ZPMC SBB365 Series Safety Disc Brake

●
●

Operator's Manual
ZPMC(Group) Fengcheng Brake Co.,Ltd.

Version:3.1 Date:December.1,2003
 Contents

1. General ………………………………………………………………(1)

2. Installation and Adjustment………………………………………(2)

2.1Lifting and transportation………………………………………………(2)

2.2Preparation before installation…………………………………………(2)

2.3Installation … …………………………………………………………(3)

2.4Adjustment … …………………………………………………………(4)

3. Operation and Maintenance………………………………………(5)

3.1Operation … …………………………………………………………(5)

3.2Maintenance … ………………………………………………………(6)
1. General
SBB365 safety disc brake (hereinafter briefly called brake) is mainly used as
emergency brake at low speed shaft (driving output shaft) for various large and
middle crane at main hoist and boom hoist mechanism and cable crane at driving
mechanism, or service and emergency brake for mine winder lifter, obliquitous belt
conveyor at driving mechanism.
The brake is applied by disc spring and released by hydraulic pressure oil£¬which
structure is shown as Fig.1, and the principle of operation is following: When the
hydraulic fluid flows into cylinder under solenoid valve controlling, the hydraulic
fluid farther press the disc spring and push the piston rod to open the arms, then
braking torque is eliminated; when the solenoid valve is powered off, the pressure oil
will return to oil tank by the spring force acting, simultaneously the spring force
through the piston rod and the arms acts on the disc, and then the rated torque is
established.

1 2 3 4 5 6 7 8 9 10 11 12 13

M18×1.5
X
Y L=60 ●

●
● ●
●

●
●

●
●
●

15 14 ●

●
16
5

17
40 ２０４
● 18 ２０６

Fig.1

1. Lock nut 2. Adjusting bolt of clearance balancing 3. Braking arm A 4. Release

indicating switch 5. Adjustment nut 6. Lining wear limit switch 7.Braking arm B 8.
Lifting bolt 9. Exhaust and pressure gauge connector 10. Hydraulic cylinder 11.
Piston 12. Disc spring group13. Monitoring window 14. Installing center adjustment
nut 15. Shoes aligning device 16. Frame 17. Shoes 18. Disc

-1-
 SBB365 technical data is following:
Released Release oil Each side released
Type pressure Clamping force
(rated/Max) volume clearance

SBB365 8/10Mpa 270mL 365KN 2mm

2. Installation and adjustment

2.1 Lifting and transportation
The brake must be lifted carefully in order to avoid damage, and must be lifted by
using crane and lifting rope for its 686kgs weight. The lifting position show as fig-2.
Prohibit from using other parts except lifting bolt to lift!
Lifting direction

●
●

204

260
Oil entry

Fig.2
2.2 Preparation before installation
The brake must be installed correctly; otherwise, it will affect the design
performance. So the users must comply with the manual strictly during installing. If
need helps, please contact with our sales department.
2.2.1 check disc and brake£º
a. Check if the nameplate parameters comply with requirement;
b. Check if have all parts;
c. If there is any corrosion and jamming at every pivot point;
d. Check if the lining surface have oil (grease) and other impurity which effect the
performance;
e. Check if the disc surface has rust, oil (grease) and damage due to welding,
unevenness and other defects. Prohibit from using disc with crack or other serious
defects.
If found abnormal situation, please install after dealing with it.
-2-
2.2.2 Check foundation and brake:
a. The foundation must be fixed and evenness;
b. The tolerance and surface roughness of the bracket refer to Fig.3.
2.3 Installation
2.3.1 Installing the bracket onto foundation
a. Clear the oil and dirt on the surface of foundation, and then lift the brake onto
the foundation by crane.
b. Release adjustment nut (part 5, Fig.1), rotate clockwise the lock nut (part 1,
Fig.1. see from the switch side) to open the arms, and ensure the distance between two
linings is over 3mm than the thickness of disc.
c. Remove the opened brake to installing position, put on the foundation bolts,
adjust the brake and make the edge of the lining retract about 3~5mm than outside
diameter of the disc (refer to Fig.1).
d. Connect the limit switch cable (signal indication). The connection must be
firmed in order to avoid accident due to the released cable. The switch cable entry
stuffing is Pg13.5(3×1.5).
0.1 B

ØD
0.05

0.2
A
3.2

3.2 B
b±0.2

0.05
0.1 A

Fig.3
2.3.2 Hydraulic pipeline connection and exhausting
a. Installing and adjusting hydraulic power unit well before installing the brake
(please refer to the operator's manual of hydraulic power unit), arrange the hydraulic
pipeline. The oil entry thread of the brake cylinder is M18×1.5 (refer to Fig.1), the
inside diameter of the pipeline must be over 10mm, and the entered oil volume is
270mL when the each side clearance of the brake is 2mm.
b. Exhaust air in the cylinder before operating and adjusting the brake, the method
is: on the top of the cylinder there is exhaust and pressure gauge connector (part 9 in

-3-
Fig.1). The thread of the connector is M16. When testing pressure, remove the cover
and connect the pressure gauge accessory; when exhausting, remove the cover ring for
anti-falling, screw the cover tightly (refer to Fig.4). After exhausting, replace the
connector as delivery state.

Non-exhausting state Exhausting state

Fig.4
2.4 Adjustment
2.4.1 All adjustment must be operated before first installing and after changing new
lining. At first installing, please according to following steps:
a. The adjustment of clamping force: release the brake by electric control or
manual-operated pump (refer to operator's manual of hydraulic power unit), release
the lock nut (part 1, Fig.1), and rotate the adjustment nut (part 5, Fig.1) for a certain
distance toward the arms direction, and then close the brake, observe the length of
piston rod shown out from cylinder head, see if the dimension L is 60mm (refer to
Fig.1), if so, the clamping force is up to rated value, and then stop rotating the
adjustment nut and tighten the lock nut; if not, open the brake again and then rotate
the adjustment nut till complying with requirement.
b. Adjustment of shoe aligning: the brake with spring aligning device (part 15,
Fig.1) on two shoes can ensure that the shoes completely deviate from the disc while
the brake opening (refer to Fig.1). To adjust, firstly open the brake and shake the shoe
with hand, observe the shoe's degree of tightness (generally, the shoe aligning device
can ensure the surface of lining parallel with the surface of disc while the brake
release. If it is loose, the shoes is easily deflected, it is too tight, the shoes can't align
automatically), if it is abnormal, please adjust the aligning bolt (part 15) till degree of
tightness is up to standard.
c. Adjustment of the clearance balancing: open the brake and observe the both
side clearances between shoe and disc are the same, if not, please adjust it to be same
according to following: first release lock nut of adjusting bolt of clearance balancing
(part 2, Fig.1, two sides), screw in adjusting bolt of the side which clearance is larger,
then operate the brake for 3~5 times and observe the two sides clearance, if is not
equivalent, please repeat above steps till up to be equal, then tighten the lock nut.
-4-
2.4.2 Adjustment of the limit switch
The brake equips released/closed indication switch (part 4 in Fig.1) and a lining
wear limit switch (part 6), which is proximity switch, and their connectors are open
normal. If power supply is DC 12×300V, current capacity of the connectors are 3×
300mA. If power supply is AC 20×250V, current capacity of the connectors are 3×
400mA.
The adjustment of switch is to adjust its relative position, as following steps:
slacken (Don't dismantle) two fasten bolt of switch seat to make the switch free,
measure dimensions X and Y, check if it comply with the value listed at following
table, if not, move the switch to correct position then tighten the fasten bolt.

Switch
Lining wear limit Released/closed indication
function

Shoe Brake closed Brake released Brake close Brake release

clearance Distance X (mm) Distance Y (mm)
2mm About 7.5 About 17.5 About 14 About 4
X listed at above table is a detected distance that will cause switch to act when the
each side brake lining is worn 0.5mm.
3. Operation and maintenance
3.1 Operation
3.1.1 Check before running in:
a. Check if installation complies with requirement;
b. Check if the adjustment is up to the standards;
c. Check if the surfaces of the disc and lining have oil (grease) or other
contaminations;
If all checks are ok, the brake can be run-in.
3.1.2 Running-in the brake
Before operating, the brake must be run-in according following steps:
a. Operated about10~20 times in normal state without load (drive motor runs
together with disc, the same requirement hereinafter), if have abnormal, dealing with
it and run again till operating normally.
b. Run about 10~20 times with 50% rated load, observe if the braking state is
stead, if so, the brake can run about 3~5 times with rated load.
c. During running-in, following items should be checked: 1.The lining fit to the
disc when braking; 2. the temperature of the disc ( less than 350¡æ); 3. Whether the
screw joint is released; 4. If the limited switch is released; 5. If the sound of braking
and running is normal; 6. If the hydraulic system has leakage.
The brake can be operated only after running-in is normal.
-5-
3.2 Maintenance
3.2.1 Check following every 3~7 days:
a. Check if the surfaces of the disc and lining are polluted;
b. Check if the disc worn is no more than 1mm, otherwise, the disc should be
changed;
c. Check the lining, if the friction material thickness is less than 3mm, the lining
must be changed;
d. Check if the screw thread joint is released;
e. Check if the hydraulic system has leakage;
f. Check if the limited switch is released;
g. Check if the clearance is varied;
If abnormal situation is found, please stop operating the brake and deal with the
fault or adjust brake again.
3.2.2 Change the lining
When friction material of lining thickness is less than 3mm, the lining must be
changed (total thickness of lining is 20mm, and steel base thickness is 11mm), the
changing method is following (refer to Fig.1):
a. Switch on hydraulic power unit, release the bake, if the distance between lining
and disc is not enough, you can increase pressure of hydraulic power unit to open the
brake further. Caution: The Max pressure can't be beyond 10Mpa, otherwise the disc
spring will be damaged;
b. Dismantle the shoes (part 17 in Fig.1)from brake£¬and release lock bolt of the
lining, then remove the lining;
c. Check new lining, observe if have oil and distortion on the surface, if so,
please clean it or change a new one;
d. Set the new brake lining key way engage with the linking key.
e. Screw down the lock bolt tightly, assembly shoes back, switch off the hydraulic
power unit to close the brake.
After installing new lining, Adjusting according to section 2.4, checking and
running-in according to section 3.1. Only all are ok, the brake can be operated.
Caution: 1.Ensure that the braked shaft is free from any load and cannot occur
accident rotation before replacing the lining. 2. As the brake lining has certain weight,
please care about hurt for body due to fall down when changing it. 3. Please ensure
brake is opened and it is no possible to suddenly close while changing lining.

-6-