Operating Manual For Disc Brake Type: SB 28 28-1105-01/6
Operating Manual For Disc Brake Type: SB 28 28-1105-01/6
Operating Manual For Disc Brake Type: SB 28 28-1105-01/6
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e-Mail: info@bubenzer.de
Table of contents
1 Safety regulations ................................................................................... 3
2 Brake ........................................................................................................ 4
2.1 Brake-description and designated use....................................................................4
2.2 Technical data ........................................................................................................4
2.3 State of shipment and storage instructions.............................................................6
3 Set-up of the brake.................................................................................. 6
3.1 Mounting and aligning of the brake.........................................................................6
3.2 Electrical connection of the brake ...........................................................................6
3.3 Running in of the brake pads ..................................................................................6
3.4 Set braking torque ..................................................................................................6
3.5 Set Reserve stroke .................................................................................................6
3.6 Activate Self centering device.................................................................................6
3.7 Check limit switches ...............................................................................................6
3.8 Function control ......................................................................................................6
4 Maintenance............................................................................................. 6
4.1 Regular maintenance tasks ....................................................................................6
4.2 Additional Maintenance for Hoist Gear Brakes .......................................................6
4.3 Lubrication ..............................................................................................................6
4.4 Use of manual release lever (Option) .....................................................................6
4.5 Maintenance of the AWC........................................................................................6
4.6 Setting of self-centering device...............................................................................6
4.7 Exchanging of brake pads ......................................................................................6
4.8 Exchange of limit switches......................................................................................6
4.9 Exchange bolts and bushes....................................................................................6
4.10 Exchange thruster...................................................................................................6
4.11 Exchange Spring unit..............................................................................................6
5 Troubleshooting ...................................................................................... 6
6 Spare parts............................................................................................... 6
7 Appendix .................................................................................................. 6
1 Safety regulations
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 2.1 “Description and proper 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.
Important!
The brake type BUBENZER BREMSEN SB 28 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!
Important!
Ensure that the brake is set to its proper values according to the manual
after finishing any work!
2 Brake
The brakes BUBENZER BREMSEN Type SB 28 are meant exclusively as disc brakes for the
conditions specified in the order together with the designated brake disc. The brake is designed as
a holding brake and emergency brake. It is designed for dynamic braking within the limits given in
section 2.2. This version of the brake is not suitable for use in areas with explosion hazards.
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!
Overview SB 28
7.21
7.22 2.14
3
4
1.22 3.4 5
6.1
1.21 5.10
5.3
1.26
Important!
The complete brake has a weight of
more than 250 Kg. Always use proper
lifting devices and transport the brake
using the lifting ore!
If the brake isn’t installed directly after delivery heed the following instructions:
• 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.
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!
5 mm
3.14
3.20 Bremsbelag
3.4
Bremsscheibe
Fig. 2:
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!
Connect thruster according to supplier’s data. Please refer to manual-manual for ELDRO / ELHY-
thrusters, included in this documentation! Refer to the type plate for the electrical data.
• Connections have to be flexible, as the brake must move freely.
• Tighten cable connections.
The running in of the brake pads is essential to insure an even contact pattern on the pad which
will avoid uneven loading of part of the surface and any resultant damage. The brake can be
damaged when it is run in under unsuitable conditions!
Do not exceed the following values during running in.
Rotate adjusting nut (3.14) clockwise, until the upper edge of the torque indicator (3.4) shows
approx. 90% of the required braking torque on the scale (3.20)
Note: The permissible minimum braking torque is 50% of the rated maximum braking torque.
Notice!
A counter clockwise turn of nut (Fig. 2 - 2.2) may damage the AWC when
the catch (Fig. 2 – 2.7) is connected! To avoid this follow the instructions:
Note: Adjust brake in released condition. Check adjustment when the brake is set!
5.60
5.10
5 2.14
Fig. 3:
When the brake pad wear is compensated, the levers are “lifted out of the adjusting bolts”. The SB
28 is equipped with a centering device. It uses a springborn wedge (1.26), that centers the brake
automatically, when the brake pads are wearing down. The wedge (1.26) is adjusted correctly prior
to shipment. In case of considerable differences in unequal brake pad lift-off a new adjustment is
necessary (section 4.5).
• Release brake.
• Dismount cover (1.21) by unscrewing bolt (1.42).
• Remove tape (1.60) at wedge (1.26) and clean wedge of remains of adhesives, if necessary.
• Insert wedge (1.26) loosely and without force into the guide way.
• Set brake
o Wedge (1.26) moves down inside the guide way.
• Check movability and position (Fig. 5) of the latch (1.27). If the position isn’t correct:
• Loosen fastening bolt (1.40).
• Adjust roller (1.28) with bolt (1.43), so the shackle fits correctly (fig. 5).
• Tighten fastening bolt (1.40).
• Actuate and release brake several times until the wedge (1.26) doesn’t move further down.
• Remount cover (1.21) and fix it with bolt (1.42).
• Do not lubricate the wedge (1.26), just keep it clean
1.26 1.21
1.27
1.42
1.43 1.40
1.28
Fig. 4:
Fig. 5:
Caution!
In case limit switches 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!
7.21
7.11
7.4
7.22
7.12
Fig. 6
The limit switches are mounted to the spring tube. For each limit switch there is an actuating roll
screwed onto a threaded rod. Fig. 6 shows the brake set.
When the brake opens, the threaded rod moves upwards. The upper actuating roll moves out of
the switching area of the switch “set-control” and the switch is idle. The lower actuating roll moves
into the switching area of the switch “release-control” and the switch is actuated.
When the brake sets, the threaded rod moves downwards. The upper actuating roll moves into the
switching area of the switch “set-control” and the switch is actuated. The lower actuating roll moves
out of the switching area of the switch “release-control” and the switch is idle.
Wear control
The limit switch is screwed (7.24) into the crosspiece (2.16) of the AWC (2.1). When the brake is
set correctly, the switch isn’t actuated. With growing wear, the spindle (2.1) moves into the
crosspiece (2.16) (arrow). As soon as the wear reaches the critical value, the switch (7.24) is
actuated.
2.16
2.1
7.24 7.23
6.1
Fig. 7: Fig. 8:
Release and set the brake several times. Check the following:
• Does the stroke indicator show approx. 10 millimeters reserve stroke, when the brake is set?
If NO: Repeat section 3.5
• Is there an equal air gap between brake pads and brake disc, when the brake is released?
If NO: Repeat section 3.6
• Did you set the required braking torque?
If NO: Repeat section 3.4
• Is catch (2.8) properly installed and fitted into its place?
If NO: Adjust according to section 3.6
• Is the catch-pin (2.8) inside the elongated hole of the catch (2.7)?
If NO: Adjust according to section 3.6
• Is the catch-pin (2.8) touched by the catch (2.7) during operation of the brake?
If YES: The AWC is not yet completely run in. Set and release the brake, until the catch pin (2.8)
isn’t touched any more.
• Is the required braking distance achieved?
If YES: Setup finished!
If NO: Reset braking torque (Section 3.4)
4 Maintenance
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!
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 BUBENZER BREMSEN spare parts!!
Check:
All 100 - 150 operating hours
All 450 operating hours or monthly (Holding brakes without dynamic braking)
In case the brake hasn’t been used for six months
• Function of the brake/brake system
• Brake shoe lift-off
• Lining wear/lining thickness
• Condition of the brake disc
• Thruster reserve stroke
• Easy mobility of the brake linkage
• Brake spring tension (torque)
• Adjustment of limit switches, hand release devices and other optional equipment
• Possible wear of the automatic wear compensator (if ordered)
Check the brake/brake system outside the regular inspection intervals if:
• Prolonged braking times or -distances appear
• Extreme operating conditions appear:
⇒ Overspeeding of the brake drum
⇒ And/or excessive braking times
• A limit switch indicates lining wear or lack of releasing stroke
• After a longer period of brake-standstill or drive standstill.
• An emergency stop occurred.
DO NOT DISENGAGE the automatic wear compensator, as otherwise lining wear must be
compensated manually!
Attention!
Cotter pins at pins have to be opened, so they can’t fall out
(left). Cotter pins at castellated nuts have to be opened
completely (right)!
The following are in addition to the visual inspection of the brakes every 100-150 operating hours
(see page 2). In Germany brake tests must be performed for the hoist brakes once a year.
(German regulation VBG9). These brake tests must be carried out without electric controlled
deceleration.
Where German crane operation legislation is not applied, we recommend the following:
and/or
Important Note
In case of exclusive static use as holding brake or low dynamic braking requirement as is
commonly the case on new cranes and especially container cranes, the surface of the sintered
lining will tend to accumulate dust particles which can reduce the friction factor and thus the
available braking torque. These dust particles in the brake pad surface can be removed by
performing the annual dynamic brake test.
Where it is not possible to carry out dynamic load tests at regular intervals, we recommend
changing brake pads every 2 years. If brake pads removed from the brake are in otherwise good
condition i.e. free from oil contamination, even wear pattern, no visible cracks or deformation and
well above minimum residual pad thickness, they can be reconditioned by grinding or machining
approx. 0.5mm off the surface.
4.3 Lubrication
Warning!
When using the manual release lever, there is no safety device active any
more! Mortal danger!
Always make sure nothing can move out of control.
Danger!
Release brake SLOWLY, so an attached load can’t move out of control!
Mortal Danger!
The manual release lever (Fig. 11 - 6.1) is not part of the standard scope of supply. By means of
the lever the brake may be released manually in case of an emergency-situation, e.g. to lower a
load after an emergency stop.
Warning!
The lever is not suited to keep the brake open for maintenance tasks.
Mortal danger!
Always follow the regulations given in section 5!
Always watch the load (2nd operator) so you don’t miss the point, where the brake releases. Pull
the lever upwards SLOWLY to open the brake (arrow). If the lever is released, before it has
reached its locking position (completely released), the brake automatically closes. It is possible to
provide the brake without a catch for the lever. Check scope of supply. By means of the lever the
load can be released controlled. As an option the manual release lever can be equipped with a
limit-switch for release control (Fig. 8).
6.1 6.1
Fig. 11:
The catch (Fig. 2.7) and the freewheel (Fig. 2.6) may be object to wear. Recognized by a constant
reduction of the reserve stroke in case of lining wear, although the AWC is actuated.
Procedure:
• Rotate nut (2.2) clockwise to compensate lining wear and thus the reduced reserve stroke.
(Refer to section 3.5)
• Replace worn parts resp. the complete AWC unit as soon as possible!
2.7
2.8
2.6
2.2
Fig. 10:
Note:
• For this task, 2 persons are necessary.
• Store all removed parts in the correct order of assembly.
• Do not mix up the spacer tubes, because they are different in length!
• Remove the 2 cotter pins of the castellated nuts (1.49) as well as cotter pin (1.23).
• Screw off castellated nuts (1.49) and remove washers on indicated side.
• Note: The nuts on the other side can remain!
• Pull out threaded pins (1.25) slowly into arrow direction, until both levers (2.14) are free.
Caution: The spacer tubes are loose now and may fall into the brake!
1.25
1.2
1.25
1.5
2.14
1.4
Caution! When pulling out the bolts (1.23) the levers (1.4 / 1.5) may tilt and fall over! Secure
both levers (1.4 / 1.5) against falling over!
• Pull pin (1.23) slowly into arrow direction, until both levers (1.4 / 1.5) are free.
• Important: Pin (1.23) must remain in lever bearing (1.2)!
• Swivel both levers (1.4 / 1.5) complete with AWC unit (2) upwards (Fig. 12 left).
• Remove levers (1.4 / 1.5) from AWC unit (3)
• Turn nut (2.14) counter clockwise to remove the unit from crosspiece (2.16).
1.4 / 1.5
2
2.16 2.16
Fig. 12:
1.42
1.21
1.61
1.43
1.26
Fig. 13:
Note: Stop side“ means the side of the brake which is equipped with the wedge (1.26).
• Release brake.
• Dismount cover (1.21) by unscrewing bolt (1.42).
• Remove screws (1.43) and clean the threads from any adhesive agent
• Tighten screws (1.43) with a screwdriver evenly (Gap „S“ =0) afterwards turn back the screws
one quarter rotation.
• Insert wedge (1.26) loosely and without force into the guide way.
• Actuate and release brake several times until the wedge (1.26) doesn’t move further down.
• Check air gap
• If the air gap of the brake pads is too large on the stop side of the brake:
o Turn both screws (1.43) clockwise.
• If the air gap of the brake pads is too large on the opposite side:
o Turn both screws (1.43) counter clockwise.
Warning!
During the braking process the brake disc and the brake shoes heat up!
Danger of burning!
Let brake disc and brake cool down before changing the brake pads!
Important!
Always exchange BOTH brake pads!
Otherwise the brake might not work properly!
3.14
1.50
1.45
1.33
2.2
Fig. 14:
• Check new brake pad (4) for cleanliness, clean if necessary (Emery paper).
• Put new brake pads on the key (1.33) and tighten it by screws (1.45) to the brake shoe (1.50).
• Do not forget special washers (1.50)!
• Readjust and run-in brake according to sections 3.3 to 3.8.
Release / Setting-control
7.21 7.51
7.11
7.12
7.22 7.52
Fig. 15:
The switch for release control (7.22) has to be actuated, when the brake is released. The limit
switch set control (7.21) must be actuated when the brake closes. Set gap
• Release brake
• Loosen nut (7.52).
• Turn switch roller (7.12) in position, until the switch is actuated.
• Release and set the brake several times electrically.
• Check if the limit switch (7.22) is actuated, when the brake is released.
• Finally tighten nut (7.52) against roller (7.12).
• Set brake
• Loosen nut (7.51)
• Turn switch roller (7.11) in position, until the switch is actuated.
• Release and set the brake several times electrically.
• Check if the limit switch (7.21) is actuated, when the brake is set.
• Finally tighten nut (7.51) against roller (7.11)
7.24
2.16
7.25
Wear control
• Loosen lock nut (7.25).
• Unscrew old limit switch (7.23).
• Disconnect limit switch (7.23) electrically.
• Connect new limit switch (7.23) electrically.
• Screw new limit switch into crosspiece (2.16) until the actuating surface coincides with the
inner bore.
• Tighten lock nut (7.25).
To exchange the bushes, the brake has to be disassembled. This means it has to be dismounted,
depending on the installation. Always secure the installation against accidental movement!
• Open brake by releasing the brake tension.
• Release brake completely by adjusting nut.
• Dismount brake
• Before removing the bushes note positions.
• Don’t damage the bores when removing the bushes.
• Clean and debur bores if necessary.
• Note the mounting-direction of the bushes. Refer to exploded views in section 7
• Don’t damage or jam the bushes when driving / pressing them into the levers.
• Reset brake to operating values according to section 3!
3.14
5.2
5.10
5.4
Fig. 18:
Caution!
When the upper bolt (5.2) is pulled out, the thruster may tilt and fall.
Secure the thruster against accidental movements!
Danger of injury!
• Remove cotter pins and washers from Eldro (5.2 and 5.4).
• Attach thruster (5) with e.g. a rope to a suitable lifting device.
• Loosen and remove bolts (5.2 and 5.4).
• Exchange thruster (5).
• Reassemble brake
• Connect new thruster
6.1 1.5a
7.24 1.5b
3 5
Fig. 19:
1.25 3
1.25
1.64
1.23
Fig. 20
5 Troubleshooting
Note:
DB - Data sheet of the limit switch
6 Spare parts
Important!
In case of ordering, please indicate the type and the serial no. of the brake
which is located on the type plate (see below: “TP”) of the 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 BUBENZER BREMSEN spare parts!!
7.24 2
7.23
3 7.21
TP 7.22
5
4
1.26
7 Appendix
Important!
Used Nordlock-washers must not be used again!
These tightening torques apply for:
µcompl. = 0,12 (black or bonderd, slightly oiled)