Power Transmission Installation and Operating Instructions for Brake
Contents
1. 5 mm and a gap of 0 5 mm between the disc and each brake pad Pos 5 The air connection G 1 4 is locked with a protective cap 5 Installing the RINGSPANN brake caliper Before installing the brake the brake disc must be cleaned with alcohol e g ethyl or isopropyl alcohol 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 Caution Oil and rust proofing agent residues reduced friction coefficient and thus diminish transmissible braking torque substantially 5 1 Installation The brake caliper 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 arm must point to the midpoint of the brake disc Installation and Operating Instructions for Brake Caliper DH 015 PFK E 09 644e pneumatically activated spring released Date 11 09 2013 Maximum permissible lateral brake disc wobble is 0 2 mm Great2. double friction surface or other special brake pad materials e the part number 4457 150106 000000 taper type lubrication nipple An identification plate with a 16 digit part number is affixed to the caliper The precise design of the brake caliper is defined by this part number only Please consult the drawings in each section when using this instructions 2 Configuration and function The brake caliper is used as a stopping and parking brake Braking force is generated by compressed air The brake is 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 starts 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 can not be attained Reductions up to 50 of the braking torques are possible Installation and Operating Instructions for Brake Caliper DH 015 PFK E 09 644e pneumatically activated spring released Date 11 09 2013 3 Drawing and parts list U _ Brake chamber in the lever A with Loctite 243 secured a connection fitting G 1 4 Compressed air QO OOOOH min remain
3. the pushrod Pos 16 Fig 3 1 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 should be followed e Remove the entire brake caliper from the machine component by loosening the screws e Disconnect the tension spring 4 e Remove the grooved pin 13 with which the lever 2 is fastened in the frame by pressing it from the frame in the direction of the groove Set the lever 2 aside see Fig 7 1 e Press the pressure piston 11 with the pushrod 16 and piston seal 12 through the G air supply bore and out of the cylindrical tube 15 using a drift punch or rod with a diameter of 5 mm e Replace the worn piston seal 12 e Clean the individual parts before reassembling and coat the inside wall thinly with Alvanina grease G2 manufactured by Shell e Push the pressure piston unit into the cylindrical tube to the stop on the bottom e Reinstall the lever 2 with a new grooved pin 13 Make sure that you insert the grooved pin opposite to its original position so that the groove fits into the previously tension free bore e Replace the tension spring Installation and Operating Instructions for Brake Caliper DH 015 PFK E 09 644e pneumatically activated spring released Date 11 09 2013 Danger to life and limb When disassembling the b
4. RINGSPANN Power Transmission Installation and Operating Instructions for Brake Caliper DH 015 PFK E 09 644e 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 Brake Caliper DH 015 PFK E 09 644e pneumatically activated spring released Date 11 09 2013 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 RINGSPANN agents e f a malfunc
5. er wobble may cause rattling and shaking of the brake unit The brake caliper is mounted to the machine component with using 2 M14 bolts strength class 8 8 Caution When assembling make sure that the brake pads are centred aligned and in full contact with the brake disc The maximum permissible wear is to observed 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 Air hoses are connected to the brake chamber with a G 14 fitting Whitworth threaded pipe DIN ISO 228 1 The caliper must first be mounted onto the brake disc before air pressure is introduced Operating pressure may range between 1 to 6 bar depending on braking force 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 Viskosity at 20 C mm s Avia Avilub RSL 3 34 BP Energol HLP 40 27 ESSO Spinesso 34 23 Shell Tellus Ol C 10 22 Mobil VAC HLP 9 25 2 Maximum air consumption per braking operations is ap
6. ing __ pad thickness 4 mm Average A B Position of wave spring washer aens Position of wave Bild 3 1 ss l R L spring washer Parts list Standard brake pad for brake caliper 4457 9011 17 000000 Brake pad from BK 5300 v 50m s for brake caliper 5 4457 901117 A00103 Brake pad with wear alarm cable for brake caliper 4457 150107 000000 Brake pad from Teflon PTFE for brake caliper 4457 901117 A00105 2472 005013 A00112 2472 005013 A00103 2472 005013 A00101 2472 005013 A00105 Installation and Operating Instructions for Brake Caliper DH 015 PFK E 09 644e pneumatically activated spring released 6 Hexagon head screw M8x12 DIN EN ISO 4017 4 5019 008003 000000 Friction lining swivel part 2476 081001 000000 Ez Grooved pin for friction lining swivel 4517 000011 000000 part 9 _ Wavespringwasher 2 124 021001 000000 Brake chamber completely to DH 15 1 3514 063100 000000 10 Part 11 12 15 and 16 11 13 1 1 Building group cylindrical tube 14 3514 065001 000000 16 Pushrod to DH 15 4 2721 020100 000000 16 17 taper type lubrication nipple M8x1 only g Le part number 4457 150106 000000 a SOVUSHI OQUO Part number for 1 brake pad Part number for 1 set 2 pieces brake pads 4 Condition on delivery The brake caliper is delivered with a standard brake gap of 13 5 mm brake disc thickness of 12
7. prox 124 cm8 Caution Check to ensure that the brake disc rotates freely 5 3 Running in procedure Optimum braking effect is achieved only when both brake pads 5 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 to 2 bar while the brake disc is rotating are required Installation and Operating Instructions for Brake Caliper DH 015 PFK E 09 644e pneumatically activated spring released Date 11 09 2013 Caution If running in cannot performed the braking torques specified in our catalog no 46 cannot be achieved Reductions of up to 50 are possible 6 Maintenance Maintenance should be performed on the brake calliper at intervals of 4 to 12 weeks depending upon the frequency and duration of operation 6 1 General maintenance e Check both brake caliper lever arms for ease from movement e Clean all bearings and glide points e Lubricate all bearing and glide points Caution Brake pads must not come in contact with lubricants Check for tight bolt screw connections e brake caliper to machine component e brake chamber to brake lever e brake pads to the swing parts on the brake lever Check the following for proper seal leaks e brake chamber e hose connection and connection to
8. rake It is essential to secure the entire drive train protected against accidental activation Rotating components can cause severe injuries Therefore rotating components e g brake disc must be secured by the operator to prevent accidental contact Caution Secure the brake for dismantling
9. the brake chamber leaks can for example be determined easily and quickly with a commercial leak searcher For part number _4457 150106 000000 Check both brake caliper lever arms and the friction lining swivel parts for ease from movement Clean all bearing and sliding points and lubricate via the taper type lubrication nipple Brake pads must not come in contact with lubricants The type of grease and lubrication intervals are defined by the machine manufacturer depending on the machine and the environmental influences Also the initial lubrication is made by the machine manufacturer 6 2 Checking brake pad wear and replacement of brake pads 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 see Fig 3 1 in Section 3 Brake pads or Installation and Operating Instructions for Brake Caliper DH 015 PFK E 09 644e pneumatically activated spring released Date 11 09 2013 brake linings Pos 5 must always be replaced in pairs For unscrewing and screwing on fixed spanners or ring spanners with SW 13 are needed Danger to life and limb Brake pads may only be replacing when the plant or the working machine is at complete standstill Caution Brake pads or brake linings must always be replaced in pairs 7 Disassembling exchange of the piston seal in the brake chamber The brake chamber is defective if
10. tion 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 DH 015 PFK E 09 644e pneumatically activated spring released Date 11 09 2013 Contents 1 General information 2 Configuration and function 3 Drawing and parts list 4 Condition on deliver 5 Installing the RINGSPANN brake caliper 5 1 Installation 5 2 Compressed air connection 5 3 Running in procedure 6 Maintenance 6 1 General maintenance 6 2 Checking brake pad wear and replacement of brake pads 7 Disassembling exchange of the piston seal in the brake chamber Installation and Operating Instructions for Brake Caliper DH 015 PFK E 09 644e pneumatically activated spring released Date 11 09 2013 1 General information These installation and operating instructions apply to e the DH 015 PFK brake caliper mounted at a right angle to the brake disc see Fig 3 1 in Section 3 for installation on a brake disc with a thickness of 12 5 mm e various types of brake pads e g with wear alarm cable increased glide speed
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