Hydraulic Failsafe Brake ID 900N General Information Installation Maintenance and Care Periodic Inspection Spare Parts
General Information Correct use of the product: According to the EEC directives No. 85/374 we outline the correct product usage observing all safety aspects to comply with our product guarantees. Design parameters: The COREMO OCMEA hydraulic brakes are designed to operate according to the application, conditions and technical specifications as specified in the data sheet included into the catalogue. We recommend that the maximum data shown is not exceeded. Application selection: A correct model selection is essential to assure that performance limits are not exceeded. It is essential when selecting to take in consideration an appropriate service factor. In case of holding duties this should be not less than 2. The COREMO OCMEA technical department is available for informations, suggestions and cooperation for the correct application and use. Use: The Mounting and Maintenance Instructions must be observed so as to prevent accidents, breakage, etc. Incorrect mounting and maintenance of the unit could also result in reduced life of the product and expensive down time. Warning: the initial torque on new unit can be 30% to 50% less than the catalogue value unit the friction facing and friction disc are lapped or worn in. Mounting and maintenance precautions: The engineers responsible are advised to wear the correct protective clothing such as gloves, safety glasses, etc. Rotating parts: The moving parts have to be protected according to EEC directives No. 98/37, or the equivalent norms effective in the countries where they are used. Spring applied failsafe brake: Failsafe brakes must be treated with special attention because they have mechanical pre-tensioned springs. Hydraulic brakes: Use with mineral oil based hydraulic fluid SAE/ISO 46. Friction parts: The COREMO OCMEA hydraulic brakes are supplied with non asbestos friction material which is in accordance to the health and safety regulations. Even though the linings are asbestos free you should not breathe in the dust produced from the brake linings and if in contact ensure that the hands are clean before eating or drinking. Oils, greases and lubricating components: The lubricating materials are employed in very low quantity on our products. Anyway the use of gloves or protective creams to prevent skin allergies is highly recommended. Remember to carefully wash your hands before handle any food or beverages. Storage: To prevent accidents during lifting and storage operations, all the safety precautions must be observed. To wear helmets, safety gloves and shoes is highly recommended. Considering the heaviness of materials, insure to use a proper lift machine during lift operations. Displacing: All our products are manufactured with non toxic-harmful materials. Therefore the displacement must be performed according with the industrial rules and local regulation of the country of employment. Stoking: Some type of brakes may contain silicon or rubber diaphragm that may generate toxic gasses in case of fire. Fire fighters are advised to wear proper gas masks during extinguishing operation.
1.0 Installation 1.1 The ID 900N brake can be mounted on a bracket whose thickness is equal to the disc thickness (see picture 1). The brake has to be fixed with N 2 screws M24 class 12.9; the clamping torque is 890 Nm. Picture 1: 1.2 The part on which the brake should be mounted must withstand the braking force F = 30000 N for ID 900N-30 (A3042 and A3725 drawings) and F = 15000 N for ID 900N-15 (A3045 and A3889 drawings). 1.3 The brake includes a bleeding device (Z50315). For air bleeding, loosen the clamping nut of pipe fitting and pull out the cap. After bleeding the circuit close the pipe fitting (see picture 2). Picture 2: 1.4 Connect the oil supply line to the brake by means of the 1/4"gas connector. On request the brake can be supplied with connector for Ø8 hose (H0045) already mounted.
Installation 1.5 Supply oil to the brake and replace the M16 safety screw (24 FW) with the red compensation indicator (C62222) complete with the grub screw, using a 5 mm allen key (see picture 3). Bleed the oil circuit as explained at point 1.3. Picture 3: 1.6 The brake must be supplied only and exclusively with hydraulic fluid based on mineral oil and the supplied oil pressure must be set to : - 110 bar (MAX pressure) 90 bar (MIN release pressure) for the brake ID 900N-30. - 110 bar (MAX pressure) 60 bar (MIN release pressure) for the brake ID 900N-15. CAUTION: Do not perform braking if the disc is not correctly placed between the pads. It's otherwise possible to accidentally hurt your fingers if this caution is not respected.
2.0 Maintenance & Care ALL MAINTENANCE OPERATIONS MUST BE PERFORMED ONLY WHEN THE MACHINE IS STOPPED. 2.1 GAP ADJUSTMENT 2.1.1 Switch off the oil pressure and turn the backlash regulator (C62221) clockwise with a key 46 FW, until restoring the optimum gap of 2 mm between the disc and each of the pads (see picture 4). Torque applied for backlash compensation: 150 Nm. One complete turn of the regulator corresponds to 4 mm of wear compensation; so in order to compensate 1 mm of wear, it s enough to turn the regulator of 90 clockwise. NOTE : Each thruster assembly is equipped with a red wear indicator. When the gap between the disc and each of the pads is 2 mm, if the brake is closed this wear indicator will be aligned with the backlash regulator. When the pads are worn, this wear indicator will stay inside the backlash regulator. Picture 4: POSITION OF COMPENSATION INDICATOR WHEN THE BRAKE IS CLOSED. 2.2 LINING PADS REPLACEMENT 2.2.1 Supply oil to the brake and replace the red compensation indicator (C62222) with the M16 safety screw. Once the safety screw is inserted, it s possible to switch off the oil pressure. NOTE : Disassemble the brake from the machine only if necessary; in this case proceed as described from point 2.3.1 up to point 2.3.3. 2.2.2 Loosen the screws (C61378) which fix the stop plates (C62174) to the brake and take out the lining pivots (C62173) completed with the other screws (C61378) and the stop plates (C62174). 2.2.3 Remove the screws C62175, the springs C60625-F and the lining pads. 2.2.4 Change the lining pads with new ones and reassemble following backward the points 2.2.3 and 2.2.2. 2.2.5 Supply oil to the brake and replace the M16 safety screw with the red compensation indicator (C62222). If the brake has been removed from the machine proceed as described from point 2.3.18 up to point 2.3.20.
Maintenance & Care 2.3 SEALS REPLACEMENT 2.3.1 Supply oil to the brake and replace the red compensation indicator (C62222) with the M16 safety screw. 2.3.2 Switch off the oil pressure and disconnect the pipes. 2.3.3 Disassemble the brake from the machine. 2.3.4 Reconnect the pipes and supply oil to the brake. 2.3.5 Remove the M16 safety screw. 2.3.6 Switch off the oil pressure and disconnect the pipes. 2.3.7 Remove the lining pads as already explained at the points 2.2.2 and 2.2.3. 2.3.8 Remove the fixing screws (C61450) and the cover (D71230) complete with the regulator (C62221). 2.3.9 Remove the springs support (C62220) and the flat springs (C62223). For the brake ID900N-15 remove also the spacer (C62226). 2.3.10 Remove the piston (D71231) from the brake body as follows: supply compressed air very carefully through the oil inlet until the piston is completely out. 2.3.11 Remove the damaged seals and replace them. We suggest to replace the complete kit of N 8 seals all together at once. 2.3.12 Reassemble the piston (D71243) in the brake body. 2.3.13 Reassemble the flat springs as described from point 2.4.4 up to point 2.4.6. 2.3.14 Reassemble the cover (D71230) complete with the regulator (C62221) on the brake body using the screws (C61450) and the washers (C61321). Clamping torque of M8 screws - 10.9 class (C61450) : 34 Nm. 2.3.15 Reassemble the lining pads following backward the points 2.2.3 and 2.2.2. 2.3.16 Connect the pipes, supply oil to the brake and insert the M16 safety screw. 2.3.17 Switch off the oil pressure and disconnect the pipes. 2.3.18 Reassemble the brake onto the machine. 2.3.19 Reconnect the pipes and supply oil to the brake. 2.3.20 Replace the M16 safety screw with the red compensation indicator (see also point 1.5 and picture 3) and bleed the oil circuit as described at point 1.3.
Maintenance & Care 2.4 FLAT SPRINGS REPLACEMENT 2.4.1 Disassemble the brake from the machine as described from point 2.3.1 up to point 2.3.6. 2.4.2 Remove the fixing screws (C61450) and the cover (D71230) complete with the regulator (C62221). 2.4.3 Remove the springs support (C62220) and the flat springs (C62223). For the brake ID900N-15 remove also the spacer (C62226). Replace ALL the flat springs, even those which may look undamaged. 2.4.4 Clean the springs support and the and the internal part of the piston from any excess of grease. 2.4.5 Before mounting the flat springs, grease them and the internal part of the piston with Molycote D321R spray (or similar). 2.4.6 Insert in the piston (D71231) the flat springs (C62223) and the springs support (C62220). For the brake ID900N-15 insert also the spacer (C62226). NOTE : Put the new springs in the right position to ensure the best performance of the brake (see picture 5). 2.4.7 Reassemble the cover (D71230) complete with the regulator (C62221) on the brake body using the screws (C61450) and the washers (C61321). Clamping torque of M8 screws - 10.9 class (C61450) : 34 Nm. 2.4.8 Reassemble the brake onto the machine as described from point 2.3.16 up to point 2.3.20. ID 900N-30 ID 900N-15 Picture 5: FLAT SPRINGS POSITION.
Maintenance & Care 2.5 FRICTION SURFACE CLEANING 2.5.1 Supply oil to the brake and replace the red compensation indicator (C62222) with the M16 safety screw. Once the safety screw is inserted, it s possible to switch off the oil pressure. NOTE : Disassemble the brake from the machine only if necessary; in this case proceed as described from point 2.3.1 up to point 2.3.3. 2.5.2 Loosen the screws (C61378) which fix the stop plates (C62174) to the brake and take out the lining pivots (C62173) completed with the other screws (C61378) and the stop plates (C62174). 2.5.3 Remove the screws C62175, the springs C60625-F and the lining pads. 2.5.4 Remove oil and grease traces from the disc surface with a not-polluting cleaning product. 2.5.5 If the linings are contaminated only on the surface, clean them with a fine-grained emery cloth. In case of deep contamination replace the lining pads with new ones. 2.5.6 Reassemble the lining pads following backward the points 2.5.3 and 2.5.2. 2.5.7 Supply oil to the brake and replace the M16 safety screw with the red compensation indicator (C62222). If the brake has been removed from the machine proceed as described from point 2.3.18 up to point 2.3.20.
3.0 Periodic Inspections THE BRAKE IS EMPLOYED AS FAILSAFE DEVICE. WE SUGGEST TO PERFORM THE FOLLOWING CHECKS ON THE BRAKE; THE FREQUENCY OF THESE CHECKS DEPENDS ON THE FREQUENCY OF BRAKE USE. ANYWAY WE SUGGEST TO PERFORM THESE CHECKS AT LEAST EVERY 3 MONTHS. 3.1 Check that the gap between the disc and each lining pad is 2 mm. If the gap is higher, restore the original gap as described at point 2.1. 3.2 The wear indicator is included in the brake basic configuration. Anyway we suggest to check the wear of the linings periodically. THE MAXIMUM WEAR LIMIT IS 8 mm FOR EACH LINING; GOING OVER THIS MAXIMUM WEAR LIMIT CAN CAUSE SERIOUS DAMAGES TO THE BRAKE. When the maximum wear limit has been reached, replace the linings as explained at point 2.2. 3.3 Check that no lubricant traces are found on the disc or pad surfaces. 3.4 Check that the flat springs are properly lubricated. 3.5 Check that all the fixing screws are tightened properly. 3.6 Check out the integrity of flexible hoses. 3.7 Switch on and off the oil supply several times, to check the seals integrity and the springs functionality. 4.0 Spare Parts 4.1 To avoid unnecessary stops we suggest to keep in stock a suitable quantity of the following spare parts according to the number of brakes in use: Lining pads : N 2 [Brake ID 900N STD] code Z50266 N 2 [Brake ID 900N ON/OFF] code Z50342 Flat springs : N 20 [Brake ID 900N-30] code C62223 N 16 [Brake ID 900N-15] code C62223 Seals kit : N 2 lip seals code C62224 N 2 lip seals code C62227 N 2 o-rings code C62225 N 2 o-rings code C62228 4.2 Those spare parts should be stored in a cool and dark place, and kept away from any substances that could damage their life and functionality.