OMM DOBA Brake

Process crane documentation Name : MHP 231
Installation and Operation instructions Datum : 24.08.2018

For drum brake series TE ÄI : 00
B 06 20 134 E – 2018-08 Ident-Nr : 468 114 46
Original operating instructions Sprache : Englisch
Installation and Operating Instructions
For drum brake series TE

B 06 20 134 E – 2018-08
Drum Brake Series TE Page 1 / 24

Änderungen vorbehalten. Nachdruck, auch auszugsweise, nur mit Genehmigung der Demag Cranes & Components GmbH, 58300 Wetter
B 06 20 134 E – 2018-08 Ident-Nr : 468 114 46
Contents
Contents ................................................................................................................ 2
1 General Information ........................................................................................ 3
2 Safety................................................................................................................ 4
2.1 Identification of Safety Information in the Operating Instructions ........... 4
2.2 Use for Intended Purpose ...................................................................... 5
2.3 Safety Information.................................................................................. 6
3 Transportation and Storage ........................................................................... 7
3.1 Scope of Delivery................................................................................... 7
3.2 Transportation........................................................................................ 7
3.3 Storage .................................................................................................. 7
4 Technical Data ................................................................................................. 8
4.1 Design and Functional Principle of the Brake ........................................ 8
4.2 Data Sheet ............................................................................................. 9
5 Installation ..................................................................................................... 11
5.1 Installing the Brake .............................................................................. 11
5.2 Adjusting the Brake.............................................................................. 13
5.3 Adjusting the Reserve Stroke .............................................................. 14
5.4 Adjusting the Wear Compensator ........................................................ 15
5.5 Commissioning / Bedding in of the Brake Linings ................................ 16
6 Maintenance ................................................................................................... 18
6.1 Routine Inspections ............................................................................. 18
6.2 Replacing the Brake Shoes ................................................................. 19
7 Disassembly .................................................................................................. 20
7.1 Preparation .......................................................................................... 20
7.2 Disassembly ........................................................................................ 20
8 Spare Parts Stock .......................................................................................... 21
9 Disposal ......................................................................................................... 23
10 Lists ................................................................................................................ 24
12.1 List of Images ...................................................................................... 24
12.2 List of Tables ....................................................................................... 24

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1. General Information
These operating instructions are an integral part of the scope of delivery of the brake and are valid only in
connection with the detailed information SIBRE Document B 06 20 134 E. The operating instructions should be
kept as a reference in the vicinity of the brake.
CAUTION!
Only detailed knowledge of the operating instructions can ensure trouble-free operation of the brake. It
is therefore in the interest of the operator to ensure that the operating instructions are read, understood
and strictly observed by all persons responsible for transportation, installation, operation, maintenance
and repair.
On compiling these operating instructions, the state-of-the-art brake described in these operating instructions
conforms to the latest technological development. In the interest of further development, we reserve the right to
make changes that are deemed necessary for increasing efficiency and safety while retaining the essential
features.
In accordance with the Machinery Directive 2006/42/EC, the manufacturer:
SIBRE Siegerland-Bremsen GmbH
Auf der Stücke 1-5, D-35708 Haiger
Telephone: +49 (0) 2773 9400-0
Fax: +49 (0) 2773 9400-10
documents the TE drum brake series brakes with the "Declaration of incorporation for incomplete machines,
Annex II 1B".
NOTE!
Commissioning (start-up) of the incomplete machine is prohibited until the incomplete machine has
been installed in a machine that corresponds to the stipulations of the EC Machinery Directive.
The manufacturer will not accept any liability for damage or operating faults due to not intended use of
the product. The operator alone shall bear the associated risk.

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2. Safety
2.1 Identification of Safety information in the Operating Instructions
Important instructions relating to personal and industrial safety in these operating instructions are emphasised
as follows.
WARNING!
This symbol draws attention to safety measures that must be observed in order to avoid personal
injury. The following warning notices are to be distinguished:
WARNING!
Warning – hot surfaces.
WARNING!
Warning – electrical voltage.
WARNING!
Warning – bruise & impact injury.
WARNING!
Warning – hydraulic oil and other fluids.
CAUTION!
This symbol indicates safety measures that must be followed to prevent damages of the product.
NOTE!
This symbol indicates general operating instructions which must be followed closely.

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2.2 Use for intended Purpose
The product described in this operating instruction:
 has been developed for stationary use in general machine and plant applications.
 may be used only for the ordered and confirmed purposes.
 may be used only under the conditions defined in the operating conditions for operation, inspection and
maintenance.
 may be used only with the SIBRE supplied and / or approved hydraulic power units / thrusters.
CAUTION!
The operating instructions of the hydraulic power unit / thruster supplier have to be observed
completely. Use above and beyond that specified, such as for higher output ratings and speeds etc. or
for non-approved operating conditions shall be deemed as use not for intended purpose.
WARNING!
Inappropriate operation and other use than for the intended purpose can pose the risk of serious or
fatal injury to the operator or other persons as well as damage to the system and other equipment.

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2.3 Safety Information
 The product described in this operation instruction is based on state-of-the-art design and is delivered in
a failsafe condition.
 The product described in this operation instruction may be used only under the conditions defined in the
scope of services and delivery.
 The operating company must ensure that the persons entrusted with the installation, operation, care,
maintenance and repair have read and understood the operating instructions and strictly observe them
in order to:
o avoid the risk of serious or fatal injury to the operator or other persons.
o ensure operational safety and reliability of the product.
o avoid downtimes and harm to the environment as the result of incorrect use.
 Relevant occupational health and safety as well as environmental protection regulations must be
observed during transportation, installation and dismantling, operation as well as care and maintenance.
 Only authorized, qualified and instructed personnel are permitted to operate, maintain or repair the
product described in this operating instructions.
 All work must be carried out with the utmost care with “safety” as top priority.
 Work on the product described in this operating instruction must be carried out only at standstill. The
drive unit must be secured to prevent it being switched on inadvertently (e.g. by locking the key-
operated switch or removing the fuse in the power supply). A warning sign indicating that work is being
carried out on the product must be displayed at the switch-on point.
 The drive unit must be shut down immediately if conspicuous changes occur at the product, e.g.
grinding noise, during operation.
 The product described in this operating instruction must be secured by corresponding safety devices to
prevent inadvertent contact. The safety devices must not impede effective operation of the brake
system.
 If the product described in this operating instruction is installed in devices or systems, the manufacturer
of the devices or systems must adopt the requirements, information and descriptions contained in the
present operating instructions into his operating instructions.
 Spare parts must be procured from SIBRE only.

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3. Transportation and Storage
3.1 Scope of Delivery
The scope of delivery is listed in the shipping papers. On delivery, the consignment must be checked to verify
that it is complete. Any damage incurred during transportation and/or missing parts are to be reported
immediately in writing.
3.1 Transportation
On delivery, the TE drum brakes are packed in such a way as to ensure maximum protection during
transportation.
WARNING!
Falling parts can cause serious or fatal injuries!
CAUTION!
Adequately secure the brake. Pay attention to the centre of gravity and use suitable sling attachment
points! Slings that are damaged or do not have the required load carrying capacity can break under
load. Make sure that all lifting gear and slings meet the safe working load and check that they are in
perfect working order. Only use tested and approved lifting gear.
3.1 Storage
Any damage to the outer preservation or exterior paintwork must be touched up. The storage room must be dry
and free of dust. The ambient temperature should not be lower than +10°C and the relative humidity should not
exceed 65%

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4. Technical Data
4.1 Design and Functional Principle of the Brake
The brake is mounted by means of 4 mounting holes onto a base frame or construction. Positions and
dimensions of holes are standardized according to DIN 15 435.
The brake levers surround the brake drum with the hinged brake shoes and transmit the braking force to the
brake drum in conjunction with the tension rod and the knee lever.
The torque spring unit consists of tube, tension rod, spring, piston plate and brake torque scale. The adjustable
spring generates the braking force.
The lifting device is used to open the brake and works against the spring force. The energy required for opening
the brake is generated either by electrohydraulic, electrically via solenoid, hydraulically or pneumatically.
The tension rod is one of the most heavily stressed parts of the brake because all the braking force is
transmitted to the brake shoes via the rod. For all types of SIBRE brakes, the tension rod is made of stainless
steel material with rolled thread.
The connection between the tension rod and the brake lever facing away from the thruster usually is the
shackle, alternatively bolt connections can be used.
To compensate upcoming pad wear, a wear adjustment is installed as an option. As it is limited in its way per
each brake stroke, a manual wear adjustment needs to be carried out by the maintenance personnel depending
on application.
Torque spring unit and thruster are connected to the knee lever. The force transmission takes place at those
connection points.
tension rod
lining wear compensator
shackle knee lever
brake lever torque spring unit
brake shoe with

organic liner thruster
base plate
Image 1: Main Components

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4.2 Data Sheet
Image 2: Data Sheet
NOTE!
Corresponding to the specific application, different safety factors must be taken into consideration in
the design layout of the brake. We would be pleased to be of assistance in the design and selection of
the brake.

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Torque
Brake Thruster Range
A B C D E F G H J K L M N P Q R d kg*
Type size in Nm at
μ = 0,4
50 –
1 / 10 640 160 475
300
TE 200 515 200 170 90 160 55 145 160 115 10 75 70 96 14 19
85 –
2 / 20 640 160 475
400
40 –
1 / 10 760 160 550
325
40 –
TE 250 2 / 20 760 160 625 250 210 110 200 550 65 180 190 133 10 95 90 113 18 30
450
100 –
3 / 30 800 195 560
850
70 –
1 / 10 885 160 650
420
70 –
2 / 20 885 160 650
550
TE 315 735 315 260 125 240 80 220 230 160 10 118 110 135 18 50
75 –
3 / 30 925 195 660
1050
90 –
4 / 40 925 195 660
1700
80 –
2 / 20 1030 160 765
575
100 –
3 / 30 1075 195 775
1100
TE 400 900 400 310 160 300 100 270 280 199 12 150 140 167 22 85
100 –
4 / 40 1075 195 775
1800
125 –
5 / 50 1075 240 775
2750
200 –
3 / 30 1225 195 870
1400
200 –
4 / 40 1225 195 870
2200
TE 500 1025 500 385 190 355 130 325 340 242 13 190 180 202 22 130
200 –
5 / 50 1215 240 870
3400
200 –
6 / 60 1215 240 870
5400
500 –
5 / 50 1365 240 1000
3300
500 –
TE 630 6 / 60 1365 240 1190 630 465 250 440 1000 170 400 420 295 15 236 225 244 27 206
5500
500 –
7 / 70 1365 240 1000
8200
500 –
5 / 50 1500 240 1100
3800
500 –
TE 710 6 / 60 1500 240 1302 710 525 270 490 1100 190 450 470 332 15 265 255 276 27 268
6300
500 –
7 / 70 1500 240 1100
9400
*weight without thruster table 1: Data Sheet
Thruster size
1 = Ed 23/5 10 = EB 220-50
2 = Ed 30/5 20 = EB 300-50
3 = Ed 50/5 30 = EB 500-60
4 = Ed 80/6 40 = EB 800-60
5 = Ed 121/6 50 = EB 1250-60
6 = Ed 201/6 60 = EB 2000-60
7 = Ed 301/6 70 = EB 3000-60
table 2: Thruster size

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5. Installation
5.1 Installing the Brake
WARNING!
Switch off the drive before working on the brake unit. Secure the drive to prevent it being switched on
inadvertently! Secure the brake against unintended movement.
 Observe the safety information under chapter 2.2 during installation.
 Installation must be carried out with the utmost care by qualified technicians.
 Approved lifting gear and sling equipment with adequate safe working load must be made available
prior to the start of installation.
 All screw/bolt connections must be tightened to the corresponding torque.
 Before installing the brake system, all rustproofing residue and dirt must be removed from the brake
disc, console mounting surface and substructure.
CAUTION!
Observe manufacturer's information on how to handle solvents and cleaning agents safely!
CAUTION!
Oil residue or remains of rustproofing agents can substantially reduce the coefficient of friction of the
brake pads and damage the brake pads.
 Ensure the place of installation is extremely clean.

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 Adjust brake shoe clearance to 5mm larger than brake drum diameter by turning the adjusting nut of
tension rod.
 Pull base plate pin out of brake lever arm.
 Swing brake lever upwards.
 Push base plate underneath brake drum.
 Align brake in radial and axial direction.
 Swing down brake lever again and fix it to base plate by means of base plate pin.
 Install thruster.
 Finally fix base plate.
CAUTION!
Maximum permissible deviation to the brake axes +/- 0.3 mm.
Brake lever
Tension rod
Adjusting nut
Base plate pin Thruster
Base plate
Image 3: Brake Installation

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5.2 Adjusting the Brake

 Switch off release thruster.
 Adjust reserve stroke (X) of thruster by turning the adjusting nut of tension rod.
 Turn the spring adjusting nut to set the required braking torque on the scale (upper edge of the spring
pressure plate = reference edge) and, if necessary, correct the reserve stroke (X )
 Adjustment of equal clearance on both brake shoes is not required due to synchronization linkage
o Centering of the brake during installation
o No end stops on brake lever arms
o Stable configuration oft he released brake, even in case of pad wear
Tension rod adjusting

nut
Reserve stroke X
(20% of total stroke, approx. 10mm)
Spring adjusting nut
Spring tube
Torque scale
Image 4: Adjusting the brake

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5.2 Adjusting the Reserve Stroke

The reserve stroke must be set with the brake closed and installed. The thruster should first be fully retracted
and then pulled out to 20% (about 10 mm) of the total stroke by turning the tension rod adjusting nut. The total
stroke lengths are specified in the section thruster units. Dimension X is not mandatory in the drawing. It merely
serves as an indication of where the reserve stroke can be measured.
The reserve stroke prevents the brake from "stalling" and producing no brake force on the drum.
CAUTION!
Non-adjustment of reserve stroke may lead to malfunction of the brake.
CAUTION!
For all brakes with readjusting unit a continuous control of the reserve stroke is indispensable.
Depending on the application an additional manual compensation of the lining wear might be required.
Brake shoe pin
Brake shoe clamping spring
Image 5: Adjusting the reserve stroke

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5.3 Adjusting the Wear Compensator

1. Press the driving pin of the compensator all the way down in the guide hole.
2. Unscrew adjusting screw in knee lever until guide hole is clear.
3. Release the brake several times and let it re-engage, the adjustment screw of the wear compensator is
now positioned.
4. Turn the adjusting screw in the knee lever back in until there is a small clearance of about 0.2 mm
between screw and the driving pin.
5. Tighten the lock nut.
Adjusting screw
Lock nut
Driving pin
Guide hole
Image 6: Adjustment of wear compensator

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5.3 Commissioning / Bedding in of the Brake Linings
NOTE!
After proper implementation and observance of all instructions and safety instructions, commissioning
can take place.
A correct setting and alignment of the brake towards the brake drum is a prerequisite for commissioning.
To achieve an optimum contact pattern, as a prerequisite for the maximum braking force, the brake pads must
be bedded in on the brake drum.
We recommend performing the bedding in - process as described below:
1. Adjust the brake with an enlarged air gap c = 7mm on each side.
2. Drive the engine at rated speed against the closed brake. Duration approx. 5-6 revolutions of
the brake drum.
3. Check the temperature on the brake pad
CAUTION!
This air gap adjustment is only allowed for the bedding in - process of the brake pads! The air gap
adjustment during operation must be in accordance with the dimension sheet.
CAUTION!
Protect from burning by hot parts!
NOTE!
Do not exceed a maximum lining temperature of 250° C when bedding in. If necessary, allow drum and
pad to cool down to ambient temperature.
4. Repeat procedures 1. to 3. five times.
Release the brake between the bedding in repetitions.
a. Check the limit switches / sensors
b. Check the screw connections
c. Watch for noises
d. Watch for leakage

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5. Check the wear pattern of the brake pad. The bedding in - process is completed when there is at least 70%
-75% contact pattern
6. Set brake with agreed clearance and carry out load test.
- Three emergency stops with test load and lowering speed approx. 33% of the rated speed
- Emergency stop with test load and rated speed
NOTE!
Pay attention to the temperature development again!
7. If the required braking distance is reached during the last emergency stop braking, the commissioning
process can be completed.
NOTE!
If deviations are detected, no release for operation can take place.
8. The deviations must be checked or corrected. Then repeat the commissioning process.
NOTE!
The test results and the execution of the emergency stop braking must be documented in a test report.
After observing these points and ensuring all brake functions, the release for the operation of the brake
in the entire system can be made.

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6. Maintenance
6.1 Routine Inspections
The following inspections are stipulated by the manufacturer to maintain operational safety.
Daily checks:
 Visually inspect brake linings and brake drum.
 Visually inspect hydraulic unit/thruster and threaded pipe connections for leaks.
Weekly checks:
 Visually inspect all bolted connections.
 Check all add-on parts (switches & sensors).
 Check the reserve stroke.
Checks every 3 – 6 months:
 Inspect entire brake system.
 Check electrical cables.
 Check brake linings and brake drum.
CAUTION!
There is an enormous danger of crushing during all installation and maintenance work!

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6.2 Replacing the Brake Shoes

 The replacement of brake shoes can be done without disassembling the brake:
 Unscrew the tension rod from the wear compensator by turning the adjusting nut so that the new brake
shoes can be fitted.
 Release the brake shoe clamp springs and remove the brake shoe pins.
 Swing out brake shoes upwards.
 Mount new brake shoes in reverse order.
 Tighten brake shoe clamping spring again.
 Adjust the brake again.
Brake shoe pin
Brake shoe clamping spring
Image 7: Replacing of Brake Shoes

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7. Disassembly
7.1 Preparation
Observe the utmost cleanliness while working on the brake system.
The components should be disassembled only in a room that is free of dust and dirt. Each component must be
cleaned, dried and freshly greased prior to reassembly. Dirt particles considerably reduce the service life of
bearing points and can cause damage to the bushings.
7.2 Disassembly
CAUTION!
Before starting any service work, switch off the drive unit and secure it against unintended power on.
WARNING!
The disassembly has to be done by qualified and well instructed personal only. Only use tested and
approved lifting gear.
1. Remove the connections of the sensors and the thruster.
2. The disassembly of the brake takes place in the reverse order compared to the assembly in chapter 5.

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8. Spare Parts Stock

Keeping a stock of the most important spare and wearing parts is an important prerequisite for ensuring the
brake system remains fully operational at all times. In case of need of spare parts contact us, we will be pleased
to assist you.
Image 8: Spare Parts
number item
1 ……………………….Brake shoe complete
2 ……………………..Brake lining with rivets
3 ……………………….Set of pins, complete
4 ……………………Set of bushes, complete
5 ……………………………Torque spring unit
6 ……………………. Tension rod with shackle
7 ……………………………………….Thruster
8 ……………………Lining wear compensator
Table 3: Spare Parts

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NOTE!
We shall accept no liability and warranty claims for damage that arises from the use of non-genuine
SIBRE spare parts!
In case of order please advise the name and the quantity of your required parts, as well as the EXACT
description of the affected brake!

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9. Disposal
Disposal of the product should only be carried out by a disposal company that has the necessary know-how and
experience in the field of waste disposal.
NOTE!
Also refer to the information provided by the release unit suppliers!
Brake linings The brake linings consist of a steel support plate, to which an organic material is
attached. The material is free of asbestos and lead and can therefore be
classified as metal scrap.
Hydraulic fluid Hydraulic fluid must be disposed of professionally in order to avoid polluting the
environment. The oil must be drained from the brake and the hydraulic unit and
filled into special vessels to dispatch it to a specialized disposal company.
Sealings The sealings in this brake are made from polyurethane (PUR) and NBR. They
can be classified as normal waste.
Electronic components If the brake is equipped with electronical components such as sensors or
control units, these components must be disposed of together with electronics
scrap.
Brake The brake frame is generally manufactured of machined steel. Once the
sealings, electronical components and/or hydraulic fluid have been removed,
the brake can be classified as metal scrap.

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10. Lists
10.1 List of Images
Image 1: Main Components .................................................................................................................... 8

Image 2: Data sheet................................................................................................................................. 9
Image 3: Brake Installation .................................................................................................................... 12
Image 4: Adjusting the Brake ................................................................................................................ 13
Image 5: Adjusting the Reserve Stroke ................................................................................................. 14
Image 6: Adjusting the Pad Wear Compensator ................................................................................... 15
Image 7: Replacing Brake Shoes ............................................................................................................ 19
Image 8: Spare Parts.............................................................................................................................. 21
10.2 List of Tables
Table 1: Data sheet................................................................................................................................ 10

Table 2: Thruster sizes ........................................................................................................................... 10
Table 3: Spare Parts ............................................................................................................................... 21


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Process crane documentation Name : MHP 231

Installation and Operation instructions Datum : 24.08.2018

Installation and Operating Instructions

For drum brake series TE

Drum Brake Series TE Page 1 / 24

Drum Brake Series TE Page 2 / 24

In accordance with the Machinery Directive 2006/42/EC, the manufacturer:

SIBRE Siegerland-Bremsen GmbH

Auf der Stücke 1-5, D-35708 Haiger

Telephone: +49 (0) 2773 9400-0

Fax: +49 (0) 2773 9400-10

Drum Brake Series TE Page 3 / 24

2.1 Identification of Safety information in the Operating Instructions

Drum Brake Series TE Page 4 / 24

2.2 Use for intended Purpose

The product described in this operating instruction:

 may be used only for the ordered and confirmed purposes.

Drum Brake Series TE Page 5 / 24

2.3 Safety Information

o ensure operational safety and reliability of the product.

 Spare parts must be procured from SIBRE only.

Drum Brake Series TE Page 6 / 24

3. Transportation and Storage

3.1 Scope of Delivery

Drum Brake Series TE Page 7 / 24

4.1 Design and Functional Principle of the Brake

shackle knee lever

brake lever torque spring unit

brake shoe with

Image 1: Main Components

Drum Brake Series TE Page 8 / 24

4.2 Data Sheet

Image 2: Data Sheet

Drum Brake Series TE Page 9 / 24

Drum Brake Series TE Page 10 / 24

5.1 Installing the Brake

 Observe the safety information under chapter 2.2 during installation.

 All screw/bolt connections must be tightened to the corresponding torque.

 Ensure the place of installation is extremely clean.

Drum Brake Series TE Page 11 / 24

 Pull base plate pin out of brake lever arm.

 Swing brake lever upwards.

 Push base plate underneath brake drum.

 Align brake in radial and axial direction.

 Finally fix base plate.

Drum Brake Series TE Page 12 / 24

5.2 Adjusting the Brake

o Centering of the brake during installation

o No end stops on brake lever arms

o Stable configuration oft he released brake, even in case of pad wear

Tension rod adjusting

Spring adjusting nut

Image 4: Adjusting the brake

Drum Brake Series TE Page 13 / 24

5.2 Adjusting the Reserve Stroke

Brake shoe pin

Brake shoe clamping spring

Image 5: Adjusting the reserve stroke

Drum Brake Series TE Page 14 / 24