Type 5

Type 4

Type 3

Type 2

Type 1

.33 Dia(8.4)

.33(8.4)

1.81(46.0)

This illustration for Type 2-5 with mounting fl anges oriented as shown


26

Ratcheting Brake LeverModel 335 (R.H.)Typical Applications and Features


• Cable Travel = 1.11 Inches (28.2mm)


• Lever Ratio = Standard 6.2 to 1 Long 7.2 to 1 X-Long 8.3 to 1



.33 (8.4)

4.13(104.9)

.33 Dia(8.4)

.61 (15.5)




3.21(81.5)

.38 Dia(9.7)

.71 (18.0)

1.18 (30.0)

4.13 (104.9)

.71 (18.0)

3.21 (81.5)

1.14 (29.0)

.33 (8.4)

1.81 (46.0)

Type 6

Type 5

Type 4

Type 3

Type 2

Type 1

.33 Dia(8.4)



1.00 (25.4)


27



• Cable Travel = (A) 1.67 Inches. (42.4mm) (B) 2.29 Inches. (58.2mm)


• Lever Ratio = (A) Standard 6.0 to 1 (B) Standard 4.4 to 1 (A) Long 7.0 to 1 (B) Long 5.1 to 1 (A) X-Long 8.1 to 1 (B) X-Long 5.8 to 1




1.21 (30.7).61 (15.5)

1.22 (31.0)

.33 (8.4).33 Dia(8.4)

.61 (15.5)



4.13 (104.9)

.71 (18.0)

4.13(104.9)

.71 (18.0)

1.18 (30.0)

.33 (8.4)

1.81 (46.0)

Type 5

Type 4

Type 3

Type 2

Type 1

(A)(B)

.32 Dia (8.1)

.32 Dia(8.1)

.33 Dia(8.4)




28



• Cable Travel = (A) 1.38 Inches. (35.1mm) (B) 2.00 Inches. (50.8mm)


• Lever Ratio = (A) Standard 7.1 to 1 (B) Standard 4.9 to 1 (A) Long 8.3to 1 (B) Long 5.8 to 1

• Electric Limit Switch Kit Option (See page 29)

.33 (8.4).33 Dia(8.4)

.61 (15.5)

14.68 (372.9) 19-0360-XXX Standard16.96 (430.8) 19-3360-XXX Long

6.17 (156.7) 19-0360-XXX Standard6.34 (161.0) 19-3360-XXX Long


3.21(81.5)

.38 Dia(9.7)

.71 (18.0)

1.18 (30.0)

4.13(104.9)

.71 (18.0)

1.67 (42.4)

.74 (18.8)

.33 (8.4)

1.81 (46.0)

Type 6

Type 5

Type 4

Type 3

Type 2

Type 1

.41 (10.4)

.53 (13.5)

.33 Dia(8.4)

.41 (10.4)

.53 (13.5)

(A)

(B)



1.00 (25.4)

4.13(104.9)


29

Ratcheting Brake Lever Accessories

• Designed to fi t any ratcheting brake lever manufactured after January 1, 2006. (Except Model 316 see page 27)• Kit includes (2) mounting screw (80-0021-06)

Rated 1A@30 VDC (Resistive Load)

Red = Normally Closed Blue = Normally Open Black = Common

Electric Limit Switch KitPart Number 01-1902-05Typical Applications and Features

Schematic

COM(BLACK)

NO(BLUE)

NC(RED)

(.16 Dia)

(.20)

(.45) Shown in Operating Position(.61) Free Position

(.63)

(.16 Dia)

Brake Cable Clip

Cable Connection Kits

• Part Number 01-1902-03

• For models 19-0316, 19-0340 & 19-0360


• For models 19-0330 & 19-0335

(.44 Dia)

(2.38)


• For use with .125 Dia Core and Cable Slug Fitting 21-1086-28

30

(Items listed in parentheses not included in kit)

• Designed to fi t in any over-center brake lever manufactured after January 1, 2000.

• Switch Specifi cations: S.P.D.T.

Temperature Range: -40° to 105° C

Designed to operate in hostile environments and is weather resistant.

Switch Ratings: Voltage: 175 VDC (Max. Switching) 200 VDC (Min. Breakdown) Current: .25 Amps (Max. Switching) 1.5 Amps (Max. Carrying) Wattage: 5 Watts Max.

Blue = Normally Closed Black = Normally Open White = Common

Electric Magnetic Switch KitPart Number - 01-5001-13Typical Applications and Features

Magnetic Switch Assy

Magnet Assy

Switch Mounting Screws (2)

(Linkage)

(Brake Lever)

(Top Side Plate)

(Bottom Side Plate)

Model 316 Electric Limit SwitchPart Number - 80-4004-07Typical Applications and Features

• Designed to fi t in any Model 316 brake lever manufactured after January 1, 2000

• Switch Ratings: Voltage: 24 VDC Current: .3 Amps

(Model 316 Brake Lever)

Limit Switch

Switch Mounting Nuts (2)

Over-Center Brake Lever Electric Magnetic Switch

Model 316 Electric Limit Switch

31

Inline Brake Cable Switches

Features and Specifi cationsAll inline switches utilized internal cable seals to retain lubrication and exclude contaminates.All inline switches are externally sealed to exclude contaminates away from contacts and cable.Switches are internally spring loaded to break contact when the load is released.Switches are overload protected and capable of repeatedly enduring 1200 lb. cable loads.

18-0101-01 Snap-In Fitting SwitchCapacity: 1.0 AMP @ 12VDCMounting: .12/.18 grip, Ø.57/.58 mounting holeFor use in applications formerly reserved for 18-0014-04 snap-in fi ttings.

18-0102-01 Clamp Type Fitting SwitchCapacity: 1.0 AMP @ 12VDCMounting: Ø.50 x .75 long body for clampingFor use in applications formerly reserved for 24-2406-01clamp type conduit fi ttings.

18-0103-01 Bulkhead Fitting SwitchCapacity: 1.0 AMP @ 12VDCMounting: 9/16-12 UNC x 1.25 long (Requires 2 ea. 80-0006-72 hex nuts)For use in applications formerly reserved for 21-2405-01 bulkheadconduit fi ttings.

Well suited for usewith model 207brake lever assemblies

Compatable with .125series brake controlsutilizing covered cable

.187 x .020 SpadeTerminal (typ)

Dust Cover (typ)

For use with model 200 and other brake levers requiringclamp mount conduit fi ttings

Ø.50

.75

Suitable for applicationsincorporating conduit anchorpoint on vehicle model 201lever assembly shown

9/16-12 UNC-1Ax 1.25 long

TAKE A LOOK AT OTHER WESCON PRODUCTS

Push-Pull Cables Control Systems Proven technology and years of experience have gone into making the Wescon push-pull cables top of the line in durability and dependability. Polyethylene covers and a variety of conduit constructions can be customized to fi t your specifi c cable usage. Other optional plastics or nylon can be added to suit your environmental, corrosion resistant or extreme temperature applications.

Remote Valve Control SystemsLook to Wescon for your remote valve applications. Wescon's Remote Valve Control (RVC) has been engineered to place versatility in the hands of the installer. Our center or end-locking feature, thumb activated by the "Big Red Button", can help your system meet OSHA Standards. We also offer options such as bent levers to fi t your mounting requirements, electric switches installed in the lever, or an adjustable friction device to "customize" your lever resistance. A wide selection of control heads, conduit, connection hardware kits, and mounting systems makes it easy to choose Wescon for your RVC application.

Panel Control SystemsOur Power Take-off (PTO), Turn-to Lock and Vernier control systems are all backed by a one-year replacement warranty and a wide range of options to meet your specifi c needs. The PTO is designed for your remote PTO shifting operations and its rugged polymer conduit cover is built to withstand harsh environments. In severe vibration applications where a reliable lock is needed, the Turn-to-Lock can be used for chokes, throttles, engine shut-offs and valves. And the latest model of our Vernier control system gives you the capability of precise RPM settings with a secure construction that reduces corrosion and temperature hazards. Contact your Wescon representative for specifi cations, prices and delivery dates.

Light Duty Cable Control SystemsOur light duty cable control systems are engineered to help your equipment run smoother while complementing the functionality and the aesthetics of your product. Call the Wescon team to help you design controls that add to the marketability of your products.

WESCON CONTROLSP.O. Box 7710 Wichita, Kansas 67277

316-942-7266 or call toll free 1-800-835-0160Fax 316-942-5114

www.wesconproducts.comISO 9001 CERTIFIED

2015-7-R14

brake cable and lever systems - wescon...

Documents