E 09.649 e
Contents
1. the brake caliper opens the LED must go off 6 Maintenance Maintenance should be performed on the brake caliper at intervals of 4 to 12 weeks depending upon the frequency and duration of operation Danger to life and limb When disassembling the brake it is essential to ensure that the entire drive train is secured against inadvertent activation Rotating components can cause severe injuries Therefore rotating components e g brake discs must be secured against accidental contact To prevent injuries to personnel secure the brake with the aid of an assembly locking device 6 1 General maintenance e Check both brake caliper lever for ease of movement e Clean all bearings and glide points e Lubricate all bearing and glide points Caution Brake pads must not be come in contact with lubricants Check for tight bolt screw connections e brake caliper to machine component e brake chamber to brake caliper lever e brake pads to brake caliper lever Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su __ pages 15 page 11 Check the following for proper seal leaks e hose connection leaks can be detected quickly and easily using e g G poflex LECKSUCHER manufactured by GUPO GmbH 77694 Kehl telephone 49 7851 4044 45 or equivalent products 6 2 Checking an2. 2472 005013 A00101 for brake caliper 4457 901131 000000 Part number for 1 pad Part number for 1 set 2 pieces brake pads Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su _ pages 15 Quant Brake pad from BK 8006 for brake calipers 4457 3001 10 000000 2472 005013 A00109 4457 3001 11 000000 4457 3011 10 000000 4457 301 128 A00109 Brake pad from BK 5300 v 50m s for brake caliper 2472 005013 A00103 4457 301 106 000000 Brake pad from BK 6230 for brake caliper 2472 005013 A00108 4457 3011 12 000000 Brake pad from BK 8006 with wear alarm cable 2472 005013 A00113 for brake caliper 4457 301114 000000 Brake pad from BK 6905 for brake caliper 2472 005013 A00117 4457 301 123 000000 Brake pad from BK 5300 v 50m s for 19 mm brake gap 2472 005016 A00101 for brake calipers 4457 300106 000000 Part number for 1 pad Part number for 1 set 2 pieces brake pads 4 Condition on delivery The brake calliper is delivered with a clamping gap of approx 13 5 mm or 26 mm between brake pads Deviating of it the special equipment with the article code is 4457 300106 000000 here the clamping gap amounts to 19 0 mm 5 Installing the RINGSPANN brake caliper Before installing the brake the brake disc must be cleaned with alcohol e g ethyl or isopropyl alcohol
3. RINGSPANN agents e f a malfunction is indicated the product or the machine into which it is installed should be stopped immediately and either RINGSPANN or an accredited RINGSPANN agent should be informed e Switch off the power supply before commencing work on electrical components e Rotating machine elements must be protected by the purchaser to prevent accidental contact e Supplies abroad are subject to the safety laws prevailing in those countries Installation and Operating Instructions for Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su __ pages 15 Contents 1 General information 2 Configuration and function 3 Drawing and parts list 4 Condition on delivery 5 Installing the RINGSPANN brake caliper 5 1 Installation 5 2 Compressed air connection 5 3 Adjusting the brake caliper 5 4 Running in procedure 5 5 Inductive proximity switch 6 Maintenance 6 1 General maintenance 6 2 Checking and adjusting the brake gap 6 3 Checking brake pad wear 7 Removal and replacement of worn parts in the brake chamber 7 1 Brake chamber for DV and DH 030 650 7 2 Brake chamber for DV and DH 030 640 7 3 Brake chamber for DV and DH 030 653 Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su __ pages 15 1 General information These inst
4. brake chamber cannot filled with compressed air be 5 2 Compressed air connection A flexible hose connection is required Please use hoses with a diameter of 6 mm Hose pressure must be at least 7 bar preferably 12 bar with a temperature range of approx 20 C to 80 C Air hoses are connected to the brake chamber with a G 1 4 fitting Whitworth threaded pipe DIN ISO 228 1 Operating pressure may range between 1 to 6 bar depending on braking force maximum pressure is 6 bar Compressed air must be filtered to remove all dirt pipe chips rust and condensation Purified air must then be enriched with a fine oil mist injected by a standard commercially available conditioning unit The quantity of oil added depends on the nominal air flow rate in l min and is specified by the manufacturer of the conditioning unit The following types of oil are recommended for conditioning units Suitable types of oil Viscosity at 20 C mm 7 s Avia Avilub RSL 3 34 BP Energol HLP 40 27 ESSO Spinesso 34 23 Shell Tellus I C 10 22 Mobil VAC HLP 9 25 2 Maximum air consumption per braking operations is for DV 030 PFK 650 and DH 030 PFK 650 approx 490 cm8 for DV 030 PFK 640 and DH 030 PFK 640 approx 313 cm8 for DV 030 PFK 653 and DH 030 PFK 653 approx 490 cm8 Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 che
5. RINGSPANN Power Transmission Installation and Operating Instructions for Brake Caliper DV DH 030 PFK E 09 649e RINGSPANN GmbH Schaberweg 30 34 Telephone 49 6172 275 0 www ringspann com 61348 Bad Homburg Telefax 49 6172 275 275 mailbox ringspann com Germany Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su _ pages 15 IMPORTANT Please read these instructions carefully before installing and operating the product Your particular attention is drawn to the notes on safety These installation and operating instructions are valid on condition that the product meets the selection criteria for its proper use Selection and design of the product is not the subject of these installation and operating instructions Disregarding or misinterpreting these installation and operating instructions invalidates any product liability or warranty by RINGSPANN the same applies if the product is taken apart or changed These installation and operating instructions should be kept in a safe place and should accompany the product if it is passed on to others either on its own or as part of a machine to make it accessible to the user SAFETY NOTICE e Installation and operation of this product should only be carried out by skilled personnel e Repairs may only be carried out by the manufacturer or accredited
6. allation and operating instructions apply to e the DV DH 030 PFK with either a 640 650 or 653 brake chamber e the DV 030 PFK brake caliper mounted parallel to the brake disc frame construction V see Fig 3 1 in Section 3 brake chamber mounted on the right e the DH 030 PFK brake caliper mounted at a right angle to the brake disc frame construction H see Fig 3 2 in Section 3 brake chamber mounted on the right e the DV DH 030 PFK with left mounted brake chamber e the DV DH 030 PFK with inductive proximity switch e for installation on a brake disc with a thickness of 12 5 mm or 25 mm e the special equipment with 19 mm brake gap e versions with enhanced corrosion protection e various types of brake pads e g with wear alarm cable increased glide speed double friction surface or other special brake pad materials An identification plate with a 16 digit part number is affixed to the calliper The precise design of the brake calliper is defined by this part number only Please consult the drawings in each section when using this instruction 2 Configuration and function The brake caliper is used as a stopping control and holding brake Braking force is generated by compressed air The brake is released opened by spring force Rotating parts must be secured by the user against inadvertent contact e g brake disc Danger to life and limb It is essential to secure the entire drive train against inadvertent start
7. checked Su __ pages 15 5 4 Running in procedure Optimum braking effect is achieved only when both brake pads 9 are in full contact with the brake disc and the brake pads have attained a temperature of approx 200 C This requires multiple brief braking while the brake disc is rotating run in Multiple brief braking actions under low pressure 1 2 bar while the brake disc is rotating are required Caution If breaking in is not performed the braking forces cited in our catalogue no 46 cannot be achieved Reductions of up to 50 are possible 5 5 Electrical connection of the inductive proximity switch An IF 5188 IFB 3002 BPKG inductive proximity switch manufactured by IFM Electronic is installed Housing M12x1 L 55mm Operating voltage 18 36V DC Material PBTB MnNi Switch function PNP closer Temp range 25 to 80 C Switching current 150 mA max Safety class IP 67 Connection 3 lead Cable 2m PVC Int voltage loss lt 2 5 V Sw distance 2mm flush Polarity reversal resistant YES The proximity switch is positioned in such a way that when the brake caliper is open the brake chamber is not under pressure and two brake caliper arms are retracted by the springs to the stop point at the adjusting screws it is closed by the brake chamber mounting bolt When the brake caliper is activated the brake chamber is pressurized the two brake calipers open and the proximity switch is no longer
8. cked Su _ pages 15 5 3 Adjusting the brake caliper The brake chamber must not be pressurized The gap between the brake pads 9 and the brake disc has been set by the manufacturer to 0 5 mm on each side If the actual dimension deviates from the specified value of 76 mm and or 77 8 mm with DH 30 the gap is altered accordingly This must be corrected using the following procedure To reduce the brake gap turn the threaded pins clockwise Turn the threaded pins counter clockwise to increase the gap Set both calliper arms to a gap of approx 0 5 mm Caution Check to ensure that the brake disc rotates freely Caution The friction block distance must after initial assembly or after replacing the brake pads or other components be new adjusted Caution The friction block distance must be corrected periodically at wear of the brake pad Caution During installation ensure that the brake pads are centred and in full contact with the surface of the brake disc The gap between the brake pads and the brake disc should always be approx 1 mm on each side Please observe maximum the wear limit Caution gt l ele It is important to ensure that the brake pads do not rub against the brake disc when the brake is released Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014
9. closed The LED goes off Compressed air brown connection fitting G1 4 Proximity switch K black Load lees Wa Retracting spring both sides i a SOEN Fig 5 2 Proximity switch circuit diagram Adjusting screw for gap between brake disc and brake pad Residual pad thickness Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su __ pages 15 page 10 Procedure for installing or replacing the proximity switch The following instructions apply to the proximity switch listed above with 2 mm switching distance e The brake chamber is not pressurized The brake is open e Check to ensure that the brake pads are not in contact with the brake disc i e that there is an equal gap 0 5 mm in the case of new pads on both sides e Turn the hex nut on the proximity switch Insert the proximity switch into the bore on the brake caliper and turn the second hex nut on the proximity switch thread Position the proximity switch axially so that a 1 mm feeler gauge is lightly clamped between the active surface of the proximity switch and the brake chamber mounting bolt Tighten the two hex nuts Connect the proximity switch and remove the feeler gauge The LED goes on e Test for proper function by repeatedly activating the brake caliper When pressure is applied
10. d adjusting the brake gap Check to ensure that the gap between the brake disc and the brake pads is equal If necessary adjust the gap equal on both sides as described in Section 5 3 6 3 Checking brake pad wear Brake pad material must have a thickness of at least 4 mm from the top surface of the brake pad to the top surface of the steel mounting plate Brake pads or brake linings Pos 9 must always be replaced in pairs For unscrewing and screwing on fixed spanners or ring spanners with SW 13 are needed e Turn the threaded pin which controls symmetrical gap adjustment back until the brake pads can be easily replaced e Replace the worn brake pads including carrier plates To do so a ring spanner or fixed spanner SW 13 is needed e Adjust the gap between the brake pads and the brake disc as described in Section 5 3 The brake is now ready for operation Danger to life and limb Brake pads may be replaced only when the equipment system and or the working machine is at a complete standstill Caution Ensure that the brake caliper is not under air pressure before replacing the brake pads Caution Brake pads must not be worn to a residual thickness of less than 4 mm mounting plate thickness plus remaining pad material Brake pads must always be replaced in pairs Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring rel
11. earing A out of the brake chamber Remove the spacer disc 4 Pull the pushrod 3 and the flat piston 2 out of the brake chamber Replace worn parts Before reassembling the unit clean the inside wall of the brake chamber 8 and the bearing bore for the pushrod 3 in cylinder bearing A Then lubricate these parts lightly with Alvania grease G2 manufactured by Shell Insert the flat piston 2 and the pushrod 3 into the brake chamber until they abut with floor of the cylinder Insert the spacer disc 4 Insert the cylinder bearing A into the brake chamber 8 Ensure that the tension pin S is inserted into the corresponding bore in the spacer disc 4 Then fix the cylinder bearing firmly in place in axial alignment with the circlip 1
12. eased Issue 03 04 2014 checked Su__ pages 15 page 12 7 Removal and replacement of worn parts in the brake chamber Caution Secure the brake for disassembly Caution Brake pads must not come in contact with lubricants Danger to life and limb gt gt amp Seals gaskets may be replaced only with the equipment system and or working machine is at a complete standstill In addition to the brake pads the following parts of the brake chamber may need replacement after long periods of operation e flat piston and pushrod The brake chamber is defective if the pushrod Pos 3 Fig 7 1 7 2 and 7 3 does not move when compressed air is applied and released or when air escapes from the brake chamber The brake chamber should be overhauled by the manufacturer If this is not possible the procedure described in Section 7 11 7 21 and 7 31 should be followed 7 1 Brake chamber for DV and DH 030 PFK 650 3514 1001 12 000000 Parts List for brake chamber 3514 100112 000000 Quantity 5108 125001 000000 Flat piston 2742 125103 000000 2722 015605 000000 2711 125101 000000 Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su __ pages 15 page 13 7 11 Disassembling assembling brake chamber Size 650 replacing worn parts Remove the brake chamber fro
13. m the brake caliper lever be loosening the screws Remove the circlip 1 Pull the cylinder bearing A out of the brake chamber Remove the spacer disc 4 Pull the pushrod 3 and the flat piston 2 out of the brake chamber Replace worn parts Before reassembling the unit clean the inside wall of the brake chamber 8 and the bearing bore for the pushrod 3 in cylinder bearing A Then lubricate these parts lightly with Alvania grease G2 manufactured by Shell Insert the flat piston 2 and the pushrod 3 into the brake chamber until they abut with floor of the cylinder Insert the spacer disc 4 Insert the cylinder bearing A into the brake chamber 8 Ensure that the tension pin S is inserted into the corresponding bore in the spacer disc 4 Then fix the cylinder bearing firmly in place in axial alignment with the circlip 1 7 2 Brake chamber for DV and DH 030 PFK 640 3514 1001 13 000000 IN Z 5108 102 001 000000 Flat piston 4 Orng St 5116 092000 040090_ 5 Glide bushing 2 313 015001 000000_ Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su__ pages 15 page 14 7 21 Disassembling assembling brake chamber Size 640 replacing worn parts Remove the brake chamber from the caliper leve
14. or a water based surfactant solution soapy water etc and then rubbed dry with a clean cloth When cleaning the brake disc with a thinner acetone or a brake cleaning agent it is important to ensure that neither these cleaners nor any cleaner residues come in contact with the brake pads This is especially important in the case of brakes used only as parking brakes as no dynamic braking operations take place during which thinner residues would be rubbed off the brake disc Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su __ pages 15 Caution Oil and rust proofing agent residues reduced friction coefficient and thus diminish transmissible braking torque substantially 5 1 Installation The brake calliper should be mounted to stabile vibration free machine components in order to ensure noise free non screech During installation it is essential to ensure that brake pads are centred and in full contact with the brake disc the midlines of the brake caliper arms must point to the midpoint of the brake disc Maximum permissible lateral brake disc wobble is 0 2 mm Greater wobble may cause rattling and shaking of the brake unit The brake caliper is using 4 M 12 bolts DV 30 or 3 M 12 bolts DH 30 the strength class 8 8 attached to the machine part Caution When mounting the brake caliper the
15. r by loosening the screws Remove the circlip 1 Pull the cover A with the O ring 4 out of the brake chamber Press the pushrod 3 and flat piston 2 out of the brake chamber Replace worn parts Before reassembling the unit clean the inside wall of the brake chamber 8 and the bearing bore for the pushrod 3 in cylinder bearing A Then lubricate these parts lightly with Alvania grease G2 manufactured by Shell Insert the flat piston 2 and the pushrod 3 into the brake chamber Insert the cover A with the O ring into the brake chamber 8 Then fix the cylinder bearing firmly in place in axial alignment with the circlip 1 Before mounting the brake caliper test for leaks at a pressure of 6 7 bar 7 3 Brake chamber for DV and DH 030 PFK 653 3514 100134 000000 Parts list for brake chamber 3514 100134 000000 1 Crip 5108 125001 000000 Flat piston 2742 125103 000000 2722 015605 000000 2711 125101 000000 1 5 Cylinder bearing 1 2772 125104 000000 nickel plated Installation and Operating Instructions for RINGSPANN Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su _ pages 15 page 15 7 31 Disassembling assembling brake chamber Size Gr 653 replacing worn parts Remove the brake chamber from the brake caliper lever be loosening the screws Remove the circlip 1 Pull the cylinder b
16. s during brake installation and maintenance Rotating components can cause severe injuries Therefore rotating components e g brake disc must be secured by the operator to prevent accidental contact Caution If the brakes are used as holding brakes the braking torques specified are not met Reduction of up to 50 of the braking torque are possible Installation and Operating Instructions for Brake Caliper DV DH 30 PFK E 09 649 e pneumatically activated spring released Issue 03 04 2014 checked Su __ pages 15 3 Drawing and parts list Brake Caliper DV 30 Brake Caliper DH 30 Compressed air Compressed air fitting G 1 4 gt om T I N x 7 y M eo aN Ne LE 3 l GTT cass l pot maz man gal RS i i EN Retracting spring Retracting spring both sides 1 ZA oth sides J WG i EERS Theadred pin for fiw rN Theadred pin for adjustmend gap G G adjustment gap beetween brake disc A beetween brake disc and brake pads 5 7 and brake pads min residual brake pad min redidual brake pad thickness 4 mm thickness 4mm Brake chamber Size 653 other diameter 135 mm cylinder bearing electroless nickel plated Standard brake pad for brake calipers 4457 300100 000000 4457 300101 000000 4457 901124 000000 4457 901 148 000000 4457 901141 000000 4457 301 128 000000 2472 005013 A001 12 Brake pad with wear alarm cable
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