operating manual for disc brake type sf 10-40...5 operating manual sf 10-40 1.2 warnings note:...

PB24-0713-01/4

PINTSCH BUBENZER GmbH Plant Kirchen Friedrichshüttenstr. 1 57548 Kirchen-Wehbach Tel.: +49-2741 - 9488 - 0 Fax: +49-2741 - 9488 -44 G E R M A N Y www.pintschbubenzer.de E-Mail: [email protected]

PINTSCH BUBENZER GmbH Plant Dinslaken Hünxer Str. 149 46537 Dinslaken Tel. +49 (0)2064 602 – 8 Fax +49 (0)2064 602 – 515 G E R M A N Y www.pintschbubenzer.de E-Mail: [email protected]

Operating manual for disc brake type

SF 10-40

2

Operating manual SF 10-40

Table of contents

1 Safety regulations ................................................................................... 4

1.1 Symbols in this manual ........................................................................................... 4

1.2 Warnings ................................................................................................................ 5

2 Brake ........................................................................................................ 7

2.1 Introduction ............................................................................................................. 7

2.2 Warranty ................................................................................................................. 7

2.3 Limitation of liability ................................................................................................. 7

2.4 Instructions and information for and obligations of the operator ............................. 8

2.5 Description and designated use .............................................................................. 9

2.6 Technical data ...................................................................................................... 11

2.7 State of shipment and storage .............................................................................. 11

3 Setup of the brake ................................................................................. 12

3.1 Mounting of the calliper halves onto the mounting bracket ................................... 12

3.2 Mounting of brake and bracket ............................................................................. 13

3.3 Hydraulic and electric connection of the brake ..................................................... 13

3.4 Removing of safety bolts ...................................................................................... 14

3.5 Alignment of brake ................................................................................................ 15

3.6 Bleeding of the brake ............................................................................................ 16

3.7 Adjustment of the releasing stroke (cylinder stroke) ............................................. 17

3.8 Adjustment of cleaning pads ................................................................................. 18

3.9 Running in of the brake pads ................................................................................ 18

3.10 Load test ............................................................................................................... 19

4 Operation ............................................................................................... 20

4.1 Release (open) brake hydraulically ....................................................................... 20

4.2 Actuate (close) brake by spring force ................................................................... 20

4.3 Emergency stop and power failure ....................................................................... 20

4.4 Manual release ..................................................................................................... 20

4.5 Proximity switches and sensors ............................................................................ 21

5 Maintenance ........................................................................................... 22

5.1 Regular checks ..................................................................................................... 22

3


5.2 Greasing ............................................................................................................... 22

5.3 Cleaning ............................................................................................................... 23

5.4 Adjust release stroke (cylinder stroke) .................................................................. 23

5.5 Replacement of brake pads .................................................................................. 25

5.6 Replacement of proximity switches and sensors .................................................. 26

5.7 Replacement of seals ........................................................................................... 27

5.8 Replacement of cylinder unit................................................................................. 29

5.9 Replacement of cleaning pads .............................................................................. 31

6 Putting out of service and disposal ..................................................... 32

7 Troubleshooting .................................................................................... 33

8 Spare parts ............................................................................................. 34

8.1 Spare parts SF 10 ................................................................................................. 35

8.2 Spare parts SF 15 ................................................................................................. 36

8.3 Spare parts SF 24 ................................................................................................. 37

8.4 Spare parts SF 30 ................................................................................................. 38

8.5 Spare parts SF 40 ................................................................................................. 39

9 Appendix ................................................................................................ 40

9.1 Data sheet ............................................................................................................ 40

9.2 Oil selection .......................................................................................................... 41

9.3 Tightening torques ................................................................................................ 42

4


1 Safety regulations 1.1 Symbols in this manual The following symbols / pictographs are used throughout this manual to point out dangers and information.

Danger for health and life!

Danger of damage to or destruction of the installation or parts of the installation!

Danger for health and life due to electrical shock!

Warning of hot surfaces! Danger of burning!

Warning of rotating machine parts!

Warning of moving parts! Danger of squeezing!

Warning of possible pollution and dangers to the environment!

Additional important information!

There may be other specific warning symbols/ pictographs used to point out dangers more precisely in certain situations.

5


1.2 Warnings Note: warnings and other security rules are presented like this throughout the manual:

The brake may only be used in the way described in chapter 2.5 “Description and designated use”. The safety of your brake / brake-system depends on proper and regular inspection and maintenance. Study the manual before starting the installation. If in doubt, please don’t hesitate to contact our service-department or your local retailer. E-Mail: [email protected] In case of a problem please always state the type- and serial-number and year of construction of the product (please refer to the typeplate). This helps us to provide you with the correct information and / or spare parts.

Also study the following manuals and Regulations: Operating manual of the installation Safety precautions of the installation Valid Safety regulations Before starting any work with the brake:

Don’t use any mechanical devices to block the brake. Ensure that the drive is disconnected from the electrical power supply. Ensure that the brake isn’t pressurized. All hydraulic and electrical works have to be done by a trained and qualified personnel. Use only genuine PINTSCH BUBENZER spare-parts. The brake must never be disassembled further than described in the manual. Ensure that the brake is set to its proper values according to the manual after finishing any

work!

Important! The brake type PINTSCH BUBENZER SF is an essential safety device. Any misuse or insufficient handling or maintenance endangers life!

Warning! A sudden startup of the installation endangers the life of the maintenance

personnel! Secure the drive and the installation against any accidental movement before starting any work!

All safety advises are marked by Symbols and frames!

Description Symbol / Pictograph

Danger of crushing When working on the brake, heavy tools are used. Particular attention

should therefore be paid to possible crushing points when: Using tools, fitting and removing the brake, accessories or spare parts.

6


The standard common safety rules and regulations must also be observed under the pressure of time. Accidents cannot be reversed. Work with care! Before carrying out any work on the brake, measures must be taken against any dangers to the life and health of persons and damage to the brake: Only closed shoes in a perfect condition must be worn. Open sandals, damaged or unsuitable

shoes must not be worn. Closed, tight-fitting working clothes must be worn. Wide work jackets and wide sleeves can be

dangerous. Long hair must be tied back. Work must only be carried out on the brake when: All dangerous movements have stopped Accidental and unexpected operation of the brake is made impossible by suitable measures If the brake is loaded, other safety devices provide a braking and holding function.

Safety distance A safety distance must be maintained to all hazardous zones to ensure

safety of personnel and prevention of damage to the brake.

Do not disassemble the brake completely! The brake must never be disassembled further than described in the

manual!

Important! Ensure that the brake is set to its proper values according to the manual

after finishing any work!

Secure dismounted parts!Due to weight and shape the components of the brake may cause heavy

injuries when dropped. When working on the brake, secure all dismounted parts against falling!

Avoid negligent behaviour Refrain from any actions that could affect the safety of the brake. Always take measures against imminent dangers for life and health or against the

safety of the brake before starting any work on the brake!

7


2 Brake 2.1 Introduction This manual has been written to the best of our knowledge. It is intended to familiarize the operation and maintenance personnel with the function, the handling, the maintenance and the safety regulations of the power unit. Furthermore these instructions should make sure that trained and qualified personnel is able to handle the power unit according to its designated use. However the manual can’t cover all the possible circumstances at the place of operation. If you have any questions concerning the power unit or this manual, please contact PINTSCH BUBENZER quoting the type and serial number of the power unit as given on the typeplate. Copyright: The reprinting and duplication of all this technical documentation or extracts from it is - except for internal requirements in connection with the operation of the device - permitted only with the approval thereto in writing of PINTSCH BUBENZER GmbH. Permitting third parties to inspect the device as described is prohibited. Similarly prohibited is the handing over of the device to third parties and its replication. 2.2 Warranty The warranty and its duration depend on the contract. For details on the supplier’s warranty please refer to the terms of the contract. Any warranty- or liability-claims are excluded in case they occur because of one or more of the following conditions: Non-designated use of the brake. Improper handling, setup, operation and maintenance of the brake by the operating company. Neglection of the regulations and notes in this manual concerning transport, setting up,

operation and maintenance of the brake. Improper maintenance and repairs of the brake. Improper monitoring of components, which are prone to wear. Catastrophes, external objects and forces and force majeure. Changes at the brake without approval of PINTSCH BUBENZER. The information in this manual has been checked thoroughly. Nevertheless we can’t accept liability for errors. 2.3 Limitation of liability All the technical information, data and instructions on or for the operating and maintenance of the product as contained in these operating instructions are up to date at the time of printing and are given to the best of our knowledge and with account being taken of our experience and findings up to the present time. We undertake no liability for losses and operational disruptions which come about as a result of operating errors, non-observation of these operating instructions or unprofessional repairs. We draw explicit attention to the fact that only original spare parts and original accessories have been checked and approved by us. Every form of liability is excluded for the use of spare parts and accessories that are not original ones.

8


Conversions and changes of every form to the brake are not permitted for reasons of safety and any such conversions and changes made render liability for any loss/damage resulting therefrom to be excluded. We are liable for any errors of omission or commission for which we are responsible within the framework of the warranty obligations entered into in the main contract whereby the advancing of further claims is excluded. The advancing of claims for damages - regardless of the legal foundation on which they are based - is excluded. 2.4 Instructions and information for and obligations of the operator The operating instructions represent an important component of the product. Thus, for example, if the brake is passed on to a third party as a component of a system, then these operating instructions are to be passed on to this third party as operator of this system. The operator of the brake or of the system containing the brake is to ensure that these operating instructions are available to his operating personnel at all times! In order to ensure that the health and safety of the operating personnel is not endangered as well as to ensure the proper working of the device, the operator is obliged to instruct his personnel on the safe and proper operating, maintaining and servicing of the device as well as on how the device should be operated in the proper manner. In this connection the relevant supervision and notifying obligations are to be observed and any special operational circumstances taken account of! Our customer service department is at your disposal should you require technical information on any of PINTSCH BUBENZER GmbH's products and how to use these correctly. See below for the address and telephone number. Should you have any questions of this device, please contact our customer service department. PINTSCH BUBENZER GmbH Plant Kirchen Friedrichshüttenstr. 1 57548 Kirchen-Wehbach G E R M A N Y Tel.: +49-2741 - 9488 - 0 Fax: +49-2741 - 9488 -44 E-Mail: [email protected] Internet: www.pintschbubenzer.de

PINTSCH BUBENZER GmbH Plant Dinslaken Hünxer Str. 149 46537 Dinslaken G E R M A N Y Tel. +49 (0)2064 602 – 8 Fax +49 (0)2064 602 – 515 E-Mail: [email protected] Internet: www.pintschbubenzer.de

Local District Court Montabaur, HRB 5590 Managing Directors: Markus E. Topp, Stefan Kröger

9


2.5 Description and designated use The brake Type PINTSCH BUBENZER SF is meant exclusively as a disc brake according to the demands specified in the data sheet. It is used as a holding- and emergency-brake. This version of the brake is not suitable for use in areas with explosion hazards and is not certified acc. to ATEX. The PINTSCH BUBENZER SF brakes are hydraulically released and closed by spring-force. Manual release isn’t possible at the brake itself but has to be done by means of an external device, e.g. the handpump of the power unit. The brake is equipped alternatively with asbestos-free organic linings or with sintered linings for long, reliable lifetimes. The operation of the brake is described in section 4. Under aggravate environmental conditions, cleaning pads are available as an option. Those pads pick up rust and dirt from the brake disc and thus keep the brake pads clean for additional safety.

Any other use or any further change of the brake is strictly forbidden! Ignoring the regulations for the designated use and /or the instructions for

setup and maintenance endangers life and leads to the loss of any warranty by the manufacturer!

10


Fig. 1:

Pos. Item Pos. Item 1.3 Adjusting bolt 3.3 Sensor – Release control 1.9 Brake pad holding screw 3.9 Sensor – Wear control

1.12 Eyebolt 4 Brake pad 2 Cylinder unit 5 Bleeder valve

2.20 Safety bolt 6 Hydraulic connection

2.20

2 3.9

4

5

3.3 6 1.12

1.3

1.9

11


2.6 Technical data Measurements and technical data: please refer to the data sheet in the appendix. Table 1:

SF 10 15 24 30 40 Contact Force FA / calliper half [kN] 100 150 240 300 400 Operating pressure (min) [bar] 140 180 180 210 210 Operating pressure (max) [bar] 200 200 200 240 240 Air gap (min) / calliper half [mm] 2 2 2 2 2 Air gap (max) / calliper half [mm] 2,5 2,5 2,5 2,5 2,5

2.7 State of shipment and storage The brake cylinders are tested with the necessary fluid. Thus the inner parts are protected

against corrosion for the transport and a short storage time. The brake is shipped completely assembled and tested. Connections are sealed by threaded plugs. The disc brake is shipped with the brake spring pre-set to its nominal value (100%) and held

released by 4 to 6 bolts, depending on the brake-size. The brake can be equipped with a proximity switch for wear-control as an option. The Contact force FA is set ex work and must not be changed! Depending on the order, the brake-callipers are supplied loosely or mounted on a bracket (e.g.

Fig. 1). Store and transport the brake dust- and waterproof. Protect the brake during the whole storage- and transport time against damage. In case of additional painting, do NOT contaminate: Hinges or joints Brake disc surfaces Brake pads Electrical components Signs and plates If the brake / installation isn’t installed directly after delivery, heed the following instructions: Connections have to be sealed by threaded plugs. Fill the cylinders with oil. Store and / or transport the brakes dust- and waterproof with drying agent until installation.

Protect the brake against external damages during the complete storage- / transport-period.

12


3 Setup of the brake

3.1 Mounting of the calliper halves onto the mounting bracket In case the callipers are either delivered loosely and are to be mounted on a customer provided

bracket, the bracket has to comply to the tolerances, given in Fig. 2: The brake disc has to comply with the tolerances given in Fig. 3. Make sure, the contact surfaces of the calliper halves and the bracket are clean. Mount calliper halves onto mounting bracket by means of bolts of quality 10.9 (not included in

scope of supply). Tighten mounting bolts with a torque-wrench to the nominal tightening torque (please refer to

table 2).

Fig. 2: Fig. 3:

Mount calliper halves with mounting bracket according to section 3.2.

Table 2:

Brake type SF 10 SF 15 SF 24 SF 30 SF 40 Bolt size M 24 M 24 M30 M36 M48 Tightening Torque MA 1050 Nm 1050 Nm 2100 Nm 3500 Nm 6400 Nm

Important! Brake discs shipped by PINTSCH BUBENZER and possibly other brakes,

are coated with rust protection. Remove this coating before setting up the brake!

Danger! A sudden startup of the installation endangers the life of the maintenance


13


3.2 Mounting of brake and bracket

Degrease and clean the brake disc. Clean the brake-pad surfaces (grinding paper) Mount bracket with brake callipers on brake disc according to the

drawing. Screw in mounting bolts but do not yet tighten them. The brake disc has to extend exactly 5 mm over the brake pads / 10

mm for SF 40 (Fig. 4). Check the position and alignment of the brake. The air gaps between the brake pads and the brake disc have to be 2

mm each. Fig. 4:

3.3 Hydraulic and electric connection of the brake

The connection is done according to the wiring diagram of the hydraulic power unit. The bleeder valve (5) has always to be higher than the hydraulic connection (6). The hydraulic connections have to be fastened to nominal torque:

o MA = 80 Nm / 59 lb*ft Note: When tightening the elbow unions (6), secure it against

turning (6.1), else the hose can be damaged. Dismount cover (2.6). The proximity switches are connected according to the data

sheet of the proximity switch. The wires are led through the connection (2.21) out of the cover

(2.6). Tighten cable-connections, seal, if necessary. Fig. 5:

5 mm / 10 mm

Brake disc

Brake pad

Important! The brake, the power unit and all tubing and hoses have to be cleaned /

flushed inside and bled before installation! Any contamination of the hydraulic oil may endanger the brake function!

Important: The proximity switches for release- and wear-control must not be

connected in line or parallel. They have to be individually connected to separate terminals at the control system / SPS.

2.21 6

5 2.6

14


3.4 Removing of safety bolts

Release brake hydraulically. Remove cover (2.6). Unscrew safety bolts (2.20)

o SF 10-24: four safety bolts (Fig. 6). o SF 30: five safety bolts (Fig. 7). o SF 40: six safety bolts (Fig. 8).

Bolts of the class 12.9 may be re-used. All other bolts must not be used again.

Fig. 6: Fig. 7: Fig.8:

Danger! In case the safety bolts are ripped off due to a pressure loss while being

unscrewed, they are being “shot” with a high velocity! Make sure the pressure cannot drop during this work! Mortal danger!

Danger! In case the safety bolts are ripped off due to a pressure loss while being

unscrewed, they are being “shot” with a high velocity! Never stand in front of the brake, when unscrewing the bolts. Mortal danger!

2.20 2.20

2.20

15


3.5 Alignment of brake

Fig. 9: Fig. 10: Fig. 11:

Set and release brake. o The brake aligns itself to the disc, at least partially.

Measure the distance between the brake disc and the calliper halves (Fig. 9 / Fig. 10) at both calliper halves (X1) and (X2), while the brake is open.

Measure the distance at four points A – D at the marked areas at each calliper half (Fig. 11). The values given in table 3 refer to the inner surface of the calliper half (Fig. 10).

Table 3:

The maximum slanting (angular deviation) between the four measuring points (A-B-C-D, fig. 11) at one calliper half must not exceed 0.5 mm.

Align bracket Check measurements. To align the brake, the bracket can be adjusted with shims. It is not allowed to use shims for the calliper halves! After aligning the brake tighten mounting bolts of bracket with torque wrench to the

nominal torque.

Brake type SF 10 SF 15 SF 24 SF 30 SF 40 Xmin 49 mm 49 mm 54 mm 64 mm 54 mm Nominal value X 50 mm 50 mm 55 mm 65 mm 55 mm Xmax 51 mm 51 mm 56 mm 66 mm 56 mm

Important! Different cylinder strokes per caliper cause axial pressure to the brake disc

and lead to higher wear and reduced braking force.

X X1 X2

D

C

B

A

16


3.6 Bleeding of the brake

Always start with bleeding the hydraulic system then both brake callipers. Remove cap (5.1) at bleeder valve (5). Fit a transparent hose to the conical part of the valve. Guide the free end of the hose into a container filled with a small amount of hydraulic oil. Actuate the brake. Check all pipes for tightness. Check function of control elements: manometer, external controls. Open Bleeder Valve of

brake slowly! Only loosen the front-part (5.2) of the valve! Don’t loosen the base!

Close bleeding valve, when a continuous, bubble-free oil stream runs through the transparent hose.

Check oil-level continuously during the bleeding (2nd operator) and refill if necessary. Repeat process at other brakes and - if installed - other bleeding valves! When all brakes and lines (if additional bleeding valve is

installed) are bled, actuate (close) brake and check pressure. Release brake and check oil level at oil sight glass. Oil level has to be visible at oil sight glass when the brake is

completely released. If necessary refill. Fig. 12:

Important! Air bulbs inside the hydraulic system endanger the correct function of the brake. The brake, the hydraulic power unit and the tubing has to be bled

before the start up.

5.2

5.1

5

17


3.7 Adjustment of the releasing stroke (cylinder stroke)

Close brake. Check measurement Yclosed.

(Fig. 13). Release brake. Check measurement Yreleased.

(Fig. 13). Fig. 13:

The difference of these two values is the release stroke.

Stroke: 2 mm / 0.079” per side Tolerance: ± 0,5mm

If necessary, adjust: Release brake hydraulically. Secure it against closing (e.g. hydraulic power unit). Loosen brake pad holding screw (1.9) Turn adjusting screw (1.3) against brake disc until stop. Turn back 1 turn = air gap is 2 mm (0.079”). Tighten brake pad holding screw (1.9) against the adjusting screw (1.3) with a tightening torque

of 200 Nm Check the air gap again, readjust if necessary Reinstall cover Set the brake (Release the pressure).

Remount cover (2.6) with flange-seal (2.14).

Make sure the seal and the mounting area are clean. Fig. 14:

Caution! A cylinder stroke of more than 2 mm affects the safe use of the brake. It

reduces the continuous strength of the Belleville washers and changes the contact force!

Y

1.9 1.3

2.14 2.6

Important! The setting of the stroke at one calliper half has an influence on the other calliper halves mounted on the same disc, too, Re-check the stroke at all

other cylinders and reset it, if necessary.

18


3.8 Adjustment of cleaning pads Mount cleaning pad (9.1) with baseplate (9.2). Position unit, so the cleaning pad has full contact with the brake disc. Tighten screws (9.4) to nominal torque. Loosen nut (9.3) until S1 = 12 mm (Fig. 14).

Fig. 15: Fig. 16:

3.9 Running in of the brake pads

For the full contact of the brake pads and by this full braking torque, it is essential to run-in the brake pads before putting the brake into service! During the run-in-procedure check the stroke every 25-30 brakings and adjust, if necessary.

(refer to section 3.4) The following parameters must not be exceeded during run in.:

Table 3:

Organic linings Sintered linings Max. speed 30m/s 75 m/s Max. disc temperature 200°C 250°C Max. braking time 5 Seconds 15 Seconds

Warning! Brake disc and brake pads are heated up during operation.

Danger of Burning. Allow brake and brake disc to cool down before commencing any work!

Important! In case the motor starts running with the brake closed the brake may be

damaged due to overload! Make sure this is situation cannot occur!

Do not exceed technical data / limitations! To help preventing damages to the brake the brake must not be operated outside its technical limits even during running in. Heed the data given in

the manuals and data sheets!

9.2

9.4 9.19.4

9.2

9.5

9.4 9.3

9.1

S1

19


Check the brake disc for cleanness Loosen brake pad holding screw (Fig. 6.3) Let motor run on HALF nominal speed. Close brake by turning brake pad holding screw (Fig. 6.2) clockwise, until the brake pads make

contact with the brake. Open and close brake several times (6.2) until the complete brake pad surface of the brake

pad is run in. Dismount brake pad (4) to check contact pattern. 3.10 Load test

To finish Setup:

Run load test according to crane suppliers specification Repeat running in procedure, if the required braking time or braking distance is not reached. Readjust stroke, if necessary.

Mortal danger! If the brake system is put into operation without the prescribed load test,

there is no warranty that the brake system will work properly. Always run a load test according to the valid specifications!

20


4 Operation

The normal operation mode the following states are possible: Brake not pressurized Brake set Brake pressurized Brake opens and remains open Hydraulic pressure drops Brake sets automatically Power down, emergency off Brake sets automatically The state of the brake is indicated by the proximity switch “release control”. 4.1 Release (open) brake hydraulically Switch on motor and energize the magnet calves of the power unit according to the manual of

the power unit! The pumped oil flows over a check valve into the cylinder and opens the brake. If the power unit is equipped with a pressure valve, the pump motor is switched off, when

reaching the operating pressure. The pressure is maintained by a check valve. It can be monitored at the pressure gauge of the

power unit. 4.2 Actuate (close) brake by spring force De-energize the magnet calves of the power unit according to the manual of the power unit! The oil flows back into the tank. The brake closes. 4.3 Emergency stop and power failure In case of an Emergency stop or power failure the brake automatically instantly sets. 4.4 Manual release

The manual release is done by means of an external device, e.g. the handpump of the power unit.

Danger! When releasing the brake manually no other safety device is active! Always secure the drive and the installation against any accidental

movement!

Danger! Release the brake SLOWLY, so no attached load can move uncontrolled.

Mortal danger!

Important! The handling of the brake can vary, depending on the used hydraulic

power unit. Always refer to the manual of the power unit!

21


4.5 Proximity switches and sensors

The SF brake can be equipped with two proximity switches: Proximity switch release control - (3.3) Proximity switch wear control (3.9) The sensors are mounted on a socket underneath the cover (2.6). They are set ex work and

must not be shifted! The screw (3.5), that is used to actuate the switches is fixed in its correct position with Loctite

638 (for hub and shaft) and must not be shifted!

Fig. 17: Fig. 18: Fig. 19:

Release-control (Fig. 17): The proximity switch has to be connected acc. to the data sheet included in this documentation

package. Release- and wear-control: There are two possible installations: In case two proximity switches are mounted on the same base plate, the proximity switch

release control is mounted on an intermediate plate (Fig. 18). In case the sensors are mounted separately (Fig. 19), the sensor release control is mounted at

the side of the bleeder valve (5).

Wichtig!Die Anlage darf ohne eine funktionierende Prozessüberwachung nicht

betrieben werden. Die von den Sensoren gelieferten Daten müssen kundenseitig in der

Anlagensteuerung weiterverarbeitet werden!

Caution! In case switches and sensors are mounted (refer to scope of supply), they

must not be put out of service, overridden or blocked in any other way. Else the safe use of the brake is no longer given!

3.33.9 3.5

3.3

3.5 3.3

3.53.9 3.5

5

22


5 Maintenance

5.1 Regular checks Check every 450 operating hours or monthly (Brakes not used for dynamic braking): Function of the brake/brake system Release stroke Lining wear/lining thickness Condition of the brake Condition of the brake disc Tubing and hoses Connections Pressure at the hydraulic power unit Adjustment of proximity switches and other auxiliary equipment Check the brake/brake system outside the regular inspection intervals if: Prolonged braking times or -distances appear Extreme operating conditions appear:

o Overspeed of the brake disc o And/or excessive braking times

A proximity switch indicates lining wear (optional proximity switch) or lack of releasing stroke After a longer period of brake-standstill or drive standstill Any leaks appear Emergency stops occur. 5.2 Greasing The brake is readily greased ex work. No further greasing is necessary as long as the brake isn’t disassembled.

Danger! A sudden startup of the installation endangers the life of the maintenance


Attention! After a longer period of standstill, rust and dirt may pollute the brake pads-

and disc. This leads to an increased braking time! Brake clean if necessary.

Notice! The use of spare parts, not meant for this brake, can lead to a malfunction

of the brake or damage the brake! Only use original PINTSCH BUBENZER spare parts!

23


5.3 Cleaning

The braking force can only be transferred to the brake disc when both contact surfaces (brake disc and brake pads) are clean. Make sure they are free from fat, oil, rust and other contaminations. The brake itself especially the moving parts have to be kept clean as well. 5.4 Adjustment of release stroke (cylinder stroke)

Fig. 20: Fig. 21:

Release the brake hydraulically. Remove cover (2.6) with seal. Check measurement Yreleased. (Fig. 21). Close brake Check measurement Yclosed. (Fig. 21). The difference of these two values is the release stroke.

Stroke: 2 mm / 0.079” per side Tolerance: ± 0,5mm

If necessary, adjust:

Do not use corrosive or acidic agents to clean the brake. Only use fat-dissolving cleaners (e.g. brake cleaner) and proper cleaning materials like

cloth. Never use high pressure cleaners or a wire brush.

Warning! Fingers and other limbs can be squeezed or crushed by the brake!

The brake has to be switched off and secured against switching on during the cleaning process!

Y

1.9 1.3

2.14 2.6

Caution! A cylinder stroke of more than 2 mm affects the safe use of the brake. It

reduces the continuous strength of the Belleville washers and changes the contact force!

24


Release brake hydraulically. Secure it against closing (e.g. hydraulic power unit). Loosen brake pad holding screw (1.9) Turn adjusting screw (1.3) against brake disc until stop. Turn back 1 turn = air gap is 2 mm (0.079”). Tighten brake pad holding screw (1.9) against the adjusting screw (1.3) with a tightening torque

of 200 Nm Check the air gap again, readjust if necessary Reinstall cover Set the brake (Release the pressure). Remount cover (2.6) with seal.

Make sure the seal and the mounting area are clean. The piston always moves to its original position and end-position (2mm) when the stroke is set

correctly. Thus it is not necessary to adjust the setting of the sensors after setting the stroke. The sensors remain in their original position.

25


5.5 Replacement of brake pads

The brake pads have to be replaced when they either reach the minimum brake pad thickness of 5 mm or if they are damaged (e.g. overheated). The brake pad carriers may be equipped with bolt holes. These can be positioned at the side or on top of the pad carriers. Fig. 22: Fig. 23:

Remove cover (2.6) with flange-seal (2.14). Release the brake hydraulically. Secure brake against setting. In case bolt holes are available.

Screw eyebolts into brake pad carriers. (1). Attach Eyebolts to proper lifting device.

Loosen brake pad holding screw (1.9), but do not remove yet! Turn back adjusting screw (1.3) until stop. Hold brake pad (4) safely.

Warning! The braking pressure is high enough to squeeze of limbs! The brake has to

be secured against accidental setting during the whole process! Danger of injury!

Important! Always exchange both pads! Pads are delivered in pairs!

Warning! During the braking process the brake disc and the brake pads heat up!

Danger of burning! Let brake disc and brake cool down before replacing the brake pads!

Important! When replacing a brake disc or brake drum, also replace the brake pads.

The disc / -drum has to be run in with the new brake pads!

4

1.91.3

2.14 2.6

26


Remove brake pad holding screw (1.9). Pull brake pad (4) out of the brake. Clean mounting surface. Install new brake pads (4), matching keyway on pads to keys on calliper. Turn brake pad holding screw (1.9) into the brake pad (4), but do not tighten yet. Turn adjusting screw (1.3), until the air gap between brake disc and brake pad is 2 mm. Reset and run in brake acc. To section 3. Tighten brake pad holding screw (1.9) against the adjusting screw (1.3) with a tightening torque

of 200 Nm Remount cover (2.6) with flange-seal (2.14).

Make sure the seal and the mounting area are clean.

5.6 Replacement of proximity switches and sensors Fig. 24: Fig. 25: In case a proximity switch is malfunctioning it can be replaced. Don’t replace or shift the screw (Fig 3.5), that is used to actuate the switches. Dismount cover (2.6) with flange-seal (2.14). Remove old proximity switch Remove electrical connection Clean mounting surface The proximity switch release control (3.3) may be mounted on an additional shim. This shim

has to be installed again, when mounting the new switch. Mount new proximity switch Screw in both screws, don’t tighten yet. Tighten inner screw slightly. Connect switch electrically. The outer screw is positioned in the longhole of the switch. Thus the switch can be adjusted. Move switch until it is actuated correctly. Control at the LED near the outer screw and the

control system. The switches must not be shifted in height Tighten outer screw. Tighten inner screw Open and close brake several times Check setting. Remount cover (2.6) with flange-seal (2.14).


3.3

3.9

3.5

2.14 2.6

27


5.7 Replacement of seals

The design of this brake allows a replacement of the seals with the brake still mounted.

Fig. 26: Fig. 27: Fig. 28:

Release the pressure of the hydraulic system (brake sets) and secure it against switching on. Dismount cover (2.6) with flange-seal (2.14). Dismount proximity switch(-es). Unscrew bleeder valve (5). Unscrew hydraulic connection (6) of the brake.

Let the oil flow into a proper container.

Fig. 29: Fig. 30: Fig. 31:

Remove screws (2.18). Remove cylinder-cover (2.5).

During the replacement of seals oil may leak out of the brake. Provide a proper container. Take care that the hydraulic fluids, lubricants and other used substances as well as oil-soiled parts are disposed environmental friendly and in compliance with the corresponding laws and regulations!

Important! Any contamination of the hydraulic oil and the brake may endanger the brake function! Keep all the components clean and store them properly

during the maintenance works.

2.14 2.6

3.3

3.8 5

6

2.3

2.12.8

2.172.5 2.18

28


Loosen threaded pin (2.17), DO NOT REMOVE as otherwise thrust piece inside the thread may be lost!

Unscrew slotted round nut (2.8). Pull off complete cylinder unit (2.1) with piston (2.3). Pull piston (2.3) off of cylinder (2.1) using a pulling-off device. Fig. 32: Fig. 33:

Remove seal (2.10) and guidance ring (2.13) as well as O-ring (2.11) from the cylinder (2.1). CAUTION: DO NOT DAMAGE ring grooves! Remove seal (2.12) from piston (2.3). Apply a thin film of hydraulic oil to all new seals. Put new O-rings and seals into the intended grooves of piston (2.3) and cylinder (2.1). Pay attention that the seals face to the correct side (refer to drawing). Before mounting the cylinder (2.1) to the inner piston (2.2): Screw-in two or three threaded spindles into the threads of the spring housing (2.2). This is

important for a true alignment of screws (2.18) later on. Mount cylinder (2.1) to inner piston (2.2). CAUTION: Do not damage the seals! Push piston (2.3) carefully into cylinder (2.1) (A plastic hammer may be helpful). Fasten slotted round nut (2.8) again and secure it by threaded pin (2.17). Note dimension X according to table 5 (fig. 33). Put cylinder-cover (2.5) in place and tighten screws (2.18) slightly. Do not fasten yet!

CAUTION: cylinder-cover (2.5) has to be in exact alignment to the outer diameter of the cylinder (2.1)!

Insert screws (2.18). Screw out threaded spindles and replace them with screws (2.18). Tighten screws (2.18) with a torque wrench to the nominal torque MA acc. to table 5. Put proximity switches in place and fasten them (refer to section 5.5) Connect hydraulic supply to the brake Operate brake several times and check for leaks and proper proximity switch function. Adjust

proximity switch if necessary. Continue according to standard operating instructions, bleed the system and adjust the brake Remount cover (2.6) with flange-seal (2.14).


Table 5:

Brake type SF 10 SF 15 SF 24 SF 30 SF 40 Measurement X 1 mm 1 mm 2 mm 3 mm 3 mm Tightening torque MA 16 Nm 16 Nm 39 Nm 72 Nm 72 Nm

2.10

2.13

2.12

2.11 2.8

X

29


5.8 Replacement of cylinder unit

When exchanging only one calliper half, it is necessary to also insert safety bolts to the other calliper half. Otherwise there would be a one sided pressure on the brake disc.

Fig. 34: Fig. 35: Fig. 36:

Release brake hydraulically. Dismount cover (2.6) with flange-seal (2.14). Dismount brake pad (4) according to section 5.5. Screw in new safety bolts of quality (2.20). Please refer to section 3.4.

o SF 10-24: four safety bolts. o SF 30: five safety bolts. o SF 40: six safety bolts .

Set brake hydraulically -> brake remains released due to safety bolts.

Fig. 37: Fig. 38: Fig. 39:

Disconnect electric and hydraulic connections. Dismount proximity switch(-es) (3.3) and (3.9). Remove 2 screws (1.10) of the twist lock (1.4).

Caution! Due to their heavy weight the cylinder units must always be secured while being mounted or dismounted. They must always be handled with proper

lifting devices! Danger of injury!

4

1.91.3

2.14 2.6

2.20

3.3

3.8 5

6

1.101.4

30


Fig. 40: Fig. 41:

Remove twist lock (1.4). Secure cylinder-unit (2)! Screw out cylinder-unit (2) carefully– heed the weight!

Clean Thread of main body. Position new cylinder unit (2) with lifting device.

Screw in cylinder unit (2) to control measurement Z (Fig. 41 /Table 6) Table 6: Note: The bleeder valve (5) has always to be higher than the hydraulic connection (6). Mount twist lock (1.4) – reposition cylinder unit (2) if necessary. Screw in both screws (1.10) with shims at the twist lock (1.4). Remount brake pads (4) – Section 5.5. Reconnect brake hydraulically and electrically – Section 3.3. Release brake hydraulically. Remove Safety bolts (2.20) at both calliper halves – Section 3.4. Check and if necessary reset equal air gap – Section 3.6 Remount cover (2.6) with flange-seal (2.14). Make sure the seal and the mounting area are clean.

Brake type SF 10 SF 15 SF 24 SF 30 SF 40 Measurement [mm] 139,4 153,4 185 224,5 229,5

Important! Insert the new cylinder unit carefully! The thread must not jam or else this

may lead to damages to the brake!

Caution! Don’t unscrew the safety bolts out of the dismounted cylinder-unit! When the first bolts are removed, the other bolts will tear due to the high tension

of the Belleville-washers. Danger of injury!

Z

2

31


5.9 Replacement of cleaning pads

In case the cleaning pads (9.1) are worn (S1= 0) or otherwise damaged, they have to be replaced including the metal carrier. Pull cleaning pad (9.1) away from the brake disc by tightening nut (9.3). Screw out mounting bolts (9.4) from base (9.2). Remove base (9.2). Loosen springs (9.5) at cleaning pad (9.1) by loosening nut (9.3). Pull out cleaning pad (9.1) with carrier. Slip on new carrier with brake pad (9.1). Tighten springs (9.5) again by tightening the nut (9.3). Mount base (9.2) with mounting bolts (9.4).

o Version with longholes: position base. Tighten bolts (9.4) with torque wrench to nominal torque. Release springs (9.5) by releasing the nut (9.3) until S1 equals 12 mm again while the cleaning

pads (9.1) have full contact with the brake disc.

Fig. 42: Fig. 43:

9.2

9.4 9.1 9.4

9.2

9.5

9.4 9.3

9.1

S1

Important! Always exchange both pads! Pads are delivered in pairs!

32


6 Putting out of service and disposal When the brake is put out of service, the following instructions have to be heeded, to help avoiding dangers to life, material and environment: The brake must only be put out of service and disposed by trained and qualified personnel. Always heed the applying laws and regulations!

Dismount brake pads acc. to section 5.5. Switch of power unit and secure it against switching on again. Dismount hydraulic connection. Let oil drain into proper container. Secure brake with eyebolts. Dismount calliper halves.

Take care that the hydraulic fluids, lubricants and other used substances as well as oil-soiled parts are disposed environmental friendly and in

compliance with the corresponding laws and regulations! Electronic scrap has to be disposed separately.

Warning! A sudden startup of the installation endangers the life of the working


Danger! The applied electrical voltages are dangerous to life!

The electrical connection and all other electrical tasks must only be done by a trained electrician!

Important! Because of the weight of the brake always use proper lifting devices and

transport the brake using the lifting ore! Danger of injury!

Caution! Make sure the system is not pressurized!

Danger of injury!

33


7 Troubleshooting

Symptom Possible reason Move Section

Brake doesn’t close

Mechanically blocked Check - Safety bolts have not been removed

Remove safety bolts 3.4

Brake is manually released Check at power unit HA Hydraulic pressure is applied Check wiring HA Belleville washers damaged Replace complete cylinder 5.8 Signal “open” is active Check wiring / setting -

Proximity switches malfunctioning

Check proximity switch connection

ES

Replace proximity switch 5.6 Brake pad wear Compensate wear 5.4 Brake pads worn Replace brake pads 5.5 Brake disc worn Replace brake disc -

Brake doesn’t open

Pressure to low Check at power unit HA Oil level to low Check at power unit HA

Connection damaged Check Tubing, hoses, connections for leakages, squeezed of parts, etc.

-

Brake is leaking Replace seals 5.7 Mechanically blocked Check - Signal “close” is active Check wiring -

Proximity switches malfunctioning

Check proximity switch connection

ES

Replace proximity switch 5.6 No electrical power Check wiring and power supply HA Emergency stop actuated Check emergency stop-buttons -

Braking distance to long

Brake pads don’t have full contact to disc

Align brake 3.5

Brake pads haven’t been run in properly

Run in brake pads 3.9

Brake pad wear Compensate wear 5.5

Brake pad soiled Clean brake pads - Check cleaning pad 5.9

Brake soiled Clean brake 5.3

Brake pads worn Replace brake pads 5.5 Brake disc worn Replace brake disc -

Note: HA: Operating manual of the hydraulic power unit ES: Data sheet of the proximity switch

34


8 Spare parts

*Note: The number of spare parts refers to a set of 2 brake-callipers = one brake. For one calliper the number has to be reduced to a half. The spare part lists for the different brakes can be found on the following pages

Information: When ordering replacement parts, please indicate brake type and serial no.

of the brake! Type and serial no. are located on the name plate of each brake.

Notice! The use of spare parts, not meant for this brake, can lead to a malfunction

of the brake or damage the brake! Only use original PINTSCH BUBENZER spare parts!

35


8.1 Spare parts SF 10

Pos. *Number Spare part for SF 10 Order-Nr.

- 2 Cylinder with Belleville washers 100 kN Tested and ready to mount

8-216.10.2.001

3 2 Brake pad with brake pad carrier 8-251.163.095 8 2 Wiper 160x172x10 8-990.413 1 Complete seal kit – consisting of 8-090161.041

47 2 Seal 70x80x11,4 8-990.135 52 2 O-Ring 70x5,33 8-990.026 53 2 Seal 140x150x11,4 8-990.136 54 2 Guidance ring 140x145x9,7 8-990.233 57 2 Flange seal SF 10 N 8-685.00308 32 2 Proximity switch release control IN0127 8-430.158.6 32 2 Proximity switch wear control IN0127 8-430.158.6 55 2 Cleaning pad 8-251.00011

36




2 Cylinder with Belleville washers 150 kN Tested and ready to mount

8-216.15.2.001


47 2 Seal 70x80x11,4 8-990.135 52 2 O-Ring 70x5,33 8-990.026 53 2 Seal 140x150x11,4 8-990.136 54 2 Guidance ring 140x145x9,7 8-990.233 57 2 Flange seal SF 15 N 8-685.00308 32 2 Proximity switch release control IN0127 8-430.158.6 32 2 Proximity switch wear control IN0127 8-430.158.6 55 2 Cleaning pad 8-251.00011

37




- Cylinder with Belleville washers 240 kN Tested and ready to mount

8-216.24.2.002

3 2 Brake pad with brake pad carrier 8-251.163.096 8 2 Wiper 200x212x10 8-990.400 1 Complete seal kit – consisting of 8-090161.012.3

47 2 Seal 100x110x11,4 8-990.00114 52 2 O-Ring 100x5,33 8-990-017.1 53 2 Seal 180x190x11,4 8-990.00113 54 2 Guidance ring 180x185x15 8-990.232 57 2 Flange seal SF 24 N 8-685.00090 32 2 Proximity switch release control IN0127 8-430.158.6 32 2 Proximity switch wear control IN0127 8-430.158.6 55 2 Cleaning pad 8-251.00005

38





8-216.30.2.002


47 2 Seal 110x130x14,5 8-990.141 52 2 O-Ring 110,49x5,33 8-990.081 53 2 Seal 210x230x14,5 8-990.140 54 2 Guidance ring 658x9,7x2,5 990.234 57 2 Flange seal SF 24 N 8-685.00475 32 2 Proximity switch release control IN0127 8-430.158.6 32 2 Proximity switch wear control IN0127 8-430.158.6 55 2 Cleaning pad 8-251.00004

39





216.40.2.001


47 2 Seal 125x145x14,5 8-990.132.1 52 2 O-Ring 125x5,33 8-990-072 53 2 Seal 220x250x22,7 8-990.133.1 54 2 Guidance ring 699x9,7x2,5 8-990.229 57 2 Flange seal SF 24 N 8-685.00504 32 2 Proximity switch release control IN0127 8-430.158.6 32 2 Proximity switch wear control IN0127 8-430.158.6 55 2 Cleaning pad 8-251.00004

40


9 Appendix

9.1 Data sheet

All dimensions in mm – Alterations reserved without notice *) Average friction factor of standard material combination Braking torque MBr in Nm = FA [kN] x x d1 [mm] Brake discs:

d2 = Disc diameter in mm d1 = Friction diameter in mm d4 = Max. permissible drum or hub diameter in mm b1 = Disc thickness in mm (min. 30 mm).

Please indicate mounting position in case of order:

TYPE SF 10 15 24 30 40

b2 165 165 195 280 300

b3 410 410 480 640 720

b4 110 110 130 155 175

b5 115 115 130 200 220

b6 85 85 100 110 125

b7 60 60 70 110 125

b8 85 85 100 140 160

b9 5 5 5 10 10

b10 90 90 105 150 170

c1 10 10 10 10 10

d5 175 175 225 290 310

d6 3/8“ 3/8“ 3/8“ 3/8“ 3/8“

d7 25 25 31 38 50

d8 12 12 12 12 12

h1 270 270 300 400 480

h2 220 220 230 300 375

h3 90 90 70 100 125

l1 685 750 810 940 981

l2 292 292 342 402 502

l3 100 100 110 130 110

l4min 40 40 130 180 200

Bolt M24 M24 M30 M36 M48

Bolt material 10.9 10.9 10.9 10.9 10.9

Tighten. Torque [Nm] 1050 1050 2100 3500 6400

Contact force FA [kN] 100 150 240 300 400

Operating press. [bar] 140 180 180 210 210

Max. Pressure [bar] 200 200 200 240 240

release stroke [mm] 2 2 2 2 2

Oil volume [l] 0,023 0,023 0,035 0,050 0,052

pad surface [cm2] 427 427 570 1050 1360

Theor. friction factor 0,4 0,4 0,4 0,4 0,4

Weight [kg] 200 210 368 760 1180

SF 10 SF 15 SF 24 SF 30 SF 40 d1 = d2 – 170 mm d2 – 170 mm d2 – 200 mm d2 – 290 mm d2 – 320 mmd4 = d2 – 420 mm d2 – 420 mm d2 – 490 mm d2 – 620 mm d2 – 700 mm

Bleeder valve

Pressure connection

41


9.2 Oil selection Always consider the existing temperature ranges before selecting an oil.

Guide lines for selection VG10, VG15: Systems intended for short time operation or use in the open or for clamping

devices. Systems intended for continuous operation (for use in the open, operation in winter) VG22, VG32: General application (for use in the open, operation in summer only) VG46, VG68 : Systems in tropical conditions at ambient temperatures up to 40°C or closed

rooms (temperature during start not lower than 20°C)

Reference temperature ISO 3448 DIN 51519

42


9.3 Tightening torques

THESE VALUES ARE VALID AS LONG AS NO OTHER VALUE IS GIVEN AT THE CORRESPONDING POINT OF THE MANUAL’

Coarse-pitch thread – with or without NORD-LOCK-washers

Size

Tightening Torques MA

8.8 10.9 12.9 SW

[Nm] [Lb*ft] [Nm] [Lb*ft] [Nm] [Lb*ft] [mm]

M4 3,0 2.3 4,6 3.4 5,1 3.8 7

M5 5,9 4.4 8,6 6.3 10,0 7.4 8

M6 10,1 7.5 14,9 11.0 17,4 12.8 10

M8 24,6 18.2 36,1 26.6 42,2 31.1 13

M10 48 35.4 71 52.4 83 61.3 17 (16)

M12 84 62.0 123 90.8 144 106.3 19 (18)

M14 133 98.2 195 143.9 229 169.0 22 (21)

M16 206 152.0 302 222.9 354 261.3 24

M18 295 217.7 421 310.7 492 363.1 27

M20 415 306.3 592 436.9 692 510.7 30

M22 567 418.4 807 595.6 945 697.4 32 (34)

M24 714 526.9 1017 750.0 1190 878.2 36

M27 1050 774.9 1496 1104.0 1750 1291.5 41

M30 1428 1053.9 2033 1500.4 2380 1756.4 46

M36 2482 1830.6 3525 2599.9 4136 3050.5 55

Important! These tightening torques apply for:

compl. = 0.12 (black or bonderd, slightly oiled) Used Nordlock-washers must not be used again!

operating manual for disc brake type sf 10-40...5 operating manual sf 10-40 1.2 warnings note:...

Documents