200-345-65925 Wbhd-Dt-Xxx-All Installation Manual

Sheet Number:
WHEEL BRAKES
Hillmar
Hillmar Industries Ltd.
WBHD-DT-030-060-090-120-ALL
INSTALLATION MANUAL
Job Number:
275-213-01649
7371 Vantage W ay PARTS & SVC Form Number: Rev:
Delta, BC V4G 1C9 ENGLISH
P:604 946-7115 F:604 946-0329
info@hillmar.com www.hillmar.com Company / Project Reference: Date: Page: Document Package No.: Rev:
Konecranes / PacNat RMG 16JAN11 1 of 8 200-345-65925
INSTALLATION MANUAL
C:\Dokumente und Einstellungen\Harald Hof\Eigene Dateien\Aufträge Job\O&M\Montage+Bedienungsanleitung\WBHD\200-345-65925 WBHD-DT-XXX-ALL INSTALLATION MANUAL.doc
WHEEL BRAKES
WBHD-DT-060-ALL
THIS PRODUCT IS PROTECTED BY INTERNATIONAL PATENT.
HILLMAR WORKS HAVE A FULLY REGISTERED ISO 9001: 2008 QUALITY ASSURANCE PROGRAMME (QCB #01-1525)
Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date
Storm Brakes • Thruster Disc Brakes • Thrusters • Industrial Disc Brakes • Hydraulic Power Units • Cable Reels
Sheet Number:
WHEEL BRAKES
Hillmar
WBHD-DT-030-060-090-120-ALL
INSTALLATION MANUAL
Job Number:
275-213-01649
P:604 946-7115 F:604 946-0329
INDEX
1.0 MODELS COVERED BY THIS MANUAL ........................................................................................................ 2
2.0 REFERENCE MANUAL .................................................................................................................................... 3

2.1 TCD-CSM MANUAL ...................................................................................................................................... 3
2.2 O & M MANUAL ............................................................................................................................................. 3
2.3 SCHEDULED MAINTENANCE MANUAL ...................................................................................................... 3

3.0 BRAKE INSTALLATION .................................................................................................................................. 3
3.1 CAGING BOLT .............................................................................................................................................. 3
3.1.1 CAGING BOLT STORAGE .................................................................................................................... 3
3.2 BOLTED MOUNTING BRACKET .................................................................................................................. 4
3.3 WELDED MOUNTING BRACKET ...................................................................................................................
3.4 CENTERING THE BRAKE ..............................................................................................................................
4.0 BRAKE PAD GAP ADJUSTMENT ................................................................................................................... 5
5.0 GUIDE ROLLER PATENTED ........................................................................................................................... 6
6.0 PROXIMITY SWITCH ADJUSTMENT ............................................................................................................. 7
7.0 TIGHTENING THE ADJUSTMENT BOLT ....................................................................................................... 7
8.0 SWEEPER (OPTION) ....................................................................................................................................... 7
9.0 WHEEL REQUIREMENTS ............................................................................................................................... 8
1.0 MODELS COVERED BY THIS MANUAL

WBHD-DT-030-TM-140-240-LH WBHD-DT-030-TM-140-240-RH
Sheet Number:
WHEEL BRAKES
Hillmar
WBHD-DT-030-060-090-120-ALL
INSTALLATION MANUAL
Job Number:
275-213-01649
P:604 946-7115 F:604 946-0329
2.0 REFERENCE MANUAL
2.1 TCD-CSM MANUAL

Refer to Document No. 240-401-42860
2.2 O & M MANUAL

Refer to Document No. 200-345-65926
2.3 SCHEDULED MAINTENANCE MANUAL
3.0 BRAKE INSTALLATION
The brakes are factory tested to the correct wheel

width. They are shipped in the released position.
Check wheel for surface flatness. All wheels must be
clean before installation of WBHD.
WARNING: Do not use if brake pad is contaminated.
All Wheel Brakes are shipped with friction pads.
1. Bolt wheel brake to the mounting bracket.
2. Position the wheel brake over the wheel and
clamp the mounting bracket to the crane.
3. Attach the mounting bracket as desired
below.
3.1 CAGING BOLT
All DT model wheel brakes are shipped with
caging bolt installed.
This ensures that the wheel brake can be

installed prior to hook up of hydraulic power.
The wheel brake caging bolt should only be

removed when hydraulic power has been shipped
to the wheel brake spring cylinder.
3.1.1 CAGING BOLT STORAGE

Provision has been made on Hydraulic Power
Unit for Caging Bolt Storage.
WARNING: Care must be taken to ensure that the wheel

brake is mounted central with the wheel. The release
position allows 0.5 mm clearance on each side of wheel
Sheet Number:
WHEEL BRAKES
Hillmar
WBHD-DT-030-060-090-120-ALL
INSTALLATION MANUAL
Job Number:
275-213-01649
P:604 946-7115 F:604 946-0329
BOLTED 3.2 BOLTED MOUNTING BRACKET

MOUNTING
BRACKET 1. Mark hole positions from mounting plate
into the truck end plate.
2. Remove the mounting bracket and wheel

brake.
3. Drill mounting holes.
4. Replace mounting bracket and wheel

brake.
WHEEL
BRAKE DT
WHEEL
WELDED 3.3 WELDED MOUNTING BRACKET

MOUNTING
BRACKET 1. Tack-weld the mounting bracket to the
truck.
2. Remove the wheel brake for remainder of

welding.
3. Paint mounting bracket.
4. Replace wheel brake
WHEEL
BRAKE DT
.
WHEEL
3.4 CENTERING THE BRAKE
6-8mm
1. Once the bracket is mounted make sure
the brake is centered.
2. Connect the hydraulic line and pressurize

the brake.
3. Remove caging bolt and install the brass

cap supplied.
4. Do not discard the caging bolt

0.5mm 0.5mm
5. Tighten all the mounting bolts
L
C
Sheet Number:
WHEEL BRAKES
Hillmar
WBHD-DT-030-060-090-120-ALL
INSTALLATION MANUAL
Job Number:
275-213-01649
P:604 946-7115 F:604 946-0329
4.0 BRAKE PAD GAP ADJUSTMENT

CAUTION: Wheel Brake comes in released position from factory. Do not pressurize the cylinder prior
to brake adjustment.
1. Piston rod
Nominal released position Piston Rod Extension = 23mm
Total stroke = 16mm of Rod Movement
2. Shoe clearance
Nominal brake clearance = 0.5 mm per side (installation clearance)
Maximum brake clearance = 1.5 mm per side (after shoe wear)
Note: Wheel brake must be readjusted at this clearance
3. Maximum adjustment
Pads must be replaced when lining thickness t< 5.5mm.
4. Maximum shoe float (S)
Maximum shoe float is S±6mm
Sheet Number:
WHEEL BRAKES
Hillmar
WBHD-DT-030-060-090-120-ALL
INSTALLATION MANUAL
Job Number:
275-213-01649
P:604 946-7115 F:604 946-0329
5.0 GUIDE ROLLER PATENTED
The main purpose of the guide roller device is to

allow the free floating of the caliper, while
preventing the wear of the friction linings, due to
rubbing on the wheel. Spring-loaded rollers are
centrally located in the brake shoe. These rollers
extend under spring load from the surface of the

friction lining when the wheel brake is retracted to
allow free running.
Since the guide roller is now protruding from the

friction lining, the roller comes in contact with the
wheel before the friction lining, thus preventing
rubbing between the friction lining and the wheel.
The spring load on the roller is high enough to
shift the entire mechanism to track the motions of
A the floating wheel, but is much smaller than the
applied force of the brake. The rollers simply
retract flush with the friction lining when the brake
0.5mm 0.5mm is applied.
Guide roller device has to be adjusted during

CL
installation.
NOTE: Once the Brake is mounted to 0.5 mm gap on
GUIDE ROLLER MUST each side of brake pad, adjust guide rollers by
PROTRUDE BEYOND PAD threading in the adjuster bolt so that there is
minimal equal force acting on both the guide
rollers to keep float on the shoes.
WHEEL
FLANGE
CAUTION: Do not tighten the bolt all the way
in, it may damage the guide roller assembly
ROLLER
PAD
0.5mm
Sheet Number:
WHEEL BRAKES
Hillmar
WBHD-DT-030-060-090-120-ALL
INSTALLATION MANUAL
Job Number:
275-213-01649
P:604 946-7115 F:604 946-0329
6.0 PROXIMITY SWITCH ADJUSTMENT
The proximity switch is preset in the factory.

Location of
1. The proximity switch along with brass adapter is
the
supplied with the brake.
proximity
switch
2. Tighten in the brass adapter in the M20
threaded hole provided as shown in the picture.
3. Do not take proximity switch out of the adapter

as it is preset.
4. Cycle brake and ensure switch is activated

properly
CAUTION
Ensure that the wheel brake pad gap adjustment
procedure has been completed prior to proximity
switch installation to avoid any physical damage
to the switch.
Adjustment bolt 7.0 TIGHTENING THE ADJUSTMENT BOLT
After the brake is properly mounted and adjusted

the bolt on the toggle of the cylinder needs to be
tightened so that adjustment does not change
during brake operation.
8.0 SWEEPER (OPTION)
SWEEPER
ASSEMBLY
Sheet Number:
WHEEL BRAKES
Hillmar
WBHD-DT-030-060-090-120-ALL
INSTALLATION MANUAL
Job Number:
275-213-01649
P:604 946-7115 F:604 946-0329
9.0 WHEEL REQUIREMENTS

MAX WHEEL FLOAT
12 mm 12 mm
C
F
E
*MIN. 75mm
A *D
NOTE : DUE TO THE FACT THAT WHEEL BRAKES WILL BE MOUNTED

TO EXISTING CRANE WHEELS (I.E. NOT NEW WHEELS) 0.2
THE REQUIREMENT FOR TOLERANCES INDICATED IN 0.2
CLOUDS IS WAIVED BY HILLMAR.
- HARDNESS OF THE WHEEL RIM HAS TO BE MIN. HB200
PLEASE PROVIDE/ OR CONFIRM DIMENSIONS A,B,C,D,E;

A=
*NOTES:
1) IF WHEEL LATERAL MOVEMENT IS > ±12mm, PLEASE CONTACT HILLMAR.
2) WHEEL SURFACES MUST BE FREE FROM CONTAMINANTS TO PROLONG PAD LIFE.
3) ALL DIMENSIONS IN mm
4) WHEEL WIDTH TOLERANCE MUST BE WITHIN ± 1 mm OF NOMINAL WHEEL WIDTH
- PARALLELISM
- FLATNESS
* - WHEEL BRAKES ONLY

REFER TO HILLMAR TCD-CSM FOR CONTRACT SPECIFIC DATA

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Sheet Number:

THIS PRODUCT IS PROTECTED BY INTERNATIONAL PATENT.

Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date

1.0 MODELS COVERED BY THIS MANUAL ........................................................................................................ 2

2.0 REFERENCE MANUAL .................................................................................................................................... 3

2.3 SCHEDULED MAINTENANCE MANUAL ...................................................................................................... 3

5.0 GUIDE ROLLER PATENTED ........................................................................................................................... 6

6.0 PROXIMITY SWITCH ADJUSTMENT ............................................................................................................. 7

7.0 TIGHTENING THE ADJUSTMENT BOLT ....................................................................................................... 7

8.0 SWEEPER (OPTION) ....................................................................................................................................... 7

9.0 WHEEL REQUIREMENTS ............................................................................................................................... 8

1.0 MODELS COVERED BY THIS MANUAL

Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date

2.0 REFERENCE MANUAL

2.1 TCD-CSM MANUAL

2.2 O & M MANUAL

2.3 SCHEDULED MAINTENANCE MANUAL

3.0 BRAKE INSTALLATION

The brakes are factory tested to the correct wheel

This ensures that the wheel brake can be

The wheel brake caging bolt should only be

3.1.1 CAGING BOLT STORAGE

WARNING: Care must be taken to ensure that the wheel

Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date

BOLTED 3.2 BOLTED MOUNTING BRACKET

2. Remove the mounting bracket and wheel

3. Drill mounting holes.

4. Replace mounting bracket and wheel

WELDED 3.3 WELDED MOUNTING BRACKET

2. Remove the wheel brake for remainder of

3. Paint mounting bracket.

4. Replace wheel brake

2. Connect the hydraulic line and pressurize

3. Remove caging bolt and install the brass

4. Do not discard the caging bolt

Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date

4.0 BRAKE PAD GAP ADJUSTMENT

4. Maximum shoe float (S)

Maximum shoe float is S±6mm

Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date

5.0 GUIDE ROLLER PATENTED

The main purpose of the guide roller device is to

extend under spring load from the surface of the

Since the guide roller is now protruding from the

Guide roller device has to be adjusted during

Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date

6.0 PROXIMITY SWITCH ADJUSTMENT

The proximity switch is preset in the factory.

threaded hole provided as shown in the picture.

3. Do not take proximity switch out of the adapter

4. Cycle brake and ensure switch is activated

Adjustment bolt 7.0 TIGHTENING THE ADJUSTMENT BOLT

After the brake is properly mounted and adjusted

8.0 SWEEPER (OPTION)

Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date

9.0 WHEEL REQUIREMENTS

NOTE : DUE TO THE FACT THAT WHEEL BRAKES WILL BE MOUNTED

PLEASE PROVIDE/ OR CONFIRM DIMENSIONS A,B,C,D,E;

* - WHEEL BRAKES ONLY

Rev. Apr. By R E V I S I O N S Date Rev. Apr. By R E V I S I O N S Date

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