Electric Control Hydraulic Disc and

Caliper Installation

SERVICE MANUAL

Beijing PSK New Technology of Petroleum

Machinery Co.,Ltd.
Service manual Electric Control Hydraulic Disc and Caliper Installation Preface

Preface
This manual describes principle, structure, operation and maintenance of PSK series
electric control hydraulic disc brake. Please read this manual carefully before operating
or repairing PSK series electric control hydraulic disc brake and perform installation,
operation and maintenance in accordance with this manual.
Using efficiency and service life of this product closely relates to rational using by users
as well as design and manufacturing of product. We will provide users high-quality
products according to quality assurance system, meanwhile we hope operators can read
carefully this manual before operating and make performance and advantage of product
be played fully and complete expected operation successfully.
For product is in improving continuously, some contents in this manual may not be
consistent with the actual product, but it will not affect understanding on product
structure and performance by users, also not affect operation. If you have any
questions，contact the manufacturer.
With the continuous advancement of drilling technology, users will have new
requirements continuously. We are willing to, together with you, improve our products
constantly and meet your special requirements. You are welcome to contact us.
Service manual Electric Control Hydraulic Disc and Caliper Installation Contents

Contents
I. Description ........................................................................................................................................1
II. Main Technology Parameter.............................................................................................................2
III. Operating Principle and Features ....................................................................................................3
IV. Installation .....................................................................................................................................10
V. Adjustment......................................................................................................................................13
VI. Rules of Operation ........................................................................................................................15
VII. Maintenance ................................................................................................................................17
VIII. Failure Examine and Repair .......................................................................................................21
IX. Dismantle and Replace of Key Parts ............................................................................................22
X. Consumable Parts...........................................................................................................................26
Appendix.............................................................................................................................................27
Service manual Electric Control Hydraulic Disc and Caliper Installation Description

I. Description
PSK series electrical hydraulic disc brake is composed of three sections: brake execute
unit, hydraulic power source and control unit.
Brake execute unit is connected with hydraulic power source by hydraulic lines, and
control unit is connected with hydraulic power source by control cable.
Hydraulic power source provides necessary power for brake execute unit; brake execute
unit is the executor of braking and consists of brake calipers, caliper support arms and
brake discs, where brake calipers is combined by main service calipers and emergency
calipers as required; control unit is the control link of the installation and it controls the
operating valves in hydraulic power source through electric signals and realizes the
action control of the brake execute unit.
PSK series electric control hydraulic disc brake has the following five functions:
1. Service brake: adjust the positive pressure of the main service caliper on brake
disc by operating the control handle of the service brake, as a consequence provide
adjustable braking torque for drawworks and meet different operating condition
requirements such as normal drilling, trip, etc.
2. Parking brake: when drilling rigs don’t work or drilling worker leaves control
desk temporarily, turn on the parking brake to braking position, so emergency
calipers brake the drawworks to prevent rotary hook from slipping down.
3. Emergency brake: in case of emergency, press down red emergency brake button,
then both main service calipers and emergency calipers brake the drawworks.
4. Over winding/crown-block protecting: when the rotary hook raises to a position
with heavy goods, the service brake fails to brake the drawworks due to operational
error or other reasons, the crown-block protecting system gives signal, then both
main service calipers and emergency calipers brake the drawworks.
5. Electricity failure automatic brake: under the condition of electricity failure of
the brake system, the emergency brake brakes automatically to prevent any
accidents from occurrence.

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 Service manual Electric Control Hydraulic Disc and Caliper Installation
Main Technology Parameter

II. Main Technology Parameter

PS440/ PS295/ PS240/ PS165/ PS140/ PS90/ PS60/ PS40 PS35/

Product model
9000 6750 4500 3150 2250 1700 1350 /900 600
Drilling rigs ZJ120 ZJ90 ZJ70 ZJ50 ZJ40 ZJ30 ZJ20 ZJ15 ZJ10
Retarding torque of
working brake 440 295 240 165 140 90 60 40 35
（kN· m）
Retarding torque of
parking brake 245 160 120 85 60 40 40 25 20
（kN· m）
Retarding torque of
emergency brake 685 455 360 250 200 130 100 65 55
（kN· m）
Brake disc diameter
2100 1900 1600 1500 1500 1500 1400 1200 1200
（mm）
Number of main
7 5 4 4 4 3 3 2 2
caliper assembly
Number of
emergency caliper 3 3 2 2 2 1 1 1 1
assembly
Caliper model A B
System pressure
8 7 8 7
（MPa）
Capacity of main
15L/min
pump
Summer：HM46# anti-wear hydraulic oil
Working medium
Winter： anti-wear hydraulic oil
Capacity of oil box 100L
Installed total
3kW×2
electric power

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

III. Operating Principle and Features

Electric control hydraulic disc brake consists of brake execute unit, hydraulic power
source and control unit.
3.1 Brake execute unit
Brake execute unit mainly consists of brake calipers, brake discs and caliper support
arms, where brake calipers includes main service caliper and emergency caliper. The
structure and layout of brake execute unit shall be as Figure 1.
Caliper frame

Main Caliper
Assembly

Emergency
Caliper Assembly

Disc Adapter Brake Disc

Figure 1 Brake Execute Unit

3.1.1 Operating principle of brake caliper
All braking functions of Model PSK disc brake are implemented by the main
components——brake calipers. The brake calipers of Model PSK disc brake consist of
main service and emergency calipers with floating lever each. Fig.2 is a sketch of both
calipers with floating lever.

(A)Main service caliper (B)Emergency caliper

Figure 2 Exterior view of caliper with floating lever

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

The operating principle of the main service caliper with floating lever (Fig 2 (A)) is that
the hydraulic force pushes the piston rightward when the hydraulic oil is supplied to the
caliper cylinder. The piston and the cylinder push upper ends of right and left levers to
move outward through upper pins，and driving the brake pad inward, thus pressing the
brake pad on the rotating brake disc. With certain amounts of normal load, the friction
force between the brake disc and the brake pad then affects the stop of the brake disc. In
this way, it can be seen that the braking force of main service caliper results from the
hydraulic force, and the higher the hydraulic oil pressure is, the greater the braking force
is.
If the pressure of the hydraulic oil entering the caliper cylinder reduces to zero, the
piston and the cylinder move inward by means of the return spring mounted on ends of
right and left upper pins, while the brake pad moves in the opposite direction and then
disengages the brake disc, which enables the brake calipers to release braking. The main
service calipers brake the drawworks with the oil pressure but release braking at the
absence of hydraulic force. Therefore, it is called the main service caliper.
The operating principle of the emergency caliper with floating lever (Fig.2 (B)) is that
when the hydraulic oil is supplied to the caliper cylinder, the hydraulic force pushes the
piston to move rightward so as to compress the disc spring and simultaneously pulls
upper ends of right and left levers to move inward (levers rotate around mid pins),
enlarging the distance between the right and left lower pins and moving the brake pad
outward. At this very moment, the brake pads disengage the brake disc, and brake
calipers release braking. When the caliper cylinder drains oil, the disc spring bounces
back and pushes the piston leftward, and upper ends of right and left caliper arms move
outward to shorten the distance between the right and left lower pins, thus making the
brake pad and the brake disc keep the contact. The brake pad force exerting on the brake
disc is called the disc spring force which generates the friction force to effect braking. It
can be seen that the braking force of the emergency caliper results from the spring force
of the disc spring.
3.1.2 Brake disc
Brake disc in one of core components of a brake system and forms brake assistant with
brake pad. Each product is equipped with two discs, which will be installed on both
ends of the drum of drawworks, in general. Each drawwork of some new type drilling
rigs is equipped with one disc which will be installed on the end of drum of drawworks.
Brake disc is divided into water cooled disc, wind cooled disc and solid disc according
to structural from.
 Water cooled disc is equipped with water cooling passage inside it, inlet, outlet at
the inside diameter of disc; discharge port at outside diameter for discharging water
inside the passage to prevent frost crack of disc due to cold climate; close the
discharge port by screw plug during normal working. Fill cooling circulating water
for brake disc when the brake system is working to balance heat quantity caused by
friction of brake assistant.
 Wind cooled disc has natural air duct inside it, heat dissipation shall be done by
natural air duct and its surface.
 Heat dissipation of the solid disc shall be done by its surface and it is used mainly
for work over rigs and small drilling rigs.

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

3.1.3 Caliper support arm

Caliper support arm is the base of brake execute unit, both main service caliper and
emergency caliper are installed on the base. Two-disc structure shall be equipped with
two caliper support arms which will be installed on the base of the draw works and on
one side of the drum.
3.2 Hydraulic power source
Hydraulic power source includes: oil tank components, pump unit, control block
assembly, oil filling components, electric control box and operating valves, etc. Its
hydraulic control principle refers to Figure 3.
3.2.1 Oil tank components
Oil tank components include: oil tank, oil absorbing valve, oil discharging valve, level
thermometer, cooler and other elements, where, the action of oil absorbing valve is to
close the valve and make oil tank disconnect with oil absorbing port of oil pump and
prevent any leakage of hydraulic oil during repairing oil pump. Oil absorbing valve is in
open state during normal working. Oil discharging valve is equipped for replacing
hydraulic oil and it is in close state during normal working. Level thermometer is used
for observing level in oil tank and temperature of oil tank. Cooler is pipe row type water
cooled cooler and used to balance heat generation of the whole system.
3.2.2 Pump unit
Pump unit is the heart of the hydraulic system. The system is equipped with two same
plunger pumps which is driven by explosion proof motor separately, one for operating,
and another for standby.
3.2.3 Control block assembly
Control block assembly consists of mainly: oil pipeline block, accumulator, cut-off
valve, one-way valve, safety valve and high pressure oil filter, etc.
The accumulator may reduce pressure fluctuation of the hydraulic loop, supply certain
energy storage when pump can not work normally and ensure main service caliper to
brake normally the drawworks 4~6 times.
Cut-off valve is used for releasing oil pressure of the accumulator; it must be closed
during normal working. Otherwise, the system pressure can not be reached.
One-way valve is used to separate oil ports of two pumps, make oil of accumulator not
flow back, and meanwhile form three oil pipelines which are independent and correlated
each other.
Safety valve is an overflow valve and used for safety protection.
High-pressure oil filter filters high pressure oil of system and keep hydraulic system
clean.
3.2.4 Oil filling components
Oil filling components is composed of a hand pump and a filter. Oil filling of oil tank
must be finished by oil filling pump unit to keep cleanness of oil.
3.2.5 Electric control cabinet
Electric control cabinet of hydraulic power source is used mainly for controlling starting
and stop of motor and heater; electric control cabinet shall be subject to explosion

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

suppression treatment.
3.2.6 Operating valves
Operating valves include service brake valve components, parking brake valve
components, emergency brake valve components and pressure gauges, etc.
Service brake valve components include two electromagnetic proportional reducing
valves which are used for adjusting the two-way oil pressure independently.
Parking brake valve component include one electromagnetic shuttle valve which is used
for controlling the pressure supply and pressure relief of emergency calipers assembly.
Emergency brake valve components include one electromagnetic air reversing valve,
one pneumatic control reversing valve and two hydraulic control reversing valves. Emergency
brake is realized by controlling the electromagnetic air reversing valve.
There are seven pressure gauge joints on hydraulic power source which used to display
system pressure, emergency calipers’ pressure, left-side service calipers’ pressure and
right-side service calipers’ pressure. Three of these are installed inside the driller house
used to display emergency calipers’ pressure and the both sides service calipers’
pressure.

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

1. oil tank 2. motor 3. oil pump

4. return oil filter
7. high pressure oil filter
10. accumulator
13.pneumatic control reversing
valve
16.amplifier
19.parking brake button
5. one-way valve
8. safety valve
11.proportional reducing valve
14. Hydraulic control reversing
valve
17.electronic brake crank
6. cooler
9. pressure gauge
12.electromagnetic reversing
air valve
15.electromagnetic reversing
valve
18.emergency brake button

Figure 3 Schematic diagram of hydraulic system

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

3.3 Control unit

Control unit includes electronic brake crank, parking brake switch, emergency brake
button and electric control box. Electric control box includes air switch, power supply,
amplifier and other electrical elements. For layout of the base plate and field wiring of
the electric control box of the control desk, please see Figure 4 and 5.
3.4 Operating principle
3.4.1 Service brake
Push electronic brake crank, output two electronic signals, magnify via electric control
box and control two proportional reducing valves (11), hydraulic oil, which output by
proportional reducing valve (11), with corresponding pressure value enters into main
service calipers to realize service braking. With the angle change of electronic brake
crank, the braking force will be changed accordingly, when the angle of electronic brake
crank is the maximum, the main service calipers reaches maximum braking force. When
the electronic brake crank is pushed back to its original position, the oil cylinder
pressure of main service calipers is 0 and main service calipers release braking.
3.4.2 Parking brake
Parking brake is used as a change-over switch to control electromagnetic reversing
valve (15) of parking brake to obtain electricity or electricity failure. It is electricity
failure when the change-over switch is on “brake” position, and emergency calipers
brake; it obtains electricity when the change-over switch is on “loose” position, and
emergency calipers release braking. The basic principle of control is electricity failure
braking. When release parking braking, first must push “electronic brake crank” to
brake load, then turn on the change-over switch to “loose” position, and release
emergency calipers.
3.4.3 Emergency brake
Emergency brake is used as an emergency button to control electromagnetic reversing
air valve (12) for obtaining electricity or electricity failure. Press button down,
electromagnetic reversing air valve will be under electricity failure and the system shall
be in emergency braking state; turn and raise up the button, then electromagnetic
reversing air valve obtains electricity, and release emergency braking state. The basic
principle of control is electricity failure braking. When release emergency brake,
first must move “electronic brake crank” to brake load, then turn and raise up the button
to release emergency braking.
3.4.4 Over winding/crown-block protecting
When the rotary hook rises to a position with heavy goods, the working brake fails to
brake the drawworks due to operational error or other reasons, the pneumatic limit valve
installed near the crown block (or over winding valve installed on the drawworks) will
act due to collision by outside force and make air pipeline be connected, air signal
output by over winding/crown-block protecting vale controls pneumatic control
reversing air valve to change direction, cut off air source and realize emergency
braking.

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

Figure 4 Field wiring diagram of electric control box of control unit

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Service manual Electric Control Hydraulic Disc and Caliper Installation Installation

IV. Installation
4.1 Installation of brake disc
4.1.1 Pulsation of the work surface of the brake disc to the drum shaft shall not be more
than 0.3mm.
4.1.2 Clean brake disc, any oil stains shall not be permitted on the friction surface.
4.1.3 Water cooled brake disc also needs to connect with water inlet pipe, outlet pipe.
4.2 Installation of brake caliper, caliper support arm
4.2.1 Fix upper, lower transitional board on the caliper support arm.
4.2.2 Install brake caliper on the caliper support arm. It should rotate flexibly without
any block and conflict phenomenon. During installing brake caliper, let out oil to
adjusting oil cylinder by oil discharging valve and make the distance between two brake
pads reach maximum for caliper installation.
4.2.3 Install integrally to the drawworks
Installation alignment requirements:
(1) Space between outer circle of brake disc and inner circle of caliper support armyh
shall be uniform (3-5mm), any interface with caliper support arm shall not be
permitted.
(2) Caliper support arm shall be in parallel with and aligned with the brake disc, the
deviation shall be ±1mm.
(3) Brake pad shall be covered within the brake disc.
(4) All brake pads shall be parallel and fully contacted to the brake disc, contact face
shall not be less than 75%.
(5) Weld upper, lower transitional boards on the design position on the base and the
transverse beam of the draw works after adjusting and alignment.
4.3 Installation of hydraulic power source
Install hydraulic power source on the design position.
4.4 Installation of control unit
Install control unit on the design position.
4.5 Connection of hydraulic pipeline
Hydraulic pipeline consists of high pressure tube, quick coupling and pipe clamp.
Connection of hydraulic pipeline is to connect hydraulic power source and brake
execute unit to a complete hydraulic system by high pressure hose. Set up quick
coupling on the position needs to be disconnected and moved for dismantling easily.
For connection of them, please see sketch 5.

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Service manual Electric Control Hydraulic Disc and Caliper Installation Installation

Figure 5 Sketch map of hydraulic pipeline connection

(1) Keep inside of pipeline to be used clean before installation. There must be no rust
inside metal pipe and pipe joint shall be installed with sealing elements. Connect
hydraulic pipeline strictly in accordance with the mark of oil opening.
WARNING!
Please connect the pipeline between brake execute unit and the hydraulic power
unit strictly in accordance with the mark of oil opening. If there is some error, the
disc brake would not work naturally so as to result in grave safety accident!
(2) Ensure quick coupling not to be affected by outer force and weight under working
condition. Do not insert and pull the quick coupling with pressure. Must plug with
cap after pulling out; keep quick coupling clean during inserting for connection.
Connection must be solid.
(3) Hydraulic pipe line shall be provided with pipe clamp every 1.5～2m for fixing.
(4) Pipeline shall be arranged in safety zone to prevent any damage.
4.6 Connection of air pipeline
Connection of air pipeline is to connect air signal of over winding valve with pneumatic
interface of hydraulic power source unit.
4.7 Connection of circuit
For wiring of electric control cabinet of hydraulic power source, please refer to Figure 6,
7 electric control schematic diagram of hydraulic power source. Carry out wiring of
electric control box of control unit as per Figure 4. Wiring between control unit and
hydraulic power source, please also see sketch map 4, it can be done by multi-core
shielded wire. Plug or socket for wiring shall meet relevant technical standard and
explosion protection specification.

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Service manual Electric Control Hydraulic Disc and Caliper Installation Installation

Figure 6 Electric control schematic diagram 1 of hydraulic power source

Figure 7 Electric control schematic diagram 2 of hydraulic power source

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Service manual Electric Control Hydraulic Disc and Caliper Installation Adjustment

V. Adjustment

5.1. Preparation before adjustment:

(1) Check connection of manifold for errors.
(2) Check level of oil tank.
(3) Check accumulator for nitrogen filling pressure, maintain the nitrogen filling
pressure for 4MPa.
(4) Turn on the stop valve at the oil absorbing port and oil discharging port of plunger
pump; turn off the stop valve for accumulator group. When cooler not required to
work, then turn on bypass stop valve of cooler; if cooler required to work, and then
turn off the bypass stop valve of cooler.
(5) Knock the motor, check its rotation direction for correctness (the rotation direction
of plunger pump is clockwise, i.e. the direction of red arrow on the pump).
5.2 Adjustment:
(1) Start up motor
(2) Adjust rated pressure, maximum pressure of the system.
Adjusting steps shall be as follows:
A. Start up motor group for one pump.
B. Loosen nut of safety valve and turn it clockwise to 3/4 position.
C. Remove pressure relief valve protective cap of the pump and loosen the nut of
pressure relief valve of the pump. Turn screw clockwise by inner hexagonal
wrench to increase pressure. Observe readings in pressure gauge of the system,
stop when it is up to 10MPa. If pressure stops to increase during adjusting, turn
the safety valve little. Adjust the safety valve and the pressure relief valve of
plunger pump alternately until readings of pressure gauge is up to 10MPa.
D. Adjust safety valve downward until the readings of pressure gauge is up to
9.5MPa, then tighten the nut of the safety valve.
E. Readjust the pressure adjusting screw downward until the reading of MA is up
to the rated pressure and maintain. Tighten nut, install protective cap and
tighten it.
Notice: maximum pressure of hydraulic power source has been adjusted before
ex-factory. Adjustment must be forbidden unless required by special conditions.
(3) Observe the pressure gauge on hydraulic power source and confirm whether it is on
the rated value.
(4) Discharge air: connect air discharging pipe to the air discharging connector on oil
cylinder, then pull slightly the electronic brake handle, and make the pressure of
main service caliper is in about 1MPa until discharged oil not contains air foam.
Discharge air for main service calipers one by one. Discharge air for the emergency
calipers by the same way when the oil cylinder has pressure.
(5) Pull the electronic brake handle, when the pressure of left and right calipers are up
to maximum value, pull out the emergency button, turn the parking switch to

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Service manual Electric Control Hydraulic Disc and Caliper Installation Adjustment

“loose” position, three pressure gauges are up to the system pressure value, then
stop, hold the pressure for 10 minutes; observe MA pressure gauge of hydraulic
power source, if the pressure value is unchanged, then the system is normal; if
pressure value reduces, it indicates leakage, solve it in time.
(6) Adjustment of brake clearance of brake caliper：
The distance between brake pad and brake disc is called brake clearance when oil
pressure of the main service caliper cylinder is zero and oil pressure of emergency
caliper oil cylinder is maximum.
The normal brake clearance of the main service caliper (unilateral) shall be 1～2mm;
the normal brake clearance of emergency caliper shall be (unilateral)0.5～1mm. It shall
be adjusted when the brake clearance exceeds normal value.
The adjustment procedures for the brake clearance are as follows:
A. Unscrew the screw plug, and connect a special oil gun filled with the clean
hydraulic oil. Seal washer in it must be ringed.
B. Rotate the oil gun handle and inject the oil to move the adjusting plunger
outward. Observe the change of the brake clearance until the normal clearance
occurs. Under normal circumstance, the brake clearance of the main service
caliper shall be adjusted to 1mm and 0.5mm for emergency caliper).
C. Remove the oil gun, and cover and tighten the screw plug. Note that combined
washers are added.
Note: Make sure the oil pressure of main caliper assembly oil tank is zero, and
that of emergency caliper assembly oil tank is the maximal.
(7) Pull slowly “electronic brake handle”, check pressure of left and right pipeline for
increasing steadily, check actuation of main service calipers for sensitivity and
response. Operate repeatedly for several times to ensure reliable performance.
(8) Backfit brake pads. Rotate brake disc, pull slowly “electronic brake handle”, make
brake pads contact with brake disc, repeat for several times.
(9) New brake pad must be contacted to 75% and above interface area before using.
Notice to control oil pressure of brake during contacting, it will be running-in under
3MPa in general.
(10) Check crown-block protecting device；
(11) Must make oil pump run for 10～30 minutes before normal using after installation
and adjustment, and operate “brake handle” repeatedly for several times. At the
same time, check level, oil pipeline system for good conditions, especially, the level
of oil tank shall be maintained between the highest and lowest level surfaces.
(12) The system can be used only after all are normal.

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Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

VI. Rules of Operation

6.1 Preparation works before start the machine.
(1) Check all the peripheral wiring (electricity supply, electronic brake handle,
proportional reducing valve (11), electromagnetic reversing air valve (12),
electromagnetic reversing valve (15), emergency brake button, parking brake
changeover switch and emergency brake remote control signal)
(2) Check all pipeline junctions.
(3) Open the oil suction valve and plunger pump oil release valve.
(4) Close the accumulator group return oil valve.
(5) Turn on the air switch of the electric control box QM1.
(6) Connect the external power source.
(7) Turn on the power.
WARNING!
Before start the machine, make sure the opening of the valve of oil suction and oil
release of the plunger pump, or it will lead to the serious damage of the plunger
pump.
6.2 Rules of Operation
(1) Recall the electronic brake handle, emergency brake button and parking brake
button, i.e. the electronic brake handle is in the position of ‘loose’, emergency brake
button is in the position of ‘brake’, and the parking brake button is in the position of
‘brake’.
(2) Turn on the electric machinery, and then the system is in an emergency brake
condition.
(3) Unlock. First pull the electric brake handle to the position of ‘brake’ to stop the load,
then move the parking brake switch, unplug the emergency brake button to the
position of ‘loose’.
(4) Working brake. Pull the electric brake handle to perform the working brake. When
do the drilling, lightly pull the brake handle to let the brake block lightly touch the
brake disc, so as to reduce the brake respond time, avoiding slip drill.
WARNING!
When lowering the drill, especially lowering the heavy drill, it’s necessary to apply
with the assistant brake. That is lowering the drill and casing by the use of disc
brake and assistant brake. It’s not allowed to lowering the drill automatically at
any time, and it is a must to decelerate continuously, to assure the safety of process,
reduce the brake load, and improve the liability and durability of the braking
system and whole drill equipment.
WARNING!
When lowering the drill, keep the connection between the assistant brake and
drawworks, or it will reduce the durability of the disc brake, or lead to the damage
of property and hurt or death of worker due to the high speed and heavy motion.

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Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

(5) Parking brake. Pull the parking brake button to the position of ‘brake’ to break the
machine. When transit to the condition of working brake, first pull the electric
brake handle to the position of ‘brake’ to stop the load, then move the parking brake
button to the position of ‘loose’ to relieve the parking brake, finally implement the
process of working brake.
NOTICE!
There are only emergency calipers for brake when it is parking brake. Therefore,
for insure the enough elasticity of the heavy stiffness plate spring inside the
emergency cylinder, please change the plate spring group at least one time every 12
months.
WARNING!
When the driller leaves the position, the parking brake should be implemented,
and slips should be applied to suspend the heavy load. It’s prohibited to suspend
heavy load long time use the disc brake.
(6) Emergency brake. Press the emergency brake button to perform the emergency
brake. When transit to the working brake condition, first pull the electric handle to
the position of ‘brake’ to stop the load, then unplug the emergency brake button to
release the emergency brake, finally implement the process of working brake.
WARNING!
When lowering the drill, especially when fast lowering the drill, it’s prohibited to
implement the parking brake button and emergency brake button, or it will lead to
serious damage of the drilling equipment.
(7) The function of restart after the electricity failure. When electricity failure occurred,
emergency brake and parking brake function in the same time, after the system get
the power again, the emergency brake will keep the brake condition, it is a must to
press the restart button to release the emergency condition.
WARNING!
Before pressing the restart button to release the emergency condition, you must
haul the electric handle to the most “brake” location.

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Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

VII. Maintenance
Because the disc brake adopted hydraulic pressure system, this enabled it is more
complicate than traditional band brake. Especially the hydraulic pump, hydraulic valve
and hydraulic oil cylinder, they are sensitive to pollutants, and need better maintenance
than the band brake. The key point of disc brake equipment maintenance is on the
hydraulic loop and brake caliper oil cylinder. Below mentioned item and maintenance
scheme should be implemented in usage.
7.1 Liquid surface
It is a must to check the liquid surface frequently and add oil timely. When the liquid
surface decreased below the warning line, it maybe lead to the temperature raise,
undissolvable air gathering, pump malfunction due to the air pocket, electric heater
exposure, and these will cause the local high temperature, oil resolve and deteriorate,
and bring to the system accident. Surface decrease shows there are some places leak oil,
check and maintenance should be performed timely.
7.2 Oil Temperature
The highest working temperature of hydraulic oil is 70°C, because higher temperature
will ageing the liquid, shorten the service life of sealed parts and pipeline. So frequently
supervise the oil temperature of the tank is a must. If the temperature rises, it shows the
hydraulic oil may be polluted or formed to gel, or plunger pump weared. Temperature
raise is a warning sign, should stop the machine immediately and check.
7.3 Pressure gauge
Frequently check the pressure gauge on the hydraulic resources, especially the
systematic pressure gauge. The pressure should be stable at the designed value.
7.4 Oil filter
Loop oil filter attached a block indicator estimate with eyes. When the pointer is in the
green area, the filter is in right condition. When the pointer is in the yellow area, it
indicates the filter is a little blocked. When it’s in the red area, the filter is blocked
seriously, and the shell should be cleaned and the filter should be changed. Everyday,
when the working temperature reaches the normal value, at least one check should be
performed. Or when working shift, the next driller should check. High pressure filter
attached a block indicator estimated with eyes. When the red pillar prop up, clean the
filter shell and change the filter. Everyday, when the working temperature reaches the
normal value, at least one check should be performed. Or when working shift, the next
driller should check. However, during the temperature raising period, the red pillar may
be propped up due to the heavy flow resistance, please distinguish.
The air filter is only adopted when liquid surface in the tank is up and down filtering the
air inlet and outlet the tank. Every one to three months check and clean or change the
filter.
7.5 Accumulator
Frequently check the inflated pressure of the accumulator. When perform the exam and
assessment, stop the machine, lose the oil pressure inside the accumulator, disassemble
the inner and outer protecting cap, connect the Nitrogen equipment, slightly screw the
knob, and measure the pressure. If the pressure is<4Mpa, connect the Nitrogen cylinder,
screw the knob and inflate. If losing pressure is needed, open all the valves to release

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Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

the oil pressure of the accumulator.

Protecting cap of Accumulator

Refined oil Cut-off Accumulator Safety valve

filter valve

Figure 8 Accumulator group

7.6 Pump group
Check the two group of pump to insure that they are in good working condition.
7.7 Crown block overhead traveling crane system
Over winding or Crown block valve should be checked frequently to assure it’s liability.
Especially in winter, the compressed air may contain vapor, the air inlet and outlet may
be freezing to block due to the low temperature, and this will lead to the malfunction of
the crown block. The crown block system should be tested once everyday to assure it’s
right condition.
7.8 Main Service Caliper Assembly
The check of the thick of brake pad and the seal of the cylinder should be performing
during the work shift. As the wear of the brake pad, brake clearance should be adjusted
in time. When the thick of brake pad is only 18mm, a new one should be replaced.
7.9 Emergency Caliper Assembly
The thick of the brake pad of the loose brake clearance ( once in every week), and the
seal of the cylinder should be checked frequently. If the clearance between brake disc
and brake pad is larger than 1mm, it should be adjusted to 0.5mm. When the emergency
brake process is performed, it’s also needed to check and adjust the loose brake
clearance. When the thick of the brake pad is wore to 18mm, it is a must to change a
new one.
WARNING!
Please adjust the loose brake clearance of Emergency Caliper Assembly timely, or
it may lead to the malfunction of emergency brake or parking brake.
WARNING!
At least change the plate spring in the oil tank once in every twelve months to
assure the liability of the Emergency Caliper Assembly.

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Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

7.10 Quick joint and hydraulic pipeline

Check the quick joint twice everyday to assure it’s right connection. Especially after
move or accidentally touch the pipeline, it is a must to check the hydraulic pipeline,
whether the pipeline is damaged, whether the joint is false connected, and to insure the
right condition of the hydraulic pump and quick joint.
7.11 Cable plug and control cable
Check the entire cable plug twice everyday to assure the right condition. Especially after
move or accidentally touch the cable, a serious check should be performed, to insure the
control cable and plug joint are in right condition.
7.12 Structure piece
The check and maintenance of the structure piece is mainly the lever caliper arm, bolt
axis, oil cylinder, caliper support arm, brake disc, joint and all the fasten pieces. Check
whether these pieces are damaged, deformed, cracked or meets other problems.
 Check all the fasten pieces to insure it’s tight.
 The key point of the maintenance of brake disc.
(8) Wear. The largest permittable wear of the brake disc is 10mm(5mm single side).
Check the thick of the working surface of every brake disc periodically.
(9) Heat fatigue crack. The brake disc heated to expand due to the slide friction in the
brake process, while cool down to contract. This alternate will lead to the heat
fatigue crack, which is a normal phenomenon. As the time goes, the initial small
crack will expand, and this must arouse high attention and perform the
maintenance. For example, grind the crack area to check the crack deep, so as to
perform the weld amendment, and polish by abrasive wheel at last.
(10) Greasy dirt. It’s prohibited to infect the working gauge with any greasy dirt, so as
to prevent the lowering of the friction coefficient, the reduction of brake ability
and drill slip accident. However, during the motion process of the cylinder, the oil
on the steel cable may spatter on the brake gauge, so check and clean it regularly.
(11) Circulatory water. For water-cool brake gauge, during the usage, frequently check
to insure the existence of the circulatory water and the unblocked pipeline.
WARNING!
If the water-cool brake gauge is not connected with the circulatory water during
working process, it’s usage life will be reduced, and crack is easy occur.
Winter time, in extremely cold region, when the drill machine is not in use, for
prevention the freezing and crack of the disc, it’s a must to discharge completely the
cooling water in the brake disc.
 Check the welding pieces, especially to check whether there is crack or rust on the
caliper support arm and brake pad plate, repair and replace when necessary. At least
check one time half a year.
 Check whether there is adhesion phenomenon on the active part, especially on the
lever and pins.

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Maintenance Table
No. Check Content
1 Tank Oil Level L-HM46 friction-guard oil or L-HV32 low
2 Oil Temperature
3 System Pressure
4 Oil Filter
Sound and Temperature
5 No abnormal noise and high temperature
of Working Pump Group
Crown block Overhead
6
traveling crane system
7 Seal of Oil Cylinder
8 Brake Clearance
9 Brake pad Thick
10 Pipeline and Joint
11 Quick Couple
The Adhesion
12
phenomenon of pins
Nitrogen pressure of
13
Accumulator
14 All Fixed Bolt
Dismantle and clean
15
the lever and pins
Allowable wear thick 10mm，Heat fatigue
Brake Disc Wear and
16
Crack
Caliper Support Arm
17
Welding Line
18 Structure Assessment
Emergency Cylinder Plate
19
Spring
Maintenance
Maintenance
Requirement
period
Below the highest surface and above the
lowest surface. When adding oil, add
temperature friction-guard hydraulic oil
through the hand pump.
Oil temperature not higher than 60℃
Every shift
Re. the parameter
Block indicator should in the green area
Touch crown block valve to insure the
right setting of the brake
No leakage
Service Brake Caliper: 1～2mm
Emergency Brake Caliper: 0.5～1mm
Everyday
Minimum thick 18mm
Good seal, no leakage, no attaint
No leakage, damage and false connection
Unload push, pull and turn the bolt axis to
insure it’s flexibility and no adhesion
Every Week
Pressure is 4MPa
Check and fasten all the fixed screw and
1months
bolt
Clean brake dust and replace damaged
parts
crack should not affect the intensity and
lose water, or it should be replaced 6months
Check if the welding line has cracks
and fasten screw
Check all the structure pieces of brake
system
Replace all the Plate Spring 12months
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Service manual Electric Control Hydraulic Disc and Caliper Installation
Failure Examine and Repair

VIII. Failure Examine and Repair

Below is some potential failure phenomenon and the reasons may cause the failure for
reader’s reference.

Phenomenon Reason Disposal Measure

Wrong intercalate of plunge pump and system safety
Reset
valve intercalate
Malfunction
of system Work failure of plunge pump and system safety valve Check, repair or replace
pressure or Low oil in tank Fill oil
working
pressure Air in the oil route Exhaust
Block in the oil filter Replace filter
Wrong indication of pressure gauge Check, readjust or replace
Leakage in the system safety valve Reset
System safety valve Check, repair or replace
Over high oil
Low oil level in tank Fill oil
temperature
Stop working or reduce
Over high temperature circumstance
temperature
Low oil level in tank or low oil temperature Fill oil or raise temperature
Air in the pump system due to the loose connection
Fasten joint and exhaust
of absorbing and oil loop tank
Big noise or Defective or loose joint of plunge pump and electric
Check and repair
vibration power

plunge pump and electric power axis not compatible Check and repair

plunge pump and electric power axis base loose fasten

Check plunge pump, system
Over low system pressure and working pressure safety valve and pressure
relieve
Filter blocked Clean and replace
Brake caliper Over low Nitrogen absorbing pressure or leakage of Maintenance, reabsorbing
lack brake the accumulator Nitrogen
power Service brake valve blocked or failure Clean, repair and replace
Air in the oiling system of the brake clearance
Exhaust, keep the seal
adjustment or loose seal
Hydraulic oil leakage Check, repair and add oil
pins mal-lubricate Clean, repair and replace
Brake caliper Brake dust accumulate in the pin and pin hole clean
arm
malfunction Over rust of pins replace
Damage of relevant parts replace
oil loop block Check and dredge oil loop
Open brake
return spring invalidation replace

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

IX. Dismantle and Replace of Key Parts

WARNING!
 MUST first stop the pump and release accumulator pressure before
maintaining hydraulic power or pipeline. Otherwise, it’s harmful.
 KEEP clean while maintaining hydraulic system. Contamination is major
reason of system’s failure. Clean the outside before loosen the whorl. Seal the
opening inside the system by clean protecting cap, to prevent contamination.
Pay full attention not to contaminate hydraulic system.
9.1 Filter core of oil loop filter
First loose the cap of oil loop filter counter-clockwise. Then dismantle the whole oil
loop filter and upper and lower cap, take out the old filter. Cleaning the inside by
kerosene, and dry it. Put the new filter core, screw the upper cap, and load the whole oil
loop filter.
9.2 Filter core of the pipeline filter
Dismantle the lower part of the pipeline filter counter-clockwise, change to the new filer
core.
9.3 High pressure filter
Dismantle the high pressure filter, open the upper cap by spanner, take out the old core,
clean the inside shell by kerosene, and dry it. Put the new core, cover the upper cap, and
stall the filter to the original.
WARNING!
When replace the old filter core, it’s prohibited cleaning an old one and reuse, but
only replaced by a new one.
9.4 Oil pump
When change a pump, the other pump can work normally, and the accumulator can be
not unload. Close the cut-off valve of oil absorbing and oil loop of the pump to prevent
the leakage of the oil tank. Dismantle the pipeline and joint of the oil outlet, oil
absorbing and oil loop. Dismantle the two bolts connect pump and electric machinery,
and then take out the pump.
Check whether the coupling is invalid. If it’s usable, dismantle the coupling and install
to the new pump. If it’s not usable, replace the whole set of coupling of the electric
machinery. Then install the new pump, connect the pipeline and joint of the oil
absorbing and oil outlet. Connect the inner leak oil pipe to the inner leak oil loop of the
pump, open the cut-off valve, full fill the shell of the pump with oil, and then connect
the pipeline. Open the cut-off valve of the oil absorbing pipeline. After checking,
perform the pump pressure adjustment.
WARNING!
 When connecting the pipeline and joint, install the O Seal Ring and Combined
Seal Washer according to the technical requirement, or it may arouse oil
leakage.
 When install the coupling of the pump, it’s prohibited to knock by the hammer.
Adjust the axis and hole, key and keyway, push in by little force, or it may lead
to the damage of the pump.

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

 Before start the pump, full fill the pump shell with oil, open the cut-off valve of
oil absorbing and oil loop, or it may lead to the damage of the pump.
9.5 The place spring and seal parts of Emergency Cylinder Assembly
The life span of the plate spring is one year. After one year, it must be replaced in group;
only change a few of the pieces is prohibited. Pay attention to the assemble order of
every plate spring during the examine and repair, it’s prohibited to mix up or exchange
it with other group. If oil cylinder leak oil, it shows the invalidation of seals and should
be replaced.
The replacing method and step of the plate spring and seal parts is as below:
(1) In the pressure condition, adjust the regulating plunger to open the brake caliper to
the largest clearance, then switchover to the no pressure condition, unplug the fast
joint, and dismantle pins on the two sides of oil cylinder. Take off the oil cylinder,
and clean the outside by kerosene.
(2) Dismantle all the parts of oil tank according to the step of Figure nine.

3.Combined Seal Washer 4.One-Way Oil Injecting

1. Bush 2. Screw Plug
14 Valve

5. Adapter of Injecting Valve 6. Exhaust Valve 7.O Ring 8. BA Seal Ring

9. Body, Cylinder 10. BA Seal Ring 11. F3 Wiper, Rod 12.Working Plunger

13. Spring 14. Ring, Guide 15. Cap 16. Washer 12

18.Bolt of
17. Screw Plug Emergency 19. C2 Seal Ring 20.A5 Dust-Proof Ring
Cylinder

21.Combined Seal Washer 18 22. Hollow Adapter 23.Articulated Body 24.Bolt of Articulated Body

25.Plunger Assembly,
Adjustable

Figure 9 Dismantle and install order of Emergency Cylinder Assembly

(3) Clean every piece of new plate spring with kerosene, then dry it, lay on every plate
spring with full lubricating grease. Begin the installation after cleaning and drying
the oil cylinder body, cap, piston and elastic guide cover.

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

(4) Install new dust-proof ring, seals and guide band inside the oil cylinder body.
(5) Install new guide band and seals on the piston.
(6) Assemble the new plate spring strictly according to the requirements. The first plate
is big opening face down, the second plate is face up, the third is face down, the
fourth up, the fifth down, the sixth up, the seventh down and the eighth up, then load
the cylinder cap.
(7) Pay attention to the guide band when assemble the piston. First add some hydraulic
oil, one person press on the piston, the other one knock the piston with a bronze
stick to fully positioning the piston.
(8) Assemble oil cylinder cap, screw tight the bolt evenly, fasten the bolt equally with a
spanner(110-120NM)
(9) Assembly the oil cylinder to the original position. Connecting the pipeline, then
adjust the brake clearance.
Pay attention to keep clean during the assembly procedure, prevent scratching and
bumping the seals.
9.6 The seal parts of Service Cylinder Assembly
1) Discharge the oil pressure inside the oil cylinder; adjust to the largest clearance.
After the piston return to the original position, take off the quick joint and return
spring, dismantle the circlips, remove the pins and take off the oil cylinder assembly.
2) Clean the oil cylinder assembly with kerosene.
3) Dismantle each part according to the step of Figure ten.

3.Combined Seal 4.One-Way Oil Injecting

1. Bush 2. Screw Plug
Washer 14 Valve
5.Adapter of Injecting 6.Plunger Assembly,
7. O Seal Ring 8. BA Seal Ring
Valve Adjustable

9. Piston 10. A5 Rod Wiper 11. F3 Wiper, Rod 12. BA Seal Ring

13.Bolt of Articulated 16.Combined Seal Washer

14. Articulated Body 15.Hollow Adapter
Body 18

17. Body, Cylinder 18. Exhaust Valve

Figure 10 The Dismantle and Installation Order of Main Cylinder Assembly

4) First dismantle the air relieve screw of the oil cylinder, pull out the piston and

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Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

adjusting plunger.
5) Take off the old guide band, seals and dust-proof ring inside the oil cylinder.
6) Clean and dry the piston and cylinder body with kerosene
7) Assemble the new seals, new guide bands and dust-proof rings into the cylinder.
8) Apply some hydraulic oil on the inner wall of oil cylinder, put in the adjusting
plunger and piston. (Prevent the guide band front dropping down).
9) Assemble the oil cylinder assembly to the original position. Connect the oil loop and
adjust the gap.
9.7 Pad Assembly
When the pad assembly is validated due to wear and other reason, replace a new one, or
slip drilling and pause drilling may occur.
Preparation work on replacing the pad assembly:
 Emergency Caliper Assembly. In the pressure condition, adjust the regulating
plunger to fully open the brake clearance, and then discharge the pressure inside the
oil cylinder.
 Main Caliper Assembly. In the no pressure condition, reset the piston; discharge the
oil in the adjusting plunger by the oil discharge valve to make the adjusting plunger
fully return the original position.

Screw loose the eight bolts connecting the pad assembly, and take off the old pad
assembly. Orderly dismantle all the pads assembly which needs to change, take off the
pads assembly. First take off the highest or lowest pad assembly of the brake caliper.
Then orderly take out the pads assembly in a round direction. At last, orderly assemble
and connect the pads assembly in an opposite direction.

Warning: Readjust the brake gap after the new pad assembly replaced.
The new pad assembly should be replaced in group.
Face grinding should be performed on the pad assembly after replace a
new one; the face grinding should be reach 75%.

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Service manual Electric Control Hydraulic Disc and Caliper Installation Consumable Parts

X. Consumable Parts

List of Consumable Parts:

No. Name Code/Model Remarks

1 Brake disc

2 Brake pad KQ-21/BQ-22

3 O-ring BG-81 Figure9-7

4 BA Sealing ring BG-82 Figure9-8

5 BA Sealing ring BG-89 Figure9-10

6 F3 Wiper, Rod BG-88 Figure9-11

7 Spring BG-47 Figure9-13

8 C2 Seal ring BG-86C Figure9-19

9 A5 Dust-proof ring BG-87 Figure9-20

10 O-ring KG-81 Figure10-7

11 BA Sealing ring KG-82 Figure10-8

12 A5 Dust-proof ring KG-83 Figure10-10

KG-84
13 F3 Wiper, Rod Figure10-11
KG-85
14 BA Sealing ring Figure10-12

15 Filer Core FAX－63×10

16 Filer Core HDX－40×20

17 Spring，Cliper Return KQ-48

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Service manual Electric Control Hydraulic Disc and Caliper Installation Consumable Parts

Appendix

Information of after-sales service

Name of Company: Beijing PSK New Technology of Petroleum Machinery Co., Ltd
Address: 12F1, Building of Jidian, No.18 Xueqing Road. Haidian Distract. Beijing
Post Code: 100083
Service Tel.: 010－82755979
Sale Tel.: 010－82310588
Fax No.: 010－82413899
Website：www.psk.com.cn
E-mail：bjpsk.support@psk.com.cn

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