Operating Instructions for

Disc Brake Type:

SB 8.2
With Automatic Wear Compensator
14-1000-01/1

Gerhard Bubenzer Ing. GmbH

Postfach 123
57540 Kirchen-Wehbach
Tel.: 02741 - 9488 - 0
Fax: 02741 - 9488 -44

www.bubenzer.de
e-Mail: info@bubenzer.de

Date:
13.12.2002 Page 1 E.Siebel
 Operating Manual Page 2
Disc Brake SB 8.2
The safety of your brake /brake system depends on regular, careful inspection and
maintenance!
Use original BUBENZER replacement parts only!!!

Follow the following regulations and instructions:

• Operating instructions of the brake
• Operating instructions of the drive
• Safety instructions of the drive
• Valid accident prevention rules regulations

Keep your hands away from the brake linkage during operation of the brake!
Danger of injury!
Check at 100 to 150 operating hours:
• Function of the brake/brake system
• Brake shoe lift-off
• Lining wear/lining thickness
• Condition of the brake disc
• Thruster reserve stroke
• Easy mobility of the brake linkage
• Brake spring tension (brake torque setting)
• Adjustment of limit switches, hand release devices and other optional equipment
• Possible wear of the automatic wear compensator (if ordered)
• DO NOT DISENGAGE the automatic wear compensator, as otherwise lining wear must be compensated
manually!

Before starting any work on the brake:

!!! SECURE THE DRIVE AGAINST ACCIDENTAL ROTATION !!!
• Do not use any mechanical tools to lock the brake open!

Check the brake/brake system outside the regular inspection intervals if:

• Longer than normal braking times or -distances appear

• Extreme operating conditions appear:
⇒ Over speed 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

In case of additional painting, do NOT contaminate:

• Hinges or joints
• Brake disc surfaces
• Brake pads
• Spindles
• Automatic wear compensator
• Piston rod of the thruster
• Electrical components

Insure that the brake is re-set to the required values after all work has been completed!

Lift and transport the brake as shown in fig. 1!

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Disc Brake SB 8.2
AWC means Automatic Wear Compensator, (if ordered) throughout the following text!

1.0 Check before mounting:

• That the brake disc rotates straight and true
• That the brake disc surface as well as the brake pad is clean and free of dirt and grease
• That the hub/coupling and disc are installed properly

1.1 Align the brake:

• Put the brake into mounting position (refer to section 2.0 when opening the brake!)
• The brake disc's outer diameter must extend past the brake pads by 5 mm (Fig.2). Deviation in either
direction can affect the braking torque
• The horizontal center line of the brake pads must align with the center line of the shaft and disc
• The disc must be centered between the brake pads
• The brake pads must be parallel with the disc and the brake levers must be vertical to the disc

1.2 Fasten the brake:

• Install mounting bolts loosely into the mounting holes of the base plate. Do not tighten.
• If the brake disc is not centered in the brake, use shims for compensation.
(Bolts and shims are not part of BUBENZER supply)
• Rotate nut (1) until 30% of torque is reached (Fig.3)

1.3 Close brake manually: (Fig. 4)

• Turn nut (3) clockwise, until the brake pads close tight on the brake disc

1.4 Tighten mounting bolts in the base plate, applying the correct tightening torque.
1.5 Connect thruster according to manufacturer's instructions. For technical data and diagram refer to the
inside of the terminal boxr.
Fig. 1

Fig. 2

1 3

Fig. 3 Fig. 4

1.6 Braking Torque Adjustment: (Fig.5 and 7)

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Disc Brake SB 8.2
• With the brake in set position rotate nut (1) clockwise, until the upper edge of the torque indicator (10)
coincides with the required braking torque on a scale.

1.7 Adjustment of an equal brake shoe lift-off: (Fig. 6)

• To avoid uneven wear on the brake pads, the stop screws (7) have to be adjusted correctly:

• Release (open) brake by energizing the thruster. DO NOT use the hand release, since it does not
completely open the brake
• Loosen lock-nuts (6) on both levers
• Rotate stop-screws (7) on the side opposite the thruster until the gap between pads and brake disc is equal
on both sides.
• Adjust the thruster side screw until it just touches
• Tighten both lock-nuts (6)

1 6

Fig. 5 Fig. 6

10

Fig. 7 Fig. 8

2.0

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Disc Brake SB 8.2
CAUTION CAUTION CAUTION
Fig. 8: A counter clockwise rotation of nut (3) may damage the AWC, when catch
(15) is connected!
To avoid this, disconnect the catch (15):
• Loosen screw (14)
• Remove catch (15)
After all work at the AWC has been completed, insure that the catch (15) is properly
fitted into its place! Insure that:
• The catch-pin (9) is inside the bore of the catch (15)
• Fasten catch (15) with screw (14)

2.1 Reserve Stroke Adjustment:

The Reserve Stroke is the amount of thruster stroke remaining past the adjustment point for use in
compensating pad wear. With increasing pad wear, the reserve stroke is reducing. If the reserve stroke is
reduced to zero, the brake will fail!

Adjust brakes with larger thrusters in released condition, because it is easier to adjust. Check adjustment
when the brake is set!

• Turn nut (3) clockwise, until the piston rod of the thruster extends to dimension "S1".
(Ref. to table 2.1a or 2.1b)

Fig. 9

Fig. 10

15
14
15
9

Fig. 11 Fig. 12

2.1a Adjusting Table

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Disc Brake SB 8.2
Thruster type S0 = Piston rod in S1 = Brake set S2 = Brake released S1min = Re-
lowest position adjust brake!
Ed 23/5 38 mm (1.5“) 48 mm (1.89“) 88 mm (3.46“) 43 mm (1.69“)
Ed 30/5 49 mm (1.93“) 59 mm (2.32“) 99 mm (3.90“) 54 mm 2.13“)
Ed 50/6 54 mm (2.13“) 64 mm (2.52“) 114 mm (4.49“) 59 mm (2.32“)
Ed 80/6
Ed 121/6
Ed 201/6 145 mm (5.71“) 155 mm (6.10“) 205 mm (8.07“) 150 mm (5.91“)
Ed 301/6
Tolerance
+ 3 mm / -1 mm
+ 0.11“ / -0.04“

2.1b Adjusting Table

Thruster S0 = Piston rod in S1 = Brake set S2 = Brake released S1min = Re-

Type lowest position adjust brake!
EB 220-50 45 mm (1.77“) 55 mm (2.16“) 95 mm (3.74“) 50 mm (1.97“)
EB 300-50 49 mm (1.93“) 59 mm (2.32“) 99 mm 3.90“) 54 mm (2.13“)
EB 500-60 87 mm (3.42“) 97 mm (3.81“) 147 mm (5.79“) 92 mm (3.62“)
EB 1250-60 135 mm (5.31“) 145 mm (5.71“) 195 mm (7.67“) 140 mm (5.51“)
EB 2000-60 160 mm (6.30“) 170 mm (6.70“) 220 mm (8.66“) 165 mm (6.50“)
EB 3000-60 63 mm (2.48“) 73 mm (2.87“) 123 mm (4.84“) 68 mm (2.67“)
Tolerance:
+ 3 mm / -1 mm
+ 0.11“ / - 0.04“

2.2 Checklist

Release and set the brake several times. Check the following:

Is dimension "S1" reached, when the brake is set? (Table above)

If not: Repeat section 2.1

Is there an equal air gap between brake pads and brake disk, when the brake is released?
If not: Repeat section 1.7

Did you set the required braking torque?

If not: Repeat section 1.6

Is catch (15) properly installed and fitted into its place?

Is the catch-pin (9) inside the bore of the catch (15)?

Is the catch-pin (9) touched by the catch (15) during operation of the brake?

If you answer "yes" to all these questions, the adjustment procedure is correctly finished.
Proceed with section 3.0 "Running-in/Commissioning"

3.0
The brake is only fully operative after the adjustment listed under 1.6 to 2.2 has been
completed. Carry out the running-in procedure in accordance to the valid safety

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Disc Brake SB 8.2
requirements and legal accident prevention regulations!)
!!! Pay also attention to our safety instructions !!!

The running-in of brake pads is essential to insure an even contact pattern on the pad which will
avoid uneven loading of part of the surface and any resultant damage or possible decrease in brake torque.
Running-in must be done in the field since the contact pattern is dependent on the alignment of brake and
disc. Running-in will compensate for the slight misalignments that are inherent in normal installations.
Running-in should be performed after the brake or it’s components have been removed and replaced as part
of a maintenance procedure.

The running-in process can be done in two ways:

3.1 Running-in under load
3.2 Running-in with drive motor (brake closed)

During running-in check the thruster reserve stroke after 25 to 30 braking cycles.
Readjust if necessary (ref. to section 2.1)

3.1 Running-in under load

• Release brake after each cycle, pausing for a 45 seconds cool down period!
a) Load drive with 50% rated load.
b) Run drive at 50% lowering speed. Conduct 10 to 15 emergency-stops.
c) Repeat procedure several times at gradually increasing speed up to maximum rated speed.
d) Check reserve stroke of the thruster. Readjust if necessary.
e) Load drive with rated load.
f) Repeat steps b) and c)

3.2 Running-in with drive motor

• Release brake after each cycle, pausing for a 45 seconds cool down period!
a) Adjust braking torque to 50 % of the required braking torque
b) Run drive motor at 50% rated speed against the closed brake for approx. 5 cycles.
c) Increase braking torque to 75 % of the required braking torque.
d) Repeat 3.2 b)
e) Adjust braking torque to 100 %
f) Run drive motor with full rated speed against the closed brake for approx. 5 cycles.

The braking torque achieved can be related to the current take-up of the electric motor.

DO NOT EXCEED THE FOLLOWING VALUES DURING RUNNING-IN:

ORGANIC LININGS SINTERED-METAL-
LININGS
Max. Running Speed 30m/s /98 ft./sec 75m/s /245 ft/sec
Max. Disc Temperature: 200°C /392°F 250°C /482°F
Max. Braking Time 5 sec. 15 sec.

Running-in is completed as soon as the stopping distance at nominal load and maximum speed is not
reducing any further after repeated braking cycles.

Check the following: Is the required stopping distance reached?

YES: Running-in procedure finished
NO: Readjust the braking torque (section 1.6)
4.0 Check every 100 to 150 operating hours:
• Brake and brake parts for wear and damage (Visually inspection)
• Function of limit switches (if ordered)

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Disc Brake SB 8.2
• Function of the brake and brake system
• The condition of the brake disc

4.1 In case of brake pad/brake disc wear:

• Check/Readjust the braking torque (section 1.6)
• Check/Readjust brake shoe lift-off (section 1.7)
• Check/Readjust the reserve stroke of the thruster (section 2.1)

A reserve stroke of less than S1min increases the danger of a brake failure!
Readjust brake manually! (ref. to sections 2.1 and 2.2)

4.2 Lubrication
• Any lubrication of hinges and joints is not required

4.3 If the brake is not operated for longer than 6 month, please check:
• All brake hinges for ease of movement
• The brake disc for rust (run in to remove rust)
• The adjustment according to sections 1.6 to 2.2

Figures 13 and 14:

The following parts may be subject of wear: Screw (21), catch pin (9) and freewheel (12) (Fig. 2b)
• Recognized by: A constant reduction of the reserve stroke in case of lining wear, although the AWC is
actuated. The wearing can sometimes be visually seen, particularly in the catch pin
• Procedure: Turn nut (3) clockwise to compensate lining wear and thus the reduced reserve stroke. (Refer
to tables 2.1a or 2.1b)
• Replace worn parts or the complete AWC unit as soon as possible! Complete replacement is
recommended in the case of freewheel malfunction. Use caution when replacing an AWC or associated
parts as the AWC is a precision device and may not function correctly if damaged.

4.4 Brake disc replacement

Replace disc if:
• Any cracks occur
• More than 1mm wear on each side occurs
• Do not machine the brake disc more than 1.5 mm per side

3
12 21

Fig. 13 Fig. 14

4.5 Additional Maintenance for Hoist Gear Brakes

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Disc Brake SB 8.2
The following are in addition to the visual inspection of the brakes every 100-150 operating hours (see page
2). In Germany brake tests must be performed for the hoist brakes once a year. (German regulation VBG9).
These brake tests must be carried out without electric controlled deceleration.

Where German crane operation legislation is not applied, we recommend the following:

a) Dynamic brake test

• perform under no load condition (Spreader) 3-4 braking cycles at maximum lowering speed

and/or

b) Static brake test (hoist drives with 2 service disc brakes)

• perform with nominal (rated) load

• lift up load approx. 30 Centimeters (12 inches)

Open one brake by using the hand release. The second brake must hold the load safely. If it does not, check
or repeat brake adjustment and section 3.0 (Commissioning). After passing the static brake test, run one
dynamic brake test as described in 4.5a.

c) Subsequent to repair of a brake with used brake pads

When mounting a brake with used brake pads proceed as though it is a new installation, to insure that the
surfaces are mated-in (match).

Important Note

In case of exclusive static use as holding brake or low dynamic braking requirement as is commonly the case
on new cranes and especially container cranes, the surface of the sintered lining will tend to accumulate dust
particles which can reduce the friction factor and thus the available braking torque. These dust particles in
the brake pad surface can be removed by performing the annual dynamic brake test (4.5a)

Where it is not possible to carry out dynamic load tests at regular intervals, we recommend changing brake
pads every 2 years. If brake pads removed from the brake are in otherwise good condition i.e. free from oil
contamination, even wear pattern, no visible cracks or deformation and well above minimum residual pad
thickness, they can be reconditioned by grinding or machining approx. 0.5mm off the surface.

Minimum pad thickness for the brakes with sintered linings is 3 mm.

4.6 Minimum thickness of the brake linings:

• Bonded and sintered linings: 3 mm
• Riveted linings: 5 mm

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Disc Brake SB 8.2
4.7 Brake Pad Replacement (Valid also if only 1 brake pad has to be replaced)

Before starting any work on the brake:

Secure the drive against accidental rotation!!!

• Caution: Brakes and braking surfaces may be hot!

• Disconnect the AWC! (Section 2.0)
• Loosen lock-nuts (6), rotate stop screws (7) a couple of mm upwards
• Rotate nut (3) counter-clockwise ⇒ Brake shoes lift-off the brake disc

Brake pads (19) of the larger brakes are heavy!

⇒ Danger of injury during replacement!
• Remove both bolts (8) from brake shoe. Hold brake pad (19) safely on the upper handle and push it off
the brake shoe.
• Check that new pads are free from grease and dirt. Clean it if necessary (Emery paper)
• Put new brake pads on the shoe (17) and tighten it by bolts (8)
• Do not forget special washers (20)!
• Readjust brake according to sections 1.6 to 2.2
• Perform the running-in procedure according to section 3.0

19

8 20

6
17

Fig. 15 Fig. 16

Fig. 17

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Disc Brake SB 8.2

Pos. Qty. Designation Order No. / Remarks

1 2 Brake pads 251.545
2 2 Brake shoe w/o pads 612.148
3 1 Limit switch 430.168
4 1 Automatic Wear Compensator 261.117 Ready for installation
5 1 Manual release lever 630.196.04
6 1 Thruster Please indicate type and voltage
7 1 Brake spring unit 240.520.3.2 Ready for installation
8 2 Pin (Base plate) 622.1211
9 2 Pin (Brake shoe) 622.1213
10 1 Pin (Main hinge) 622.1212
11 2 Threaded pins 622.1214
12 1 Pin (Brake spring unit) 622.1215
13 1 Pin (Thruster lower) 622.1266
14 1 Pin (Thruster upper) 622.1216
15 1 Bushing kit Does one brake

All pins can also be ordered as a kit!

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