Operating manual for disc brake type SF 10-40

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Tighten mounting bolts with a torque-wrench to the nominal tightening torque (please refer to table 2). Fig. 2: Fig. 3:
Operating manual for disc brake type SF 10-40

PINTSCH BUBENZER GmbH Plant Kirchen

PINTSCH BUBENZER GmbH Plant Dinslaken

Friedrichshüttenstr. 1 57548 Kirchen-Wehbach Tel.: +49-2741 - 9488 - 0 Fax: +49-2741 - 9488 -44 GERMANY

Hünxer Str. 149 46537 Dinslaken Tel. +49 (0)2064 602 – 8 Fax +49 (0)2064 602 – 515 GERMANY

www.pintschbubenzer.de E-Mail: [email protected]

www.pintschbubenzer.de E-Mail: [email protected]

PB24-0713-01/4

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  2

Operating manual SF 10-40 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 

3

Operating manual SF 10-40 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.

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Operating manual SF 10-40 1.2

Warnings

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

All safety advises are marked by Symbols and frames! Symbol / Pictograph

Description

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

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: 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!       

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! 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.

5

Operating manual SF 10-40

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

Safety distance A safety distance must be maintained to all hazardous zones to ensure safety of personnel and prevention of damage to the brake.

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! Important! Ensure that the brake is set to its proper values according to the manual after finishing any work!

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.

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Operating manual SF 10-40 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.

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Operating manual SF 10-40 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 GERMANY

PINTSCH BUBENZER GmbH Plant Dinslaken Hünxer Str. 149 46537 Dinslaken GERMANY

Tel.: +49-2741 - 9488 - 0 Fax: +49-2741 - 9488 -44

Tel. +49 (0)2064 602 – 8 Fax +49 (0)2064 602 – 515

E-Mail: [email protected] E-Mail: [email protected] Internet: www.pintschbubenzer.de Internet: www.pintschbubenzer.de Local District Court Montabaur, HRB 5590 Managing Directors: Markus E. Topp, Stefan Kröger

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Operating manual SF 10-40 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!

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Operating manual SF 10-40

4

2.20

5

1.3 1.9

3.3

3.9

6

2

1.12

Fig. 1:

Pos. 1.3 1.9 1.12 2 2.20

Item Adjusting bolt Brake pad holding screw Eyebolt Cylinder unit Safety bolt

Pos. 3.3 3.9 4 5 6

10

Item Sensor – Release control Sensor – Wear control Brake pad Bleeder valve Hydraulic connection

Operating manual SF 10-40 2.6

Technical data

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

SF Contact Force FA / calliper half Operating pressure (min) Operating pressure (max) Air gap (min) / calliper half Air gap (max) / calliper half

2.7         

[kN] [bar] [bar] [mm] [mm]

10 100 140 200 2 2,5

15 150 180 200 2 2,5

24 240 180 200 2 2,5

30 300 210 240 2 2,5

40 400 210 240 2 2,5

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.

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Operating manual SF 10-40 3 Setup of the brake Danger! 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! Important! Brake discs shipped by PINTSCH BUBENZER and possibly other brakes, are coated with rust protection. Remove this coating before setting up 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 Bolt size Tightening Torque MA

SF 10 M 24 1050 Nm

12

SF 15 M 24 1050 Nm

SF 24 SF 30 M30 M36 2100 Nm 3500 Nm

SF 40 M48 6400 Nm

Operating manual SF 10-40 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.

5 mm / 10 mm

Brake pad

Brake disc

Fig. 4:

3.3

Hydraulic and electric connection of the brake 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.

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. 2.6 5  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:

2.21

13

6

Operating manual SF 10-40 3.4

Removing of safety bolts 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! 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!

  

 

Release brake hydraulically. Remove cover (2.6). Unscrew safety bolts (2.20) o SF 10-24: four safety bolts o SF 30: five safety bolts o SF 40: six safety bolts Bolts of the class 12.9 may be re-used. All other bolts must not be used again.

2.20

Fig. 6:

(Fig. 6). (Fig. 7). (Fig. 8).

2.20

2.20

Fig. 7:

Fig.8:

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Operating manual SF 10-40 3.5

Alignment of brake Important! Different cylinder strokes per caliper cause axial pressure to the brake disc and lead to higher wear and reduced braking force.

A X X1

B

X2

D C

Fig. 9:

   

    

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:



Fig. 10:

Brake type Xmin Nominal value X Xmax

SF 10 49 mm 50 mm 51 mm

SF 15 49 mm 50 mm 51 mm

SF 24 54 mm 55 mm 56 mm

SF 30 64 mm 65 mm 66 mm

SF 40 54 mm 55 mm 56 mm

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.

15

Operating manual SF 10-40 3.6

Bleeding of the brake 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.

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. 5.1  Oil level has to be visible at oil sight glass when the brake is 5.2 5 completely released.  If necessary refill. Fig. 12:

16

Operating manual SF 10-40 3.7

Adjustment of the releasing stroke (cylinder stroke) 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!

   

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

Fig. 13:



         

Y

1.9

1.3

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). 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.



Remount cover (2.6) with flange-seal (2.14).  Make sure the seal and the mounting area are clean.

Fig. 14:

17

2.6

2.14

Operating manual SF 10-40 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). 9.4 9.4

9.4

9.1

3.9

9.2

S1

9.1

9.2 Fig. 15:

9.3

9.5

Fig. 16:

Running in of the brake pads 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! 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:

Max. speed Max. disc temperature Max. braking time

Organic linings 30m/s 200°C 5 Seconds

18

Sintered linings 75 m/s 250°C 15 Seconds

Operating manual SF 10-40      

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

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! 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.

19

Operating manual SF 10-40 4 Operation Important! The handling of the brake can vary, depending on the used hydraulic power unit. Always refer to the manual of the power unit! 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    

4.2   

4.3 

4.4

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.

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.

Emergency stop and power failure In case of an Emergency stop or power failure the brake automatically instantly sets.

Manual release Danger! Release the brake SLOWLY, so no attached load can move uncontrolled. Mortal danger!

Danger! When releasing the brake manually no other safety device is active! Always secure the drive and the installation against any accidental movement! The manual release is done by means of an external device, e.g. the handpump of the power unit. 20

Operating manual SF 10-40 4.5

Proximity switches and sensors 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!

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!

3.3

3.5

5

3.3

3.9

Fig. 17:

3.5

Fig. 18:

3.3

3.5

3.9

3.5

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).

21

Operating manual SF 10-40 5 Maintenance Danger! 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! Attention! After a longer period of standstill, rust and dirt may pollute the brake padsand 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!

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.

22

Operating manual SF 10-40 5.3

Cleaning Do not use corrosive or acidic agents to clean the brake. Only use fatdissolving 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! 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) 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!

2.6

2.14

Y

1.9

Fig. 20:

     



1.3

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: 23

Operating manual SF 10-40          



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.

24

Operating manual SF 10-40 5.5

Replacement of brake pads 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!

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. 2.6

2.14 1.3

4

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. 25

1.9

Operating manual SF 10-40         

5.6

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.

Replacement of proximity switches and sensors 2.6

2.14 3.3

3.5

Fig. 24:

Fig. 25:

3.9

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).  Make sure the seal and the mounting area are clean. 26

Operating manual SF 10-40 5.7

Replacement of seals 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.

The design of this brake allows a replacement of the seals with the brake still mounted. 2.6

2.14

3.8

5

3.3

6 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.

2.18

2.5

2.3

2.17

2.1

2.8 Fig. 29:

 

Fig. 30:

Fig. 31:

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

27

Operating manual SF 10-40    

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.

2.11

2.13

2.8

X

2.10

2.12

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).  Make sure the seal and the mounting area are clean.

Table 5:

Brake type Measurement X Tightening torque MA

SF 10 1 mm 16 Nm

28

SF 15 1 mm 16 Nm

SF 24 2 mm 39 Nm

SF 30 3 mm 72 Nm

SF 40 3 mm 72 Nm

Operating manual SF 10-40 5.8

Replacement of cylinder unit 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!

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. 2.6

2.14 2.20 1.3

1.9

4

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.

3.8

5

1.4

3.3

6

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). 29

1.10

Operating manual SF 10-40

Z

2 Fig. 40:

  

Fig. 41:

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

 

Clean Thread of main body. Position new cylinder unit (2) with lifting device. Important! Insert the new cylinder unit carefully! The thread must not jam or else this may lead to damages to the brake!



Screw in cylinder unit (2) to control measurement Z (Fig. 41 /Table 6)

Table 6:

         

Brake type Measurement

[mm]

SF 10 139,4

SF 15 153,4

SF 24 185

SF 30 224,5

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.

30

SF 40 229,5

Operating manual SF 10-40 5.9

Replacement of cleaning pads Important! Always exchange both pads! Pads are delivered in pairs!

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. 9.4 9.4

9.4

9.1

9.2

S1

9.1

9.2 Fig. 42:

9.3

Fig. 43:

31

9.5

Operating manual SF 10-40 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! Important! Because of the weight of the brake always use proper lifting devices and transport the brake using the lifting ore! Danger of injury!

Warning! A sudden startup of the installation endangers the life of the working personnel! Secure the drive and the installation against any accidental movement before starting any work!

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!

Caution! Make sure the system is not pressurized! Danger of injury!

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.      

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.

32

Operating manual SF 10-40 7 Troubleshooting Symptom

Possible reason Mechanically blocked Safety bolts have not been removed Brake is manually released Hydraulic pressure is applied Belleville washers damaged Brake doesn’t Signal “open” is active close Proximity switches malfunctioning

Move Check Remove safety bolts

3.4

Check at power unit Check wiring Replace complete cylinder Check wiring / setting Check proximity switch connection Replace proximity switch Compensate wear Replace brake pads Replace brake disc

HA HA 5.8 -

Check at power unit Check at power unit Check Tubing, hoses, connections for leakages, squeezed of parts, etc. Replace seals Check Check wiring Check proximity switch connection Replace proximity switch Check wiring and power supply Check emergency stop-buttons

HA HA

5.6 HA -

Align brake

3.5

Run in brake pads

3.9

Compensate wear Clean brake pads Check cleaning pad

5.5 5.9

Brake soiled

Clean brake

5.3

Brake pads worn Brake disc worn

Replace brake pads Replace brake disc

5.5 -

Brake pad wear Brake pads worn Brake disc worn Pressure to low Oil level to low Connection damaged Brake is leaking Brake doesn’t Mechanically blocked open Signal “close” is active Proximity switches malfunctioning No electrical power Emergency stop actuated

Braking distance to long

Section -

Brake pads don’t have full contact to disc Brake pads haven’t been run in properly Brake pad wear Brake pad soiled

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

33

ES 5.6 5.4 5.5 -

5.7 ES

Operating manual SF 10-40 8 Spare parts 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! *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

34

Operating manual SF 10-40 8.1

Spare parts SF 10

Pos. *Number -

2

3 8

2 2 1 2 2 2 2 2 2 2 2

47 52 53 54 57 32 32 55

Spare part for SF 10 Cylinder with Belleville washers 100 kN Tested and ready to mount Brake pad with brake pad carrier Wiper 160x172x10 Complete seal kit – consisting of Seal 70x80x11,4 O-Ring 70x5,33 Seal 140x150x11,4 Guidance ring 140x145x9,7 Flange seal SF 10 N Proximity switch release control IN0127 Proximity switch wear control IN0127 Cleaning pad 35

Order-Nr. 8-216.10.2.001 8-251.163.095 8-990.413 8-090161.041 8-990.135 8-990.026 8-990.136 8-990.233 8-685.00308 8-430.158.6 8-430.158.6 8-251.00011

Operating manual SF 10-40 8.2

Spare parts SF 15

Pos. *Number 2 3 8 47 52 53 54 57 32 32 55

2 2 1 2 2 2 2 2 2 2 2

Spare part for SF 15 Cylinder with Belleville washers 150 kN Tested and ready to mount Brake pad with brake pad carrier Wiper 160x172x10 Complete seal kit – consisting of Seal 70x80x11,4 O-Ring 70x5,33 Seal 140x150x11,4 Guidance ring 140x145x9,7 Flange seal SF 15 N Proximity switch release control IN0127 Proximity switch wear control IN0127 Cleaning pad

36

Order-Nr. 8-216.15.2.001 8-251.163.095 8-990.413 8-090161.041 8-990.135 8-990.026 8-990.136 8-990.233 8-685.00308 8-430.158.6 8-430.158.6 8-251.00011

Operating manual SF 10-40 8.3

Spare parts SF 24

Pos. *Number 3 8 47 52 53 54 57 32 32 55

2 2 1 2 2 2 2 2 2 2 2

Spare part for SF 24 Cylinder with Belleville washers 240 kN Tested and ready to mount Brake pad with brake pad carrier Wiper 200x212x10 Complete seal kit – consisting of Seal 100x110x11,4 O-Ring 100x5,33 Seal 180x190x11,4 Guidance ring 180x185x15 Flange seal SF 24 N Proximity switch release control IN0127 Proximity switch wear control IN0127 Cleaning pad 37

Order-Nr. 8-216.24.2.002 8-251.163.096 8-990.400 8-090161.012.3 8-990.00114 8-990-017.1 8-990.00113 8-990.232 8-685.00090 8-430.158.6 8-430.158.6 8-251.00005

Operating manual SF 10-40 8.4

Spare parts SF 30

Pos. *Number -

2

3 8

2 2 1 2 2 2 2 2 2 2 2

47 52 53 54 57 32 32 55

Spare part for SF 30 Cylinder with Belleville washers 300 kN Tested and ready to mount Brake pad with brake pad carrier Wiper 265x280x13 Complete seal kit – consisting of Seal 110x130x14,5 O-Ring 110,49x5,33 Seal 210x230x14,5 Guidance ring 658x9,7x2,5 Flange seal SF 24 N Proximity switch release control IN0127 Proximity switch wear control IN0127 Cleaning pad 38

Order-Nr. 8-216.30.2.002 8-251.163.097 8-990.462 8-090161.042 8-990.141 8-990.081 8-990.140 990.234 8-685.00475 8-430.158.6 8-430.158.6 8-251.00004

Operating manual SF 10-40 8.5

Spare parts SF 40

Pos. *Number -

2

3 8

2 2 1 2 2 2 2 2 2 2 2

47 52 53 54 57 32 32 55

Spare part for SF 40 Cylinder with Belleville washers 400 kN Tested and ready to mount Brake pad with brake pad carrier Wiper 300x315x13 Complete seal kit – consisting of Seal 125x145x14,5 O-Ring 125x5,33 Seal 220x250x22,7 Guidance ring 699x9,7x2,5 Flange seal SF 24 N Proximity switch release control IN0127 Proximity switch wear control IN0127 Cleaning pad 39

Order-Nr. 216.40.2.001 8-251.163.076 8-990.452 8-090161.043 8-990.132.1 8-990-072 8-990.133.1 8-990.229 8-685.00504 8-430.158.6 8-430.158.6 8-251.00004

Operating manual SF 10-40 9 Appendix 9.1

Data sheet TYPE SF b2 b3 b4 b5 b6 b7 b8 b9 b10 c1 d5 d6 d7 d8 h1 h2 h3 l1 l2 l3 l4min Bolt Bolt material Tighten. Torque [Nm] Contact force FA [kN] Operating press. [bar] Max. Pressure [bar] release stroke [mm] Oil volume [l] pad surface [cm2] Theor. friction factor  Weight [kg]

Bleeder valve

Pressure connection

All dimensions in mm – Alterations reserved without notice

10 165 410 110 115 85 60 85 5 90 10 175 3/8“ 25 12 270 220 90 685 292 100 40 M24 10.9 1050 100 140 200 2 0,023 427 0,4 200

15 165 410 110 115 85 60 85 5 90 10 175 3/8“ 25 12 270 220 90 750 292 100 40 M24 10.9 1050 150 180 200 2 0,023 427 0,4 210

24 195 480 130 130 100 70 100 5 105 10 225 3/8“ 31 12 300 230 70 810 342 110 130 M30 10.9 2100 240 180 200 2 0,035 570 0,4 368

30 280 640 155 200 110 110 140 10 150 10 290 3/8“ 38 12 400 300 100 940 402 130 180 M36 10.9 3500 300 210 240 2 0,050 1050 0,4 760

40 300 720 175 220 125 125 160 10 170 10 310 3/8“ 50 12 480 375 125 981 502 110 200 M48 10.9 6400 400 210 240 2 0,052 1360 0,4 1180

*) Average friction factor of standard material combination Braking torque MBr in Nm = FA [kN] x  x d1 [mm] Brake discs: d1 = d4 = d2 d1 d4 b1

SF 10 SF 15 SF 24 SF 30 SF 40 d2 – 170 mm d2 – 170 mm d2 – 200 mm d2 – 290 mm d2 – 320 mm d2 – 420 mm d2 – 420 mm d2 – 490 mm d2 – 620 mm d2 – 700 mm = Disc diameter in mm = Friction diameter in mm = Max. permissible drum or hub diameter in mm = Disc thickness in mm (min. 30 mm).

Please indicate mounting position in case of order:

40

Operating manual SF 10-40 9.2

Oil selection

Always consider the existing temperature ranges before selecting an oil.

Reference temperature ISO 3448 DIN 51519

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)

41

Operating manual SF 10-40 9.3

Tightening torques Important! These tightening torques apply for: compl. = 0.12 (black or bonderd, slightly oiled) Used Nordlock-washers must not be used again!

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

Size M4

Coarse-pitch thread – with or without NORD-LOCK-washers Tightening Torques MA 8.8 10.9 12.9 [Nm] [Lb*ft] [Nm] [Lb*ft] [Nm] [Lb*ft] 3,0 4,6 5,1 2.3 3.4 3.8

SW [mm] 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

42