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PB32-0909-01/2
Operating manual
BSC 95.5
Table of contents
1 Safety regulations ................................................................................... 3
2 Brake ........................................................................................................ 4
2.1 Introduction .............................................................................................................4
2.2 Warranty .................................................................................................................4
2.3 Description and designated use..............................................................................4
2.4 Technical data ........................................................................................................5
2.5 State of shipment and storage ................................................................................6
3 Setup ........................................................................................................ 7
3.1 Preparations for installation ....................................................................................7
3.2 Brakes with bracket in scope of shipment (hydraulic pressure available) ...............7
3.3 Brakes with bracket in scope of delivery (hydraulic pressure not available) ...........7
3.4 Brakes without bracket in scope of delivery (two detached halves) ........................8
3.5 Hydraulic system ....................................................................................................8
3.6 Checking/setting of the release stroke of the brake ................................................8
3.7 Check limit switches ...............................................................................................9
3.8 Bleeding of the brake..............................................................................................9
3.9 Commissioning (Running-in of the brake pads) ....................................................10
4 Maintenance........................................................................................... 11
4.1 Regular checks .....................................................................................................11
4.2 Lubrication ............................................................................................................11
4.3 Adjustment of pad wear ........................................................................................11
4.4 Exchange limit switch ...........................................................................................12
4.5 Replacement of brake pads ..................................................................................13
4.6 Exchange seals ....................................................................................................13
4.7 Exchange Belleville washers ................................................................................15
5 Putting out of service and disposal..................................................... 16
6 Spare parts............................................................................................. 17
7 Appendix ................................................................................................ 18
Seite 2
Operating manual
BSC 95.5
1 Safety regulations
Note: warnings and other security rules are presented like this throughout the manual:
The brake may only be used in the way described in chapter 2.3 “Description and designated use”.
The safety of your brake / brake-system depends on proper and regular inspection and
maintenance. Study the manual before starting the installation. If in doubt, please don’t hesitate to
contact our service-department or your local retailer.
Important!
The brake type PINTSCH BUBENZER BSC is an essential safety device.
Any misuse or insufficient handling or maintenance endangers life!
Warning!
A sudden startup of the installation endangers the life of the maintenance
personnel! Secure the drive and the installation against any accidental
movement before starting any work!
Important!
Ensure that the brake is set to its proper values according to the manual
after finishing any work!
Seite 3
Operating manual
BSC 95.5
2 Brake
2.1 Introduction
This manual has been written to the best of our knowledge. It is intended to familiarize the
operation and maintenance personnel with the function, the handling, the maintenance and the
safety regulations of the power unit. Furthermore these instructions should make sure that trained
and qualified personnel is able to handle the power unit according to its designated use.
However the manual can’t cover all the possible circumstances at the place of operation. If you
have any questions concerning the power unit or this manual, please contact PINTSCH
BUBENZER quoting the type and serial number of the power unit as given on the typeplate.
2.2 Warranty
The warranty and its duration depend on the contract. For details on the supplier’s warranty please
refer to the terms of the contract. Any warranty- or liability-claims are excluded in case they occur
because of one or more of the following conditions:
• Non-designated use of the brake.
• Improper handling, setup, operation and maintenance of the brake by the operating company.
• Neglection of the regulations and notes in this manual concerning transport, setting up,
operation and maintenance of the brake.
• Improper maintenance and repairs of the brake.
• Improper monitoring of components, which are prone to wear.
• Catastrophes, external objects and forces and force majeure.
• Changes at the brake without approval of PINTSCH BUBENZER.
The information in this manual has been checked thoroughly. Nevertheless we can’t accept liability
for errors.
The PINTSCH BUBENZER BSC 95.5 disk brake is used in connection with a brake disk in
traveling installations and lifting gear as a hydraulic actuated safety brake. The disk brake consists
of two halves which operate independently and consist in each case of a mounting flange with
brake cylinder and brake disk.
The two halves of the disk brake are mounted by the customer on a bracket arranged in front of
the brake disk. The data of the dimensional drawing must be accurately observed for this.
The brake is released (opened) by a hydraulic system. If the hydraulic pressure is switched off or
the EMERGENCY OFF actuated, the brake sets by the built-in Belleville washer assembly.
This version of the brake is not suitable for use in areas with explosion hazards.
Any other use or any further change of the brake is strictly forbidden! Ignoring the
regulations for the designated use and /or the instructions for setup and maintenance
endangers life and leads to the loss of any warranty by the manufacturer!
Seite 4
Operating manual
BSC 95.5
4.2 5
7 1.5 1.6
Seite 5
Operating manual
BSC 95.5
Both calliper halves are pre-assembled. The dividing surfaces of both calliper halves are machined
and metallically clean. The disc brake callipers have been tested before shipment with the
designed operating liquid (mineral oil or brake fluid). That means that the interior components of
the callipers are preserved against corrosion for the time of transportation as well as during a
shorter storage period.
• Keep brakes, brake discs and power units dustproof and waterproof together with drying
material during the storage and/or transportation period.
• Protect the brakes against external damage for the complete storage-/transport period.
• Pipe connections and connections on manifolds should be provided with threaded plugs.
• Fill up hydraulic cylinder with hydraulic fluid if they are not directly used after manufacturing.
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Operating manual
BSC 95.5
3 Setup
Warning!
A sudden startup of the installation endangers the life of the maintenance
personnel! Secure the drive and the installation against any accidental
movement before starting any work!
ATTENTION: BUBENZER brake disks are treated with a protective coating before shipment. This
must be thoroughly removed before the brake is installed.
Important!
Air bulbs inside the hydraulic system endanger the correct function of the
brake. The brake, the hydraulic power unit and the tubing has to be bled
before the start up.
• Connect brakes hydraulically (6) and release (open) with manual pump or hydraulic power unit.
• Slide brake with bracket on to the brake disk (take note of relevant installation drawing).
• Screw in attachment screws (7) for the bracket (not provided) but do not yet tighten.
• Release hydraulic pressure, the brake sets and centers on the brake disk.
• Slightly tighten attachment bolts (7) of the bracket.
• Release the brake hydraulically.
• Check alignment once more and correct if necessary.
• Tighten bolts (7) with a torque wrench to correct torque.
5
1.20 1.21
1.6
1.15
1.8
1.5
7 6
2
Fig. 2: Fig. 3:
3.3 Brakes with bracket in scope of delivery (hydraulic pressure not available)
• Unscrew screws (1.6) with retraction springs (1.15) from pad carrier (2).
• Loosen screws (1.21). Do not loosen screws (1.20).
• Pull back guide pins (1.5) with plate (1.8) and screws (1.20).
• Remove the brake pad carrier (2)
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Operating manual
BSC 95.5
• Slide brake with bracket on to brake disk (take note of relevant installation drawing)
• Screw in attachment bolts for the bracket (not provided!) but do not yet tighten
• Connect brakes hydraulically and release (open) with manual pump or power unit
• Refit brake pads (2)
• Release hydraulic pressure, the brake sets and is centered on the brake disk
• Slightly tighten attachment screws of bracket
• Release the brake hydraulically
• Check alignment once more and correct if necessary
• Tighten screws with torque wrench to correct torque
The contact surfaces of the brake caliper halves must be metallically clean. Align brake halves on
bracket provided by customer and screw in position. Measure parallelism and offset between the
caliper halves and brake disk and correct if necessary.
• Proceed as described above1
High tensile bolts M 20 quality 8.8 (HV washers as per DIN 6916), Torque 415 Nm. (screws lightly
oiled)
Take note of the separate instructions for the unit. Carry out the pipework according to the
corresponding hydraulic circuit diagram.
Actuate brake several times. Check whether the release stroke of the brake is 1 mm per side. The
release stroke is defined as the lift off of the brake pads from the brake disk when the brake is
released.
• For better reading: Unscrew screws (1.22) and remove twist
1.22
lock (9).
• Measure Xopen (Fig. 4). X 1.7
• Set brake.
• Measure Xclosed (Fig. 4).
• The difference ∆X is the stroke.
• Normal stroke: 1 mm per side 5
• Maximum stroke: 1.5 mm per side
Fig.4:
In case the stroke is bigger or smaller than 1 mm adjust it according t section 4.3.
• After finishing the checks / adjustment, secure twist lock (1,7) again with screws (1.22)
Seite 8
Operating manual
BSC 95.5
For each calliper half there is a limit switch for release control.
• When the brake opens the brake pad carrier moves into the
sensing range of the limit switch.
• The limit switch has to emit a signal when the brake is
completely open.
• If not:
2 4.2
• Check signal / connection
• Adjust position according to section 4.4
Fig. 5:
Important!
Air bulbs inside the hydraulic system endanger the correct function of the
brake. The brake, the hydraulic power unit and the tubing has to be bled
before the start up.
Always start with bleeding the hydraulic system then both brake callipers.
• Remove cap from bleeder valve at brake!
• Fit a transparent hose to the conical part of the valve.
• Guide the free end of the hose into a container filled with a small amount of hydraulic oil.
• Actuate the brake.
• Check all pipes for tightness!
• Check function of control elements: manometer, external controls. Open Bleeder Valve of
brake slowly!
Î Only loosen the conical front-part of the valve! Don’t loosen the base!
• Close bleeding valve, when a continuous, bubble-free oil stream runs through the transparent
hose.
• Check oil-level continuously during the bleeding (2nd operator) and refill if necessary.
• Repeat process at other brakes and - if installed - other bleeding valves!
• When all brakes and lines (if additional bleeding valve is installed) are bled, actuate (close)
brake and check pressure.
• Release brake and check oil level at oil sight glass.
• Oil level has to be visible at oil sight glass when the brake is completely released.
• If necessary refill.
• Check filter and clean if necessary after finishing the procedure.
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Operating manual
BSC 95.5
New brake pads do not possess the full contact area for satisfactory braking.
Running in removes any unevenness in the pad surface and increases the braking performance in
comparison with brakes with pads that have not been ran in. Running in of the pads is essential
especially for dynamically applied brakes and emergency brakes.
The running in procedure is completed when the braking distance at the rated load and at
maximum speed is not reducing any further after repeated braking actions.
Seite 10
Operating manual
BSC 95.5
4 Maintenance
Warning!
A sudden startup of the installation endangers the life of the maintenance
personnel! Secure the drive and the installation against any accidental
movement before starting any work!
Check the brake/brake system outside the regular inspection intervals if:
• Prolonged braking times or -distances appear
• Extreme operating conditions appear:
⇒ Overspeed of the brake disc
⇒ and/or excessive braking times
• A limit switch indicates lining wear or lack of releasing stroke
• After a longer period of brake-standstill or drive standstill
• Any leaks appear
4.2 Lubrication
The brake is shipped fully greased. As long as it is not disassembled it does not have to be
greased again.
Important!
A release stroke of more than 1.5mm reduces the service life of the
Belleville washers! If this is exceeded, the fatigue strength of the disk
springs can no longer be guaranteed!
With increasing wear of the pad, the release stroke of the brake increases and the tension of the
Belleville washers decrease. This leads to a reduction of the braking force or braking torque.
Compensation for pad wear must therefore be carried out at regular intervals:
Seite 11
Operating manual
BSC 95.5
Fig. 6:
In case the stroke is too big or too small adjust it in steps of 0.5 mm.
• Pitch of thread at adjustment piston = 2 mm
• Rotation by 90° (quarter turn) = 0.5 mm
• Rotation by 180° (half turn) = 1.0 mm
• Release brake
• Put twist lock (1.7) onto the two pins and turn it
• Clockwise rotation stroke decreases
• Counter-clockwise rotation stroke increases
• Loosen hexagon screws (1.22), turn twist lock (1.7) by 90° in clockwise direction.
• If more wear occurs, keep turning the twist lock (1.7)
• Adjust both brake calliper halves to the same extent.
• When BOTH brake halves have been adjusted, secure twist lock (9) again with screws (10)
• Secure twist lock (1.7) with screws (1.22) again.
• If present, readjust limit switch adjustment
• Actuate brake several times and check the release stroke.
Fig. 7:
Seite 12
Operating manual
BSC 95.5
Warning!
The brake-pressure is strong enough to injure or severe fingers! Secure
the brake against setting while changing the the brake pads
Danger of injury!
• Unscrew screws (1.6) with retraction springs (1.15) from pad carrier (2).
• Loosen screws (1.21). Do not loosen screws (1.20).
• Pull back guide pins (1.5) with plate (1.8) and screws (1.20).
• Remove the brake pad carrier (2).
• Clean mounting area.
• Mount new brake pads (2).
• Insert guiding pin (1.5).
• Fix guiding pin (1.5) with screw (1.21).
• Mount screws (1.6) with retraction springs (1.15) to pad carrier (2).
• Adjust the release stroke evenly.
• Check function of limit switch.
• Carry out commissioning.
1.22 1.23
1.2
1.20 1.21 1.7
1.3
1.24
1.6 1.17
1.14 1.16
1.15
1.8
1.4 1.18
1.5 1.19
1.13
2
Abb. 8: Abb. 9
• Release brake
• Unscrew screws (1.6) with retraction springs (1.15) from pad carrier (2).
• Loosen screws (1.21). Do not loosen screws (1.20).
• Pull back guide pins (1.5) with plate (1.8) and screws (1.20).
• Remove the brake pad carrier (2).
• Release the hydraulic system pressure and secure it against switching on
• Loosen screws (1.22).
• Turn adjusting piston (1.39 with twist lock (1.7) clockwise until stop.
• Loosen screws (1.23) one after the other in several cycles
• Note: There may be a small spring pressure remaining.
• Dismount housing (1.2).
Seite 13
Operating manual
BSC 95.5
Important!
Use soft tools like a brass-screw driver to remove the seals! Never use a
hard standard tool, as this will damage the surface of the cylinder and lead
to leakages!
• It is normally not necessary to exchange the scraper ring. In case you have to:
• To remove the scraper rings (8), it is necessary to dismount the brake calliper halves.
• Loosen mounting bolts (7).
• Dismount calliper half.
• Remove the scraper ring (1.18) from its groove
• Clean the brake housing inside using clean cloth and brake cleaner.
• Do not use high pressure cleaners.
• Check for any damage or dirt. Apply a thin film .of cylinder grease (grease for cylinders and
valves) to the inside of the brake housing
• If the scraper ring has been taken out:
• Put in a new scraper ring (1.18) if dismounted.
• Take care that the scraper ring is evenly pressed evenly into the groove.
• Remount calliper halves according to section 3.
• Regrease the cylinder surfaces with Rexroth Cylinder Grease or an adequate substitute.
• CAUTION: Install the new seals and support rings carefully.
• Take care that the seals are pressed evenly into the groove.
• In case the grease of the Belleville washers has been washed out by the leaking oil regrease
them with Klüber Alltemp QNB 50 or an appropriate substitute.
• Put the adjusting piston (1.3) together with piston (1.4).
• Remount Belleville washers (1.14) back in place. Pay attention to the correct order of the
Belleville washer arrangement and the thrust washers!
• Put housing (1.2) in place and tighten it by screws (1.23).
• Tighten screws (1.23) in several cycles up to 84 Nm (65 Lbf-ft).
• Remount twistlock (1.7) on housing and tighten it several turns.
• Put brake pads (2) in place.
• Remount guiding pins (1.5).
• Fix guiding pins (1.5) with screws (1.21).
• Screw bolts (1.6) with springs (1.15) into the brake pad (2) and tighten it afterwards.
• Connect brake hydraulically.
• Commission brake according to section 3.
• Adjust the air gap between the brake disc and the brake pads according to section 4.3.
• Remount twistlock (1.7) and tighten it with screws (1.22).
• Bleed the brake/brake system and check the function of the brake.
• Check function of limit switch.
Seite 14
Operating manual
BSC 95.5
1.22 1.23
1.7
1.24
1.10
1.11
1.14
Fig. 10:
• Release brake
• Unscrew screws (1.6) with retraction springs (1.15) from pad carrier (2).
• Loosen screws (1.21). Do not loosen screws (1.20).
• Pull back guide pins (1.5) with plate (1.8) and screws (1.20).
• Remove the brake pad carrier (2).
• Release the hydraulic system pressure and secure it against switching on
• Loosen screws (1.22).
• Turn adjusting piston (1.39 with twist lock (1.7) clockwise until stop.
• Loosen screws (1.23) one after the other in several cycles
• Note: There may be a small spring pressure remaining.
• Dismount housing (1.2).
• Dismount Belleville washers (1.14) and thrust washers (1.10) and (1.11).
• Check for any damage or dirt. Apply a thin film .of cylinder grease (grease for cylinders and
valves) to the inside of the brake housing
• Regrease the cylinder surfaces with Rexroth Cylinder Grease or an adequate substitute.
• Grease Belleville washers with Klüber Alltemp QNB 50 or an appropriate substitute.
• Mount Belleville washers (1.14) in place. Pay attention to the correct order of the Belleville
washer arrangement and the thrust washers (1.10) and (1.11)!
• Put housing (1.2) in place and tighten it by screws (1.23).
• Tighten screws (1.23) in several cycles up to 84 Nm (65 Lbf-ft).
• Remount twistlock (1.7) on housing and tighten it several turns.
• Put brake pads (2) in place.
• Remount guiding pins (1.5).
• Fix guiding pins (1.5) with screws (1.21).
• Screw bolts (1.6) with springs (1.15) into the brake pad (2) and tighten it afterwards.
• Connect brake hydraulically.
• Commission brake according to section 3.
• Adjust the air gap between the brake disc and the brake pads according to section 4.3.
• Remount twistlock (1.7) and tighten it with screws (1.22).
• Bleed the brake/brake system and check the function of the brake.
• Check function of limit switch.
Seite 15
Operating manual
BSC 95.5
The brake must only be put out of service and disposed by trained and qualified personnel.
Important!
Because of the weight of the brake always use proper lifting devices and
transport the brake using the lifting ore!
Danger of injury!
Warning!
A sudden startup of the installation endangers the life of the working
personnel! Secure the drive and the installation against any accidental
movement before starting any work!
Take care that the hydraulic fluids, lubricants and other used substances
as well as oil-soiled parts are disposed environmental friendly and in
compliance with the corresponding laws and regulations!
Electronic scrap has to be disposed separately.
Seite 16
Operating manual
BSC 95.5
6 Spare parts
Information:
When ordering replacement parts, please indicate brake type and serial no.
of the brake! Type and serial no. are located on the name plate of each
brake.
Notice!
The use of spare parts, not meant for this brake, can lead to a malfunction
of the brake or damage the brake!
Only use original PINTSCH BUBENZER spare parts!
1.14
1.17
4.2
1.16
1.15
1.18
1.19
1.13
2
Seite 17
Operating manual
BSC 95.5
7 Appendix
Type BSC 95.5
a 220
b 213
b2 112
c 380
c1 12
d 137
d3 21
e 435
f 57
g 40
h 75
i 78
k 32
l 78
m 142
n 8
p 120
q 25x45°
r 3/8“
s 34
t D 12
Bolts M20
Material 8.8
Tightening torque [Nm] 410
Contact force FA* [kN] 20
Operating pressure* [bar] 60
Max. pressure* [bar] 100
Stroke* [mm] 1
Oil volume* [l] 0,004
Contact surface* [cm2] 195
Friction factor (theoretical) µ** 0,40
Weight [Kg] 30
All dimensions in mm. Alternations without notice.
*) = Data per calliper half
**) = Average friction factor of standard material combination
Brake disc
d1 d2 – 105 mm
d4 d2 – 284 mm
Seite 18
Operating manual
BSC 95.5
Important!
These tightening torques apply for:
µcompl. = 0.12 (black or bonderd, slightly oiled)
Used Nordlock-washers must not be used again!
Seite 19