Standard Dokumentation + SD SB16 En1!1!00

Standard-Documentation disc brake SB 16
Language: English
Content:
Dimension sheets disc brake SB 16 SB 16 mit BUEL-en

SB 16 mit ELDRO-en
Operating manual SB 16 PB-SB16-en10
Operating manual BUEL BL 22-5 / BL 30-5 PB-Buel-BG0-en3
Operating manual BUEL BL 35-5 - BL 600-8 PB-Buel-en9
Operating manual ELDRO PB-Eldro-en1
Operating manual ELHY PB-Elhy-en2
Installation instruction disc brakes PDF-002075
Technical data sheets proximity switches IG0400-en
IG0403-en
IN0136-en
2018 PINTSCH BUBENZER GmbH

www.pintschbubenzer.de
e-Mail: Info@pintschbubenzer.de
PINTSCH BUBENZER GmbH

Friedrichshüttenstr. 1
57548 Kirchen-Wehbach
Tel.: +49-2741 - 9488 - 0
Fax: +49-2741 - 9488 -44
e-Mail: info@pintschbubenzer.de
Disc Brake SB 16 MB-001270 f
21.03.2018
Dimensions and technical data Reifenrath
ca. 250 ca. 160
ca. 225 e
ca. 760
Ød
ca. 505
2
Ø
d1
Ød
4
160
17
20
170 100
k1
150 80
15 for M12
Right-hand execution Left-hand execution

4
200
230
37
270
15
*) Average static coefficient of friction

for standard material combination
The coefficient of friction is subject to fluctuations depending

on operational-, material- and ambient-conditions!
This must be considered during the selection!
All dimensions in mm
For crane brake layout use safety factors documented in the FEM 1.001, Section 1 Alterations reserved without notice
Disc Brake SB 16 MB-001214 d
19.03.2018
Dimensions and technical data Reifenrath
ca. 200 ca. 160
ca. 225 e
ca. 760
Ød
ca. 505
2
Ø
d1
Ød
4
160
17
20
170 100
k1
150 80 Right-hand execution Left-hand execution

15 for M12
4
200
230
37
270 *) Average static coefficient of friction

15
for standard material combination

The coefficient of friction is subject to fluctuations depending
on operational-, material- and ambient-conditions!
This must be considered during the selection!
All dimensions in mm
For crane brake layout use safety factors documented in the FEM 1.001, Section 1 Alterations reserved without notice
Disc brake Type:
SB 16
Operating manual- Translation
State: 12/2018
Version: 10
Index
SB 16
1 Basics ............................................................................................................................ 3
1.1 Foreword ....................................................................................................................................................... 3
1.2 Copyright ....................................................................................................................................................... 3
1.3 Guarantee and liability................................................................................................................................... 4
1.4 Conformity ..................................................................................................................................................... 4
1.5 Presentation of hazard warnings ................................................................................................................... 5
1.6 Notices and obligations of the plant operator ................................................................................................ 7
1.7 Personnel training ......................................................................................................................................... 7
1.8 Protective equipment..................................................................................................................................... 7
2 Safety ............................................................................................................................. 8
2.1 General .......................................................................................................................................................... 8
2.2 Use in accordance with the intended purpose .............................................................................................. 9
2.3 Use not in accordance with the intended purpose ........................................................................................ 9
2.4 Residual risks .............................................................................................................................................. 10
2.5 Procedure in the event of Emergency STOP or power failure .................................................................... 10
2.6 Safety notes for assembly, start-up and maintenance ................................................................................ 11
2.7 Notes on waste disposal ............................................................................................................................. 12
3 Product description .................................................................................................... 13

3.1 View of product............................................................................................................................................ 13
3.2 Function ....................................................................................................................................................... 14
3.3 Technical data ............................................................................................................................................. 15
3.4 Type plate .................................................................................................................................................... 15
3.5 State of shipment ........................................................................................................................................ 16
3.6 Storage instructions..................................................................................................................................... 16
3.7 Tool-list ........................................................................................................................................................ 17
4 Mounting of the brake ................................................................................................. 18

4.1 Preparation .................................................................................................................................................. 18
4.2 Mounting of the brake.................................................................................................................................. 19
4.3 Electrical connection ................................................................................................................................... 21
5 Set-up of the brake...................................................................................................... 22

5.1 Set braking torque ....................................................................................................................................... 22
5.2 Set reserve stroke ....................................................................................................................................... 23
5.3 Running in of the brake pads and disc ........................................................................................................ 25
5.4 Final function check..................................................................................................................................... 28
©2018 PINTSCH BUBENZER GmbH

www.pintschbubenzer.de 1
Telefon +49 (0) 2741 / 9488-0 ∙ Telefax +49 (0) 2741 / 9488-44 ∙ info@pintschbubenzer.de
Index
SB 16
5.5 Load test ...................................................................................................................................................... 29
6 Operation ..................................................................................................................... 30
6.1 Normal operation mode ............................................................................................................................... 30
6.2 Emergency stop and power failure .............................................................................................................. 31
6.3 Manual operation......................................................................................................................................... 31
6.3.1 Manual lowering of the load ................................................................................................................................ 32
6.4 Switches and sensors ................................................................................................................................. 33
7 Maintenance ................................................................................................................ 35
7.1 Maintenance schedule ................................................................................................................................ 36
7.2 Lubrication ................................................................................................................................................... 36
7.3 Cleaning ...................................................................................................................................................... 37
7.4 Maintenance of the automatic wear compensator (AWC) .......................................................................... 37
7.5 Replacement of brake pads ........................................................................................................................ 40
7.6 Replacement of switches and sensors........................................................................................................ 43
7.7 Replacement of thruster .............................................................................................................................. 44
8 Troubleshooting .......................................................................................................... 47
9 Putting out of service and disposal ........................................................................... 49

9.1 Putting out of service ................................................................................................................................... 49
9.2 Dismounting of the brake ............................................................................................................................ 49
9.3 Disposal ....................................................................................................................................................... 51
10 Spare parts .................................................................................................................. 52

10.1 Spare part list – main components .............................................................................................................. 53
10.2 Switches and sensors ................................................................................................................................. 54
11 Appendix ...................................................................................................................... 55
11.1 Data sheet ................................................................................................................................................... 55
11.2 Tightening torques for regular threads ........................................................................................................ 57
11.3 Customer support ........................................................................................................................................ 58
11.4 CE-certificate ............................................................................................................................................... 59

Basics
SB 16
1 Basics
1.1 Foreword
These Operating Instructions (OI) are an essential aid for the trouble-free assembly, commissioning, safe
operation and maintenance of this product.
Read these Operating Instructions before you assemble the product and put it into operation.
They will help you:
o to avoid danger for the fitter, operator and maintenance personnel
o to get to know the product better
o to avoid faults from incorrect operation
o to extend the service life of the product
o to avoid repair costs and downtimes
o to maintain the product properly
o to use the product efficiently.
1.2 Copyright
To avoid faults in operation and assure the trouble-free use of the product, the Operating Instructions
must always be accessible for the operating personal.
These Operating Instructions are confidential. They may only be used by authorized persons. They may
only be given to third parties with the consent in writing of PINTSCH BUBENZER GmbH.
All documents are protected by the German Copyright Law. The distribution and duplication of
documents, also parts thereof, the use and communication of the contents are prohibited unless
expressly permitted.
Any contraventions are punishable and subject to compensation. All rights for the exercise of industrial
property rights are reserved.

Basics
SB 16
1.3 Guarantee and liability
These Operating Instructions must be thoroughly read before the assembly and commissioning of the
product.
A general exclusion applies to guarantee and liability claims:
o if the product is not used in accordance with its intended purpose,
o in the case of incorrect commissioning, operation or upkeep/maintenance,
o in the case of non-observance of the notes in these Operating Instructions,
o in the case incorrect repairs,
o in the case of faulty monitoring of wearing parts,
o in the case of the structural changes without the prior agreement of PINTSCH BUBENZER GmbH,
o if damage is caused by foreign bodies.
We accept no liability for damage and operating faults resulting from operating faults or incorrect repairs
and upkeep.
Any liability is excluded for damage resulting from the failure to use genuine spare parts and accessories.
All technical information, data and notes on the operation and maintenance of the product in these
Operating Instructions correspond to the current state of the art at the time of printing. They take account
of our experience and findings up to now to the best of our knowledge.
Technical changes in the course of the further development of the product presented in these Operating
Instructions are reserved. No claims may therefore be inferred from the data, illustrations or descriptions.
1.4 Conformity
The conformity assessment is based on the applicable directives (with their relevant amending directives)
in the version at the time of commissioning. The particular directives in question can be found from the
Declaration of Conformity or Manufacturer’s Declaration.
The Declaration of Conformity or Manufacturer’s Declaration is enclosed with the product documentation.

Basics
SB 16
1.5 Presentation of hazard warnings
In these Operating Instruction, use is made of the following symbols for the presentation of hazard
warnings and notices:
DANGER!
Indicates a dangerous situation, which leads to serious injury or death.
WARNING!
Indicates a dangerous situation, which can lead to serious injury or death.
CAUTION!
Indicates a dangerous situation, which can lead to minor or fairly serious injuries and
to damage to property.
NOTICE!
Indicates a situation which can lead to damage to property. Additional important
information is also given here.

Basics
SB 16
Symbols of hazard warnings
Warning of a danger point
Warning of dangerous voltage
Warning of automatic start
Warning of cut and crush injuries
Warning of hot surfaces
Warning of environmental pollution
Warning of falling loads

Basics
SB 16
1.6 Notices and obligations of the plant operator
The Operating Instructions constitutes an important part of the product. E.g. if the product is installed in a
plant, the Operating Instructions are to be made available to the operator of the plant. The plant operator
must ensure that these Operating Instructions are always available to the operating personnel!
To protect operating personnel from health hazards and to assure the operational reliability of the
product, the plant operator is obliged to instruct its personnel in the safe and sound operation,
upkeep/maintenance and correct operation of the product. Due attention has to be paid to supervisory
and reporting obligations and special operating features.
The instructions and details in these Operating Instructions must be known and familiar to the operating
and maintenance personnel employed.
In addition to the Operating Instructions, universally valid, legal and other mandatory rulings on accident
prevention and environmental protection as well as basic safety and health requirements are to be
observed.
1.7 Personnel training
Assembly, commissioning, operating and upkeep/maintenance personnel must be adequately qualified

and trained. The responsibility for this lies exclusively with the plant operator.
1.8 Protective equipment
During all work on the product

o safety footwear is to be worn,
o close-fitting clothes are to be worn,
o long, loose hair is to be tied back or a hair net worn,
o the wearing of jewellery is prohibited,
o for work in the port, reflective clothing in compliance with ISO 471 is to be worn.

Safety
SB 16
2 Safety
2.1 General
The product has been developed and built according to the state of the art and recognized safety rules.
Nevertheless, hazards can result from the product for the operator or damage to the product and other
assets if:
o the product is operated by untrained personnel or personnel not instructed in its use,
o the product is not used in accordance with its intended purpose,
o the product is not correctly maintained or serviced,
o the safety notes in these Operating Instructions are not observed,
o the product is improperly modified or converted,
o the maintenance and inspection jobs described above are not properly carried out.
NOTE!
Any person operating, maintaining or repairing the product must have read and understood the
Safety Regulations. The Safety Regulations must be observed.
Attention must also be paid to the observance of the following regulations and provisions which can also
be additionally supplemented by Works or Internal Regulations:
o the relevant labour safety regulations,
o recognized safety rules in general use,
o country-specific regulations,
o documentations of other manufacturers accompanying the product,
o use in accordance with the intended purpose.

Safety
SB 16
2.2 Use in accordance with the intended purpose
The brakes PINTSCH BUBENZER Type SB 16 are meant exclusively as disc brakes for the conditions
specified in the order together with the designated brake disc. The brake is designed as a holding brake
and emergency brake. It is designed for dynamic braking within the limits given in section 3.3.
Use in accordance with the intended purpose includes the observance of the following notes and
warnings:
o on safety,
o on operation,
o on upkeep/maintenance,
o concerning technical specifications as described in the Operating Instructions.
2.3 Use not in accordance with the intended purpose
Any use other than the above or exceeding such is considered as not in accordance with the intended
purpose. The plant operator bears the sole liability for damage resulting from such use.
Hazards may result from the product if it is operated incorrectly or not for the intended purpose by
personnel who have not been trained and familiarized with it.
NOTE!
The product is not designed for operation in a potentially explosive environment and does not
have ATEX certification.

Safety
SB 16
2.4 Residual risks
Operating Instructions correspond to the current state of the art at the time of printing. Account is taken of
our experience and findings up to now to the best of our knowledge.
Even when all the safety regulations are observed, there remain residual hazards in the operation of the
product.
For all jobs on the brake, make sure that

o all potentially dangerous movements have completely stopped;
o the unintentional and unexpected start-up of the brake is excluded by appropriate measures;
o when there is a load on the brake, the braking and stopping action is assumed by other devices.
There are the following dangers:
o risk of crushing by moving parts
o draw-in points,
o brake lining particles can be hurled out
o components may break under excessive pressure
o The brake spring is may lead to contusions due to breaking of components when under pressure
o parts such as brake discs and pads in particular can become hot after braking.
2.5 Procedure in the event of Emergency STOP or power failure
 In the event of Emergency STOP or power failure, the brake is closed automatically.

Safety
SB 16
2.6 Safety notes for assembly, start-up and maintenance
Assembly, start-up and maintenance work on the mechanical and electrical devices may only be carried
out by authorized specialists with due observance of the safety regulations and accident prevention
regulations.
The assembly and maintenance jobs specially explained in these Operating Instructions must be carried
out in a professional manner. Only then is the trouble-free operation of the product assured.
Before starting any work at all on the brake, make sure that the drive is dead.
Before starting any work at all on the brake, make sure that the brake is dead
Electrical jobs may only be carried out by trained electricians!
For all repairs and maintenance work, use only genuine PINTSCH BUBENZER spare parts!
On completion of any maintenance work as described in these instructions, adjust the brake again to the
necessary values.
Due to their weight and construction, the components of the brake can cause serious injury if they fall.
During work on the brake, all dismantled parts must be secured against falling.
The brake may only be taken apart to the extent prescribed by these Operating Instructions. Any further
dismantling of assemblies is prohibited.
If unusual changes at the brake are noticed, switch off the braking current immediately. Report the
unusual changes, e.g., a strange smell from the brake, without delay to your superior or contact the After-
Sales Service!
WARNING!
Danger from sudden start-up of the plant
All maintenance work must only be carried out with the drive at a standstill and secured.

Safety
SB 16
2.7 Notes on waste disposal
In the use and handling of the product, due attention must be paid to the national and communal legal
regulations concerning environment protection and waste disposal. Internal regulations are to be
compared with the corresponding data issued by the manufacturer and upgraded if necessary.
WARNING!
Risk of environmental pollution.
Due attention is to be paid to the environmentally friendly disposal of consumables, lubricants,

auxiliaries and oily components.
Electrical waste is to be collected separately and passed on for recycling.

Product description
SB 16
3 Product description
3.1 View of product
Main components
6.1
3.14
2.7
5
2.14 2.8
6.1
2
No Item No Item
2 AWC 3 Spring tube
2.7 Catch 3.14 Adjusting nut - torque
2.8 Catch pin 4 Brake pad carrier with brake pad
2.14 Adjusting nut - stroke 5 Thruster
6.1 Manual release lever
Note: Please refer to the following page for an overview of the proximity switches.

Product description
SB 16
Switches and sensors
7.21
7.23 7.24
7.22
Pos. Item Pos. Item

7.21 Proximity switch – set control 7.21 Proximity switch – wear control
7.22 Proximity switch – release control 7.24 Proximity switch – manual release control
Notes: The proximity switches are optional. Please refer to scope of supply.
3.2 Function
The brakes PINTSCH BUBENZER Type SB 16 are meant exclusively as disc brakes for the conditions
specified in the order together with the designated brake disc. The brake is designed as a holding brake
and emergency brake. It is designed for dynamic braking within the limits given in the section technical
data.
This version of the brake is not suitable for use in areas with explosion hazards and not certified
according to ATEX.
The SB 16 may be connected to a suitable control system (e.g. Pintsch Bubenzer CMB2).
Function
Opening: By electrohydraulic thruster
Setting: By spring force (fail safe installation)
Braking torque Adjustable
Wear compensation Automatically by AWC
Centring Automatically by AC
Manual Release Manual release lever - Option: Locking in open position
Sensors (optional) Proximity switch release control
Proximity switch set control
Proximity switch manual release control
Proximity switch brake pad wear
Linings Sintered metal
Organic

Product description
SB 16
3.3 Technical data
NOTE!
Please also refer to the data sheet in the appendix
The data given below are only valid if the brake is equipped with the designated original PINTSCH-
BUBENZER linings
With organic With sintered

Technical data for steel brake discs linings
linings
Maximum running speed 50 m/s 90 m/s

Maximum permissible inertia temperature at the brake
disc(frequent stop braking and permanent braking) 250°C 250°C
Maximum permissible limit temperature at equilibrium during

braking (frequent stop braking) 450°C 450°C
Maximum permissible limit temperature of the surface during
braking (onetime emergency stop braking) 600°C 700°C
With organic With sintered

Technical data for LiTec brake discs linings
linings

Maximum permissible inertia temperature at the brake
disc(frequent stop braking and permanent braking) 150°C 150°C
Maximum permissible limit temperature at equilibrium during

braking (frequent stop braking) 180°C 180°C
Maximum permissible limit temperature of the surface during
braking (onetime emergency stop braking) 200°C 200°C
ATTENTION: The maximum permissible limit temperatures of 200 °C (LiTec brake discs) and 600,
respectively 700 °C (steel brake discs) must not be exceeded in no case. After reaching the limit
temperatures, the brake discs must be cooled down sufficiently until a safety operation of the system
can be guaranteed!
The temperature has a significant influence on the coefficient of friction. With increasing
temperatures, the coefficient of friction and thus the braking torque decreases. At
temperatures above 200 °C, the coefficient of friction may drop by up to 50%.
3.4 Type plate
o If you have any questions about the brake or when ordering spare parts, please give us the complete
brake type and the serial number according to the type plate.
o The type plate is mounted at the spring tube.

Product description
SB 16
3.5 State of shipment
o The brake is shipped ready to mount and tested.

o The brake is shipped with spring under tension, if a thruster is mounted
3.6 Storage instructions
IMPORTANT!
Depending on the thruster the complete brake can have

a weight of over50 Kg. If the brake is not lifted with
correct lifting devices and / or lifting it at other points
than the designated ones, the brake may be damaged.
Always use proper lifting devices and attach the brake

at the designated ore.
Heed the following instructions and notes for the correct storage:
o Store and / or transport the brakes dust- and waterproof with drying agent until installation.
o Protect the brake against external damages during the complete storage- / transport-period.
In case of additional painting, do NOT contaminate:

o Brake disc surfaces
o Brake pads
o Spindle and AWC

Product description
SB 16
o Hinges or joints
o Rod of the thruster
o Other movable parts
o Electrical components
o Signs and plates
3.7 Tool-list
NOTE!
Please note, that you need a torque wrench to tighten some of the screws and bolts correctly.
Function Tool
Mounting bolts Wrench 19 mm*
Braking torque Wrench 19 mm
Reserve stroke Spanner socket 22 mm
Catch Allen key 4 mm
Brake pads Spanner socket 10 mm + extension
Crosspiece Punch 5 mm
Nuts – release- / set- / wear-control Wrench 24 mm
Screws manual release-control Flat screwdriver 0.8 x 4 mm
Spindle replacement Allen key 3 mm and Allen key 6 mm
* The mounting bolts are not part of our supply. Thus, it may be that other bolts are used (e.g.
imperial system).

Mounting of the brake
SB 16
4 Mounting of the brake
WARNING
A sudden start-up of the installation endangers the life of the maintenance personnel!
Secure the drive and the installation against any accidental movement before starting any work!
4.1 Preparation
Make sure that:

o The brake disc runs true
o The brake disc surface as well as the brake pads are clean and free from dirt and grease
o The brake disc is free of rust protection.
o Check positions of the mounting-bores acc. to drawing (appendix).
o Check evenness and cleanliness of the mounting surface.
o Check cleanliness of the brake pads
NOTE!
It is forbidden to install stop bars or similar devices in the mounting area as this may block hinder
the correct positioning of the brake.
IMPORTANT
Depending on the thruster, the complete brake can have a
weight of over50 Kg. If the brake is not lifted with correct
lifting devices and / or lifted at other points than the
designated ones, the brake may be damaged.
Always use proper lifting devices and attach the brake at the
designated ore.

SB 16
4.2 Mounting of the brake
CAUTION!
Danger of injury due to moving parts.
The brake must be secured against closing while people are working on it.
 Unscrew screw (2.23).

 Dismount catch (2.7).
 Mount extension tube onto manual release lever (6.1). 6.1
2.23
 Manually release brake.
 Dismount extension-tube (6.1) and store it safely in its place.
2.7
 Mount brake onto brake disc according to drawing (also refer ZP

to data sheet in the appendix).
 The centre line of the brake disc must coincide with the centre
line of the brake.
 Tolerance: 2 mm.
 Use main pins as reference
ZP
 Use shims to adjust differences in height if necessary.
 Do not use washers or small shims with a small contact
surface.
 Bolts and shims are not included in our scope of supply.
 The brake disc's outer diameter must exceed the brake pads 2
mm. Brake pad 2 mm
o Note: Use outline of the brake pad, not of the brake pad
carrier!
Brake disc

SB 16
 Screw bolts with shims 200 HV / 300 HV (DIN 125 / DIN EN

ISO 7090) into the base but do not tighten them yet.
 Bolts and shims are not included in our scope of supply.
 Push released brake with the brake pad of the spring-tube-
side as far as possible towards the brake disc.
 Mount extension tube onto manual release lever (6.1).

 Manually close brake.
 Check, if the centring role has full contact with the camdisc
(2.17).
 If this is not the case, realign brake.
 Check air gaps visually, when the brake is released.
Note:
 Do not grease cam disc (2.16) and roll (2.17), just keep it 2.17 2.16
clean.
NOTE!
The air gaps may not be completely equal. It is important that there is an air gap between the
brake pads and brake disc.
The brake is not released completely by the manual release lever. This can only be done when the
brake is opened by the thruster.
 Tighten mounting bolts with a torque wrench to the nominal

torque (refer to appendix).
o M12 – 8.8 / 10.9 : 60 Nm ( = 0,12).

SB 16
4.3 Electrical connection
DANGER!
The applied electrical voltages are dangerous to life!
The electrical connection and all other electrical tasks must only be done by a trained electrician!
IMPORTANT!
Please also refer to the note in the operating manual of the thruster and the wiring diagram on the
inside of the terminal-box-cover.
 The thruster has to be connected acc. to the diagram given in

the corresponding thruster manual.
 Connect thruster at terminal box (5.8) according to supplier’s
data. 5.8
 Please refer to the thruster manual for further information.
 Please refer to the type plate for the electrical data. 5
 Connections have to be flexible, as the brake must move
freely.
 Tighten cable connections.
 Connect proximity switches according to the corresponding data sheets (contained in this
documentation package).

Set-up of the brake
SB 16
5 Set-up of the brake
WARNING
A sudden startup of the installation endangers the life of the maintenance personnel!
5.1 Set braking torque
INFORMATION!
The set contact force must not exceed the values given in the appendix.
The type plate shows the maximum torque (data by PINTSCH BUBENZER) and – if demanded by the
customer – the set torque (data given by the installation builder).
Note: Older versions only display the maximum torque!
 Refer to crane- / installation-builders data.
 In case this data is not given:
 Set braking torque to 100%.
 Clarify necessary torque and set it as soon as possible.
 Rotate nut (3.14) clockwise until the upper edge (3.4) of the
torque indicator shows the nominal braking torque (3.20).
 Open and close the brake.
 Check setting. 3.14
 Readjust, if necessary.
3.20
3.4

Set-up of the brake
SB 16
5.2 Set reserve stroke
WARNING
Danger of injury due to moving parts.
The brake must be secured against closing while people are working on it.
IMPORTANT
A counter clockwise turn of nut (2.14) may damage the AWC when the catch (2.7) is mounted!
To avoid this follow the instructions.
 The stroke can be checked at the piston rod (5.10) of the

thruster (5).
5.10
 The various thrusters ( /6 or /8 and /10) differ at the area of the
rod.
 Adjust and check the stroke according to the correct type.
5
Ed ***/5 / 6 Thruster
Buel-Thruster
EB ****/50 /60 Thruster
5.10
S 5.10 S

Set-up of the brake
SB 16
Increase reserve stroke:

 Turn Nut (2.14) clockwise, until the piston rod of the thruster
has risen to the necessary value for S.
 Check at ***/6 thrusters: The lower edge of the cap has to
coincide with the centre of the notch „10“ (5.10). 2.14
 Open and close brake.
 Check measurement S = „S1“
 Reset stroke with brake open, if necessary.
Decrease reserve stroke:

 Turn Nut (2.14) counter-clockwise, until the piston rod of the
thruster has risen to the necessary value for S.
 Check at ***/6 thrusters: The lower edge of the cap has to
coincide with the centre of the notch „10“ (5.11). 2.14
 Reset stroke with brake open, if necessary
After finishing all tasks:

 Make sure the catch (2.7) is reinstalled correctly. 2.23 3.14
 The catch pin (2.8) has to be within the catch (2.7).
 Tighten screw (2.23).
 Open and close brake until the AWC is not adjusting anymore.
 Reset stroke, if necessary. 2.8
2.7
2.14
 Check braking torque
3.14
3.20 3.4

Set-up of the brake
SB 16
S = S0 = Piston rod S = S1= S = S2=

Thruster - Type
in lowest pos. Brake set Brake released
BL 22-5 41 mm 51 mm 91 mm
BL 30-5 49 mm 59 mm 99 mm
BL 35-5 49 mm 59 mm 99 mm
ED 23/5 38 mm 48 mm 88 mm
ED 30/5 49 mm 59 mm 99 mm
EB 120/40 31 mm 41 mm 71 mm
EB 220/50 41 mm 51 mm 91 mm
EB 300/50 47 mm 57 mm 97 mm
Tolerance S1: + 3 mm / 3 mm – short stroke thrusters
IMPORTANT
Do not disengage the automatic wear compensator in normal operation, as otherwise lining wear
must be compensated manually!
5.3 Running in of the brake pads and disc
WARNING!
Brake disc and brake pads are heated up during operation. Danger of Burning.
Allow brake and brake disc to cool down before commencing any work!
CAUTION!
In case the motor starts running with the brake closed, the brake may be damaged due to
overload!
Make sure this is situation cannot occur!
WARNING!
Do not exceed technical data / limitations!
To help preventing damages to the brake the brake must not be operated outside its technical
limits even during running in. Heed the data given in the manuals and data sheets
DANGER!
The correct setting of the brake is essential for a safe operation of the brake!
After running in the brake pads commence a LOAD TEST according to the applicable regulations
to make sure the brake is properly set!

Set-up of the brake
SB 16
The running in of the 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. The brake can be damaged when it is
run in under unsuitable conditions!
Do not exceed the following values when running in.
Technical data for running in (steel discs) With organic linings With sintered linings

Maximum permissible brake disc temperature 250°C 250°C
Maximum braking time (per braking)* 10 Sec. 15 Sec.
Technical data for running in (LiTec discs) With organic linings With sintered linings

Maximum permissible brake disc temperature 150°C 150°C
Maximum braking time (per braking)* 5 Sec. 5 Sec.
*The maximum braking time depends on running speed, contact force/braking torque and temperature
and therefore can only be understood as an approximate value.
ATTENTION: At all following described running in procedures, the maximum permissible brake disc
temperature must not be exceeded. Therefore the brake disc temperature must be checked at suitable
intervals during the running in procedures and if necessary the braking times, the cooling down times and
the number of successive braking must be accommodated in such a way, that an exceeding of the
maximum permissible brake disc temperature will be prevented!
NOTE!
For the brake at the boom hoist, a “soft” running in procedure is advised.
During the running in the hydraulic safety, brakes have to remain open.
Choose one of the following procedures.
DANGER!
New brake pads / brake discs cannot transfer the full braking torque. Thus the load may drop,
even when the service brakes are closed.
Make sure the hydraulic safety brakes instantly set in this case (2nd operator at the ball valve of
the power unit)!

Set-up of the brake
SB 16
 To make sure the brake pads (4) are completely run in;
dismount them to check the contact pattern. 2.23
 At least 70 % of the contact surface have to be run in.
 Set proximity switches Release- / Set-control out of order.
 Unscrew screw (2.23).
2.7
Running in under load

 Load drive with approx. half rated load.
 Open safety brakes and keep them open.
 Run drive with half lowering speed.
 Carry out approx. 10 to 15 emergency-stops.
 Repeat procedure several times at gradually increasing speed up to maximum speed.
 Check reserve stroke at the thruster.
 Readjust if necessary.
 Load drive with rated load.
 Run drive with half lowering speed.
 Carry out approx. 10 to 15 emergency-stops.
Running-in with brake applied

 Attention: Do not brake longer than 5 seconds!
 Open the brake between the braking and let it cool down for about one minute.
 Set braking torque to 50% of the nominal value (3.14)
 Run drive motor with half speed against the closed brake for approx. 5 cycles.
 Release brake after each cycle.
 Increase braking torque to 75 % of the required braking torque.
 Run drive motor with full speed against the closed brake for approx. 5 cycles.
 Adjust braking torque to 100 %.
 Run drive motor with full speed against the closed brake for approx. 5 cycles.
Running in with main spindle

 Set braking torque to 50% of the nominal value (3.14)
 Let motor run on half nominal speed.
 Close brake by turning the adjusting nut (2.14) clockwise, until 3.14
the brake pads make contact with the brake disc.
 Open and close brake several times (2.14) until the complete 2.14
brake pad surface of the brake pad is run in.
 Dismount brake pad (4) to check contact pattern

Set-up of the brake
SB 16
NOTE!
After the running in procedure the setting (stroke, torque, air gaps) has to be rechecked and
maybe reset, as there might be changes due to the running in procedure.
 Make sure you do not mix them up, when remounting them.
 Reset reserve stroke (2.14). 3.14

 Reset braking torque (3.14). 2.23
 Remount catch (2.7).
 Make sure the catch (2.7) is reinstalled correctly.
2.8
 Check measurement S = „S1“ 2.7
 Reset stroke, if necessary.
2.14
5.4 Final function check
WARNING
Make sure the brake settings are correct, especially after commencing a full running in procedure
Item Refer to section

Brake aligned correctly 4.2
Mounting bolts tightened with nominal torque 4.2
Electrical connection of the thruster 4.3
Electrical connection of the sensors 4.3
Signals of sensors correct 6.4
Brake torque correct 5.1
Air gaps at both brake pads 4.2
Brake pads aligned correctly 4.4
Reserve stroke correct 5.2
Catch mounted (Catch pin inside catch) 5.2
AWC is not adjusting any more 5.2
Stopping distance correct (Load test) 5.3 / 5.5
* = depending on the mounting situation it might not be possible to visually check the air gaps. In this
case use a feeler gauge 0.5-0.8 mm.

Set-up of the brake
SB 16
5.5 Load test
DANGER!
Commence a LOAD TEST according to the applicable regulations to make sure the brake is
properly set!
IMPORTANT!
Observe the valid laws, regulations and end users specifications.
These may vary from country to country.

To finish Setup:
 Run load test according to crane supplier’s specification!
 Repeat running in procedure, if the required braking time or braking distance is not reached.
 Readjust stroke, if necessary.

Operation
SB 16
6 Operation
CAUTION!
Danger of injury from moving parts of the brake (e.g. when the brake sets).
Stay clear of the danger zone of the brake while the installation is running. It is the duty of the
operator to close off or enclose this area properly.
CAUTION!
Danger of pulling in due to moving rotating parts (brake disc).
Stay clear of the danger zone of the brake while the installation is running.
CAUTION!
Danger of burning due to hot surfaces and hot particles of the brake pad.
Brake pads and –disc must not be used over their maximum allowable temperature.
During the braking the following effects may occur:

o There may be an increased noise emission due to the friction of the brake pads on the brake disc.
o There may be vibrations, e.g. due to bad alignment.
o Brake dust is emitted into the atmosphere.
6.1 Normal operation mode
o The brake is normally (not energized) closed.

o In normal operation mode the following states are possible:
State of Thruster State of brake

Thruster not energized Brake set
Thruster energized Brake opens and remains open
Thruster is being switched off Brake sets automatically
Power down, emergency stop Brake sets automatically

Operation
SB 16
6.2 Emergency stop and power failure
 In case of a power failure or after the EMERGENCY-STOP has been activated, the brake
automatically closes via spring force.
 The brake remains closed.
6.3 Manual operation
DANGER!
Mortal Danger because of suspended load!
Release brake SLOWLY, so an attached load cannot move out of control!
Always watch the load so you do not miss the point, where the brake releases For this a 2nd
operator is necessary. One operator watches the load and sets the time for the releasing and
setting of the brake, the second operator opens or closes the brake with the manual release lever.
WARNING!
Danger due to a sudden starting of the drive in an unsafe condition. When using the manual
release lever, there is no safety device active anymore!
All tasks must only be carried out when the drive is at a standstill and secured.
Always release the brake carefully, so nothing can move out of control.
WARNING!
The Manual release lever is not suited to keep the brake open for maintenance tasks.
WARNING!
The manual release lever can be executed so it locks in the open position and the brake remains
open, even if you let go of the lever in that position. This state is not safe for the lowering of the
load!
Never keep the manual release lever locked in the open position during manual release!
By means of the lever the brake may be released manually in case of an emergency-situation, e.g. to
lower a load after an emergency stop.
The manual release lever may be equipped with a proximity switch „manual release control (7.24).

Operation
SB 16
 Mount extension tube (6.2) at manual release lever.

 Pull the lever upwards SLOWLY to open the brake (arrow). If
the lever is released, the brake automatically closes. 6.1
 If the lever is released before it is locked in the final position,
the brake automatically closes.
 After finishing the releasing:
 Set brake manually
6.3
 Dismount extension-tube (6.2) and store it safely in its place.
6.3.1 Manual lowering of the load
ATTENTION! Incorrect manual lowering of the load may cause the brake disc temperature to rise
extremely rapidly, resulting in thermal overload or breakage of the brake disc. There is danger to your life!
It is imperative to make sure that the limit temperature is never exceeded during the manual
lowering of the load.
The following description gives recommendations how to manually operate service and emergency
brakes in case of an emergency lowering process.
Please assure that the brakes have been sized according to the applicable relevant crane standards
(FEM 1.001, DIN EN 13135, DIN EN 14492, …).
 Make sure that all brakes can be operated safely without any interference for hand lever operation.
Operators should be in safe distance of rotating and moving parts.
 A visual brake check needs to be performed (brake settings, damages, pollution of brake disc and
linings) and the real operation may only be started, if the brake system is in a proper condition!
 The brake disc temperature shall be measured in the friction zone by use of a contact thermometer
before the lowering process is started.
 Do not start to lower the load until the brake disc temperature is below
o 100 °C for steel brake discs
o 80 °C for LiTec® brake discs
 Each brake must be operated by one person separately! Another person has to observe the load
permanently.
 Open the emergency brakes first.
 Open service brake (s) slightly until the disc is starting to turn. As soon as the disc is turning service
brake(s) has/have to be closed. (*)
 Measure the brake disc temperature in the friction zone after each lowering of the load.
The maximum permissible brake disc temperature is:

o For steel brake discs: 250 °C
o For LiTec® brake discs: 180 °C
 Once the maximum brake disc temperature is reached, the brake disc has to be cooled down
sufficiently! Check the brake disc and linings for damages.
 Before starting the next lowering try, the brake disc temperature must be below
o 100 °C for steel brake discs
o 80 °C for LiTec® brake discs

Operation
SB 16
 Repeat the last four points until the load has been grounded.
In the event of slightest doubt that the brake or other equipment is not in proper condition or
other reasonable doubts in the practicability of the process it is necessary to stop immediately
lowering or to use additional cranes (e.g. mobile harbor crane) to lower the load.
In case the load cannot be stopped by the service brakes, the emergency brake(s) has/have to be closed
immediately.
(*): For manual release levers with stop (locking position):
 Do never open the hand lever to the locked position!
6.4 Switches and sensors
CAUTION!
In case the brake has been equipped with switches and / or sensors, it is not allowed to put these
out of operation or bridge them.
The data supplied by the sensors has to be processes in the installations control unit by the
customer.
Release- and set-control

When the brake is released, the actuating lever (7.4) moves
upwards. 7.22
 The lever (7.4) moves into the sensing range of the proximity
switch release control (7.22).
 The lever (7.4) moves away from the proximity switch set
control (7.21). 7.21 7.4
 The proximity switch release control (7.22) is actuated when
the brake is completely released.
 The proximity switch set control (7.21) is idle
When the brake is set the actuating lever (7.4) moves downwards
 The lever (7.4) moves into the sensing range of the proximity
switch set control (7.21).
 The lever (7.4) moves away from the proximity switch release
control (7.22).
 The proximity switch set control (7.21) is actuated when the
brake is completely set.
 The proximity switch release control (7.22) is idle

Operation
SB 16
Wear control
2.1
The proximity switch is screwed (7.23) onto the crosspiece (2.16)
of the AWC.
 When the brake is set correctly, the switch is not actuated.
 With growing wear, the spindle (2) moves into the crosspiece
(2.16).
 As soon as the wear reaches the critical value, the switch
(7.23) is actuated. 7.23
Manual release control

6.1
The proximity switch (7.24) is mounted at the spring tube
 When the brake is manually released, the manual release
lever (6.1) moves in front of the switch (7.24).
 When the brake is manually released, the switch (7.24) is
actuated.
 As soon as the lever (6.1) moves back, the proximity switch
7.24
(7.24) is idle again.

Maintenance
SB 16
7 Maintenance
DANGER!
During the maintenance the brake is not active. The overall braking force of the installation is
reduced!
Secure the drive and the installation against all accidental movements!
WARNING!
The Installation has to shut down during the cleaning process and has to be secured against
switching on again.
WARNING!
IMPORTANT!
Spiral springs have to be replaced after 2 Million cycles. After that the full braking force cannot be
guaranteed anymore!
NOTE!
After a longer period of standstill, the surface of the linings can accumulate dirt and thus the
available braking torque will be reduced. Keep the brake pads and disc surface clean, e.g. by
performing a dynamic brake test.
NOTE!
All maintenance tasks must only be executed by trained and designated personnel!
Cotter pins at pins have to be opened, so they cannot fall out.

Maintenance
SB 16
7.1 Maintenance schedule
Interval [operating hours]

Maintenance tasks (Holding brakes without
(dynamic brakes)
dynamic braking)
Function of the brake/brake system 100 - 150 450 or monthly
Brake shoe lift-off 100 - 150 450 or monthly
Lining wear/lining thickness 100 - 150 450 or monthly
General state of the brake 100 - 150 450 or monthly
Thruster reserve stroke 100 - 150 450 or monthly
Brake spring tension (torque) 100 - 150 450 or monthly
Adjustment of proximity switches, hand release
100 - 150 450 or monthly
devices and other optional equipment
Easy mobility of the brake linkage 100 - 150 450 or monthly
State of the automatic wear compensator 100 - 150 450 or monthly
Condition of the brake disc 100 - 150 450 or monthly
Check the brake/brake system outside the regular inspection intervals if:
 Prolonged braking times or -distances appear
 Extreme operating conditions appear:
Overspeeding of the brake disc
And/or excessive braking times
 A proximity switch indicates lining wear or lack of releasing stroke
 After a longer period of brake-standstill or drive standstill.
 An emergency stop occurred.
NOTE!
In case the brake is used as holding brake or with low dynamic braking requirement, the surface
of the sintered lining will accumulate dirt and thus the available braking torque will be reduced.
Keep the brake pads and disc surface clean, e.g. by performing a dynamic brake test.
7.2 Lubrication
Because of the maintenance-free bushings installed on the brake, no lubrication is needed. Neither
additional lubrication nor greasing is allowed.

Maintenance
SB 16
7.3 Cleaning
WARNING!
Danger due to chemical substances.
Do not use corrosive or acidic agents to clean the brake. Only use fat-dissolving cleaners (e.g.
brake cleaner) and proper cleaning materials like cloth. The cleaning must be carried out with
proper tools and agents. Never use tools like high-pressure cleaners or a wire brush.
The braking force can only be transferred to the brake drum when both contact surfaces (brake disc and
brake pads) are clean.
 Make sure they are free from fat, oil, rust and other contaminations.
 Keep all movable parts of the brake clean
 The brake itself has to be kept clean as well.
7.4 Maintenance of the automatic wear compensator (AWC)
The catch (2.7) and the freewheel (2.6) may be object to wear. Recognized by a constant reduction of the
reserve stroke in case of lining wear, although the AWC is actuated. Procedure:
 Rotate nut (2.14) clockwise to compensate lining wear and thus the reduced reserve stroke.
 Replace worn parts resp. the complete AWC unit as soon as possible!
NOTE!
o For this task, two persons are necessary.
o Store all removed parts in the correct order of assembly.
 Loosen screw (2.23).

2.23 3.14
 Release brake spring: Turn nut (3.14) counter clockwise.
 Turn nut (2.14) counter clockwise.
2.8
2.7
2.14

Maintenance
SB 16
 Loosen screws (2.9) at special nut (2.10).

 Do not unscrew completely.
2.9
2.10

 Pull special nut (2.10), Belleville-washers (2.11) and spacer- 2.16
tubes (2.12) of the spindle.
2.17
 Please store them in the correct order for the re-mounting (see
below).
 Pull spindle unit (2) out of the crosspiece.
 Check mounting area for cleanliness. Clean, if necessary. 2.14
 Grease new spindle unit (2.1).
 Insert new spindle unit (2.1) into crosspiece. 2.1
 Loosen cotter pin (2.36).

 Pull pin (2.25) out of crosspiece (2.16). 2.16
 Replace crosspiece (2.16).
2.36
 Carefully insert new pin (2.25) into brake levers and cross
piece.
 Make sure the pin (2.25) is aligned correctly. The thread has to
coincide with the bore in the crosspiece (2.16).
 Retighten holding screw (2.37).
2.25
 Loosen holding screw (2.39).

 Pull pin (2.38) out of crosspiece.
2.38
2.39

Maintenance
SB 16
 Lift elbow-lever unit.

 Dismount pin (2.37).
 Replace block (2.17).
 Remount pin (2.37).
2.37
 Make sure the pin (2.37) is aligned correctly.
2.17
 Release elbow-lever unit.

 Reinsert pin (2.38).
2.38
 Retighten holding screw (2.39).
2.39

 Mount special nut (2.10), Belleville-washers (2.11) and spacer-
tubes (2.12) onto spindle.
2.10 2.13
 Make sure they are mounted in the correct order.
 Slightly tighten screws (2.9). 2.12
 Tighten special nut (2.10), until the freewheel is tight, but still
movable.
 Fully tighten screws (2.9).
2.12
2.11

 Screw spindle unit (2) into crosspiece (2.16) by turning nut
(2.14) clockwise. 2.16
2.14
2.1

Maintenance
SB 16
 Reset brake acc. to section 4.

2.23 3.14
 Check measurement S = „S1“ 2.8
2.7
2.14
7.5 Replacement of brake pads
NOTE!
Always replace BOTH brake pads!
Otherwise the brake might not work properly!
NOTE!
When replacing a brake disc, also replace the brake pads. The disc has to be run in with the new
brake pads!
CAUTION!
During the braking process the brake disc and the linings heat up!
Danger of burning! Let brake disc and brake cool down before changing the brake pads!
Replace brake pads either when

o the minimum thickness of the linings is reached:
o Glued linings / sintered linings: 3 mm
o Riveted linings / Glued and riveted linings: 5 mm
o Or in case the lining is damaged, e.g. due to:
o cracks
o breaks
o overheating

Maintenance
SB 16

2.23 3.14
 Release brake spring: Turn nut (3.14) counter clockwise
 Turn nut (2.14) counter clockwise
  Brake shoes move away from brake disc.
2.8
2.7
2.14
 Screw both screws (1.45) out of brake pad (4) at the opposite 1.46
side of the thruster. 1.45
 The screw (1.46) holds the brake shoe pin in position and
must not be loosened.
1.45
 Dismount old brake pad (4).

4
 Caution when removing the brake pads! Heed weight of
brake pads (4)!
 Lift brake pads (4) from key (1.33).
 Dismount second brake pad (4) the same way.

4 1.33
 Open the brake further, if necessary.

Maintenance
SB 16
 Check new brake pad (4) for cleanliness, clean if necessary

(Emery paper).
4
 Check mounting area for cleanliness, clean if necessary 1.33
 Put new brake pads onto the key (1.33).
 The new brake pads may be thicker the ones removed. Thus,
it might be necessary to open the brake further (2.14).

 Screw screws (1.45) with new washers to the brake shoe.
 Tighten screws (1.45) to nominal torque with a torque wrench.
1.45
1.45
Tightening torque at
Quality of screws µ=0.14* µ=0.12* µ=0.10* µ=0.08*
Stainless steel 3 Nm 3.5 Nm 2.5 Nm -
8.8 3 Nm 3.5 Nm 2.5 Nm 2 Nm
Friction factor Zinc coated screws, dry  µ ≈ 0.14

Black screws, slightly oiled  µ ≈ 0.12
Stainless steel screws, greased with graphite  µ ≈ 0.10
Zinc-lamellar-coated screws, dry  µ ≈ 0.08
 Mount second brake pad (4) at the opposite side the same
way. 1.33 4

Maintenance
SB 16
 Reset reserve stroke acc. to section 4 (2.14).

2.23 3.14
 Reset braking torque acc. to section 4 (3.14).
 Run in brake pads acc. to section 4.
2.8
 Tighten screw (2.23). 2.7
 Open and close brake until the AWC is not adjusting anymore. 2.14
7.6 Replacement of switches and sensors
NOTE!
o It is possible to use various sensors that look similar. Make sure to replace the old sensor with the
correct new sensor.
o Please also refer to the data sheets of the sensors. These data sheets are part of the documentation
package.
Release control (Type IG0400) / Set control (Type IG0400)
 Measure position of sensor (7.21 / 7.22). 7.32

 Loosen lock nuts (7.31 / 7.32).
 Pull out old sensor (7.21 / 7.22).
 Put in new sensor (7.21 / 7.22) at original position. 7.22
 Release control
 Connect sensor according to data sheet (included in this
7.21
documentation).
 Release control: The distance between the sensor-surface and
the actuating flag has to be about 4 mm, when the brake is 7.31
released.
 Set control: The distance between the sensor-surface and the
actuating flag has to be about 4 mm, when the brake is set.
 Check function and adjust if necessary.
 Tighten lock nut (7.31 / 7.32).

Maintenance
SB 16
Wear control (Type IG0403)

 Measure position of the switch (7.23).
2.1
 Disconnect proximity switch (7.23).
 Loosen lock nut (7.33).
 Replace sensor (7.23).
 Connect switch according to data sheet (included in this
documentation). 7.33
 Reset switch (7.23) to original position.
 Check function and adjust if necessary. 7.23
 Tighten lock nut (7.33).
Manual release control (Type IN0136)
 Loosen screws (7.36) and (7.37).

 Dismount old proximity switch (7.24).
 Disconnect proximity switch (7.24) electrically.
 Mount new proximity switch (7.24) with two screws. 7.36
7.24
 Do not yet fully tighten screws (7.36) and (7.37).
 Connect switch according to data sheet (included in this
documentation).
 The screw (7.37) is inside a longhole.
 Position the switch until it is actuated correctly (switching
7.37
distance 4-5 mm).
 Check at LED and control system.
 Open and close brake manually.
 Check function and adjust if necessary.
7.7 Replacement of thruster
NOTE!
Also refer to the instructions in the operating manual of the thruster, as well as the wiring diagram
the inside of the terminal box cover.
DANGER!

Maintenance
SB 16
 Disconnect thruster (5) at terminal box (5.8).

 Dismount proximity switch (-es) if mounted.
 Roll up cable and store it safely.
5.8

 Dismount catch (2.7). 2.23 3.14
 Turn nut (2.14) counter clockwise until the piston rod of the
thruster is completely retracted.

2.8
2.7
2.14
WARNING!
When the upper pin (5.2) is pulled out, the thruster may tilt and fall.
Secure the thruster against accidental movements!
 Remove cotter pins and washers from thruster pin (5.2).

 Secure thruster against tilting.
 Loosen and remove pin (5.2).
5.2

Maintenance
SB 16
 Attach thruster (5) with e.g. a rope or hook to a suitable lifting

device and secure it against tilting.
 Remove cotter pins and washers from Eldro pin (5.4).
5
 Loosen and remove pin (5.4).
 Replace thruster (5).
 Re-insert lower pin (5.4). 5.4
 Remount cotter pins and washers from Eldro pin (5.4).

 Position thruster (5) so the bushing in the piston rod coincides
with the inner bore of the elbow levers.
 Re-insert upper pin (5.2).
 Remount cotter pins and washers from Eldro pin (5.2).
5.2
5

 Connect new thruster at terminal box (5.8).
 Seal connections.
5.8
 Reset reserve stroke acc. to section 4 (2.14).

 Reset braking torque acc. to section 4 (3.14).
2.23 3.14
2.8
2.7
2.14

Troubleshooting
SB 16
8 Troubleshooting
Problem: Brake does not close

Possible reason Action Section
Brake is mechanically blocked Check -
Brake is manually released Manually close 6.3
Braking torque too low Adjust braking torque 5.1
Spring damaged Replace spring unit Customer
support
Signal „open“ is active Check connection -
Proximity switch malfunctioning Check connection ES
Check lever / actuating devices 6.4
Replace proximity switch 6.4
Reserve stroke to small Adjust reserve stroke 5.2
Brake pads worn Replace brake pads 7.5
Problem: Brake does not open

Braking torque too high Adjust braking torque 5.1
Signal „close” is active Check connection -
Proximity switch malfunctioning Check connection ES
Check lever / actuating devices 6.4
Replace proximity switch 6.4
Reserve stroke to big Adjust reserve stroke 5.2
No power supply Check electrical supply and connection 4.3
Thruster damaged Replace thruster 7.8

Troubleshooting
SB 16
Problem: Braking time / distance to long

Braking torque too low Adjust braking torque 5.1
Brake pads have uneven contact Align brake 4.2
Brake pads haven’t been run in correctly Run in brake pads 5.3
Reserve stroke to small Set Reserve-stroke 5.3
AWC malfunctioning Check and reset / replace, if necessary 7.4
Automatic centring device malfunctioning Check and reset / replace, if necessary 4.2
Brake pads soiled Brake clean 7.3
Brake soiled Clean brake 7.3
Brake pads worn Replace brake pads 7.5
Brake disc worn Replace brake disc -
ES – Data sheet of switch / sensor

Putting out of service and disposal
SB 16
9 Putting out of service and disposal
9.1 Putting out of service
DANGER!
The electrical connection and all other electrical tasks must only be done by a trained electrician.
WARNING!
Dismounting a brake reduces the overall braking and holding force!
WARNING!
Danger due to heavy loads!
Always lift the brake with a proper lifting device.
o The brake must only be put out of service and disposed by trained and qualified personnel.
o Always heed the applying laws and regulations!
9.2 Dismounting of the brake
WARNING!
switching on again.

 Dismount catch (2.7). 2.23 3.14
 Turn nut (2.14) counter clockwise
  Brake shoes move away from brake disc.
2.8
2.7
2.14

SB 16
 Disconnect thruster (5) at terminal box (5.8).

 Dismount proximity switch (-es) if mounted.
 Roll up cables and store them properly.
5.8
 Loosen mounting bolts.
WARNING!
The weight distribution of the brake is unequal. Danger of injury when the brake is dismounted.
When dismounting the brake move it slowly and carefully!
 Attach brake to a proper lifting device (e.g. crane).

 Dismount brake.

SB 16
9.3 Disposal
WARNING!
Danger of pollution.
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 and recycled.
o Always heed the corresponding laws and regulations, when disposing the product and its
components.
o Always check which operating fluid is used in the thruster
o Also heed the operating manual of the thruster.

Spare parts
SB 16
10 Spare parts
NOTE!
Only use original PINTSCH BUBENZER spare parts!
The use of spare parts, not meant for this brake, can lead to a malfunction of the brake or damage
the brake!
NOTE!
In case of ordering, please indicate the type and the serial no. of the brake, which is located on the
type plate of the brake!
Please note, that the thruster has a separate type plate (see below).

Spare parts
SB 16
10.1 Spare part list – main components
2.7
4
4
Positon No item
2 1 Automatic wear compensator - complete

2.7 1 Catch
4 2 Brake pad with brake pad carrier
5 1 Thruster

Spare parts
SB 16
10.2 Switches and sensors
7.21
7.23 7.24
7.22
Position No item
7.21 1 Proximity switch – Set control – IG0400*

7.22 1 Proximity switch – release control– IG0400*
7.23 1 Proximity switch – Wear control – IG0400*
1 Proximity switch – Wear control – IG0403*
7.24 1 Proximity switch – Manual release control – IN0127*
1 Proximity switch – Manual release control – IN0136*
* If other sensors / switches are mounted, please state type.

Appendix
SB 16
11 Appendix
11.1 Data sheet
1) If ordered with manual release lever

*) Average static friction factor of standard material combination
The friction factor may vary depending on the application, environment material. Always heed these
variations during the design of the installation.
For crane brake lay-out use safety factors documented in the FEM 1.001, Section 1
All dimensions in mm. Alterations reserved without notice

Appendix
SB 16
With ELDRO- / Elhy - thruster
Thruster-type: EB 120/40 EB 220/50 EB 300/50

Weight w/o thruster
Ed 23/5 Ed 30/5
Contact
ca. 83 kg 1545 2500 3400
force Fmax
Max. *MBrmax. *MBrmin. *MBrmin. *MBrmax. *MBrmin. *MBrmin. *MBrmax. *MBrmin. *MBrmin.
Disc-n Friction-n bmax.
Hub-n k1 (Nm) at (Nm) at (% of (Nm) at (Nm) at (% of (Nm) at (Nm) at (% of
d2 d1 e
d4 µ = 0.4 µ = 0.4 MBrmax.) µ = 0.4 µ = 0.4 MBrmax.) µ = 0.4 µ = 0.4 MBrmax.)
250 195 95 97.5 60.5 120 60 50 195 117 60 265 133 50
280 225 125 112.5 75.5 140 70 50 225 135 60 305 153 50
315 260 160 130 93 160 80 50 260 156 60 355 178 50
355 300 200 150 113 185 93 50 300 180 60 410 205 50
400 345 245 172.5 135.5 215 108 50 345 207 60 470 235 50
450 395 295 197.5 160.5 245 123 50 395 237 60 535 268 50
500 445 345 222.5 185.5 275 138 50 445 267 60 605 303 50
With BUEL® - thruster
Weight w/o thruster Thruster-type: BL 22-5 BL 30-5 BL 35-5
Contact 2610 N 3400 N

ca. 83 kg 5000 (on request)
force Fmax
Max. *MBrmax. *MBrmin. *MBrmin. *MBrmax. *MBrmin. *MBrmin. *MBrmax. *MBrmin. *MBrmin.
Disc-n Friction-n bmax.
Hub-n k1 (Nm) at (Nm) at (% of (Nm) at (Nm) at (% of (Nm) at (Nm) at (% of
d2 d1 e
d4 µ = 0.4 µ = 0.4 MBrmax.) µ = 0.4 µ = 0.4 MBrmax.) µ = 0.4 µ = 0.4 MBrmax.)
250 195 95 97.5 60.5 205 103 50 265 133 50 390 195 50
280 225 125 112.5 75.5 235 118 50 305 153 50 450 225 50
315 260 160 130 93 270 135 50 355 178 50 520 260 50
355 300 200 150 113 315 158 50 410 205 50 600 300 50
400 345 245 172.5 135.5 360 180 50 470 235 50 690 345 50
450 395 295 197.5 160.5 410 205 50 535 268 50 790 395 50
500 445 345 222.5 185.5 465 233 50 605 303 50 890 445 50

Appendix
SB 16
11.2 Tightening torques for regular threads
NOTE!
These values are valid as long as there is no other data given at the corresponding point in the
manual.
These torques are valid for:

compl. = 0.12 (black or bonderd, slightly oiled)
NOTE
Used Nordlock-washers must not be re-used!
Size Tightening Torques M A Wrench size [mm]
8.8 10.9 12.9

M4 3,0 4,6 5,1 7
M5 5,9 8,6 10,0 8
M6 10,1 14,9 17,4 10
M8 24,6 36,1 42,2 13
M10 48 71 83 17 (16)
M12 84 123 144 19 (18)
M14 133 195 229 22 (21)
M16 206 302 354 24
M18 295 421 492 27
M20 415 592 692 30
M22 567 807 945 32 (34)
M24 714 1017 1190 36
M27 1050 1496 1750 41
M30 1428 2033 2380 46
M36 2482 3535 4136 55

Appendix
SB 16
11.3 Customer support
Our customer service department is at your disposal should you require technical information on any of
PINTSCH BUBENZER GmbH's products and how to use these correctly. See below for the address and
telephone number.
Should you have any questions of this device, please contact our customer service department.
If you have any questions concerning the product or this manual, please contact PINTSCH BUBENZER
quoting the type and serial number of the product as given on the typeplate (also refer to section 1).This
allows us to supply you with the correct data and / or spare parts for your product.
Plant Kirchen
Germany
Tel.: +49 (0) 27 41/94 88-0

Fax: +49 (0) 27 41/94 88-44

Appendix
SB 16
11.4 CE-certificate

PB-SB16-en10 PINTSCH BUBENZER GmbH
D-57548 Kirchen-Wehbach
Telefon +49 (0) 27 41/94 88-0
MADE IN GERMANY
Electrohydraulic Thruster
BUEL ® BL 22-5 and BL 30-5
Operating manual
- Translation -
State: 03/2018
Version: 3
Index
BUEL® - BG0
1 Basics ............................................................................................................................ 3
1.1 Foreword ....................................................................................................................................................... 3
1.2 Copyright ....................................................................................................................................................... 3
1.4 Conformity ..................................................................................................................................................... 4
1.8 Protective Equipment .................................................................................................................................... 7
2 Safety ............................................................................................................................. 8
2.1 Basics ............................................................................................................................................................ 8
2.4 Residual risks .............................................................................................................................................. 10

3.1 View of product............................................................................................................................................ 13
3.2 Function ....................................................................................................................................................... 14
3.3 Technical data ............................................................................................................................................. 14
3.5 Type plate .................................................................................................................................................... 15
3.6 Thruster labelling ......................................................................................................................................... 16
4 Mounting of the thruster ............................................................................................. 18

4.1 Preparation .................................................................................................................................................. 18
4.2 Mounting ...................................................................................................................................................... 19
5 Setting of the thruster ................................................................................................. 21

5.1 Adjust setting time - Option S, only BL 30-5 ............................................................................................... 21
6 Operation ..................................................................................................................... 23

Index
BUEL® - BG0
7 Maintenance ................................................................................................................ 24
7.2 Lubrication ................................................................................................................................................... 25
7.3 Cleaning ...................................................................................................................................................... 26
7.4 Check oil level ............................................................................................................................................. 27
7.5 Refilling ........................................................................................................................................................ 27
7.6 Replacement of bearing at piston rod ......................................................................................................... 29
7.7 Replacement of seals at piston rod ............................................................................................................. 29

9.2 Dismounting of thruster ............................................................................................................................... 32
9.3 Disposal ....................................................................................................................................................... 33
10 Spare part list .............................................................................................................. 34
11 Appendix ...................................................................................................................... 35
11.1 Data sheet ................................................................................................................................................... 35

Basics
BUEL®- BG0
1 Basics
1.1 Foreword
operation and maintenance of the product.
They will help you:
1.2 Copyright
The Operating Instructions or even parts thereof may not be saved in a data processing system or
translated into another language.

Basics
BUEL®- BG0
product.
o in the case of incorrect commissioning, operation or upkeep,
and upkeep.
1.4 Conformity

Basics
BUEL®- BG0
DANGER!
Indicates a dangerous situation which leads to serious injury or death.
WARNING!
Indicates a dangerous situation which can lead to serious injury or death.
CAUTION!
Indicates a dangerous situation which can lead to minor or fairly serious injuries and
NOTICE!

Basics
BUEL®- BG0

Basics
BUEL®- BG0
The Operating Instructions constitutes an important part of the product. E g. if the product is installed in a
plant the Operating Instructions are to be made available to the operator of the plant. The plant operator
observed.

1.8 Protective Equipment

o A protective helmet and protective goggles have to be worn.
The safety measures necessary for all tasks concerning the hydraulic fluid can be found in the
corresponding safety-data sheet.

Safety
BUEL®- BG0
2 Safety
2.1 Basics
assets if:
NOTE
o Operating manual of the brake.
o Operating manual of the installation
o safety-data sheet of the hydraulic medium

Safety
BUEL®- BG0
The PINTSCH BUBENZER BUEL ® thruster is meant exclusively as an electrohydraulic thruster to create
a linear lifting movement with a defined lifting force and a defined stroke.
In case of a power failure the thruster is switched off. The thruster is designed for the operation in
combination with a spring-actuated brake. It is meant to open the brake electro-hydraulically.
warnings:
o on safety,
o on operation,
o All electric components of the BUEL®-thruster are mounted inside the housing and are
environmentally sealed.
o The only interface is the terminal box.
o Protective class of the terminal box: IP 65.
WARNING

Safety
BUEL®- BG0
2.4 Residual risks
product.
o draw-in points,
o parts such as the housing in particular can become hot after braking.
o In case of a power failure or after the EMERGENCY-STOP has been activated, the supply voltage of
the BUEL®-thruster is cut off.
o Due to the fail-safe principle the des BUEL®-thruster is idle and the brake automatically closes via
spring force.
o A controlled opening of the brake is now only possible by means of the manual release device of the
brake.
o In case of a power down the brake also sets automatically.
IMPORTANT!
The installation has to be secured against uncontrolled starting in case the supply voltage is
switched on again.
o The pre-set setting time of the brake does not change in case of an Emergency-stop or a power
failure.

Safety
BUEL®- BG0
regulations.
Before starting any work at all on the brake, make sure that the drive is switched off and protected against
switching on again.
Before starting any work at all on the brake, make sure that the electrical connection of the thruster is
switched off and protected against switching on again.
Electrical tasks must only be carried out by trained and instructed electricians.
The thruster must not be opened, while it is still hot. Let it cool down to at least room-temperature before
working on it to avoid burns.
necessary values.
The thruster may only be taken apart to the extent prescribed by these Operating Instructions. Any further
If unusual changes at the thruster are noticed, switch off the supply voltage immediately. Report the
Sales Service!

Safety
BUEL®- BG0
WARNING!
Due attention is to be paid to the environmental-friendly disposal of consumables, lubricants,


Product description
BUEL®- BG0
3.1 View of product
2
Filling level of
hydraulic fluid
3
8
9
10
12
Pos. Item Pos. Item

1 Piston rod with joint head 8 Bearing-unit
2 Sealing-section for piston rod 9 Motor-unit
3 Valve disc 10 Terminal box
4 Piston 12 Mounting base
5 Pump

Product description
BUEL®- BG0
3.2 Function
Release brake
 When the supply voltage is switched on, the pump (P) draws the hydraulic medium out of the tank (T)
and generates a pressure- and volume-flow moving the piston upwards into the end-position.
 The motor remains switched on and keeps up the hydraulic pressure.
 The brake remains open.
Set brake
 When the supply voltage is switched off, the motor slows down and the hydraulic pressure decreases.
 The piston is pushed down by the force of the external brake spring.
 Option S: The volume flow can be adjusted continuously by a throttle valve (5), if necessary. This can
result in a longer setting time of the brake
3.3 Technical data
NOTE!
Please also refer to the data sheet in the appendix.
The technical data refers to an operation with a supply voltage of: 3 ~ 400 V, 50 Hz
Max. max. Weight

BL max. lifting current
Force Power (incl. oil)
22-5 400 N 0.15 kW 0.4 A 11 kg
30-5 450 N 0.16 kW 0.4 A 13 kg
Operating conditions
Ambient temperature -30°C - + 60°C*
Protection class* IP 65 (IP 67)
Class of insulation F
Hydraulic medium Pentosin CHF 11S
Mounting position Vertical*
Duty cycle Permanent- / Intermittent duty.
S1 /S3 Up to 1000 c/h , 60 % ED
* please contact PINTSCH BUBENZER for other applications

Product description
BUEL®- BG0
NOTE!
Different temperature ranges require special hydraulic fluids.
Please contact PINTSCH BUBENZER!
Pentosin CHF 11S

Colour Green DIN 10964
Density at 15 °C kg/m³ 830 DIN EN ISO 12185
Kinematic viscosity at 100°C mm²/s 6,0 DIN EN ISO 3104
Kinematic viscosity at -40°C mm²/s 1100 DIN EN ISO 3104
Viscosity-index 313 DIN ISO 2909
Flash point °C 156 DIN EN ISO 2592
Pourpoint °C -57 ISO 3016
Water endangering class WGK 2
Storage class 10
3.4 Type plate
o If you have any questions about the brake or when ordering spare parts, please give us the
complete brake type and the serial number according to the type plate.
o The typeplate is mounted:
o Buel 22-5 on the cover
o Buel 30-5 at the bearing-unit.

Product description
BUEL®- BG0
3.5 Thruster labelling
o The BUEL thruster is labelled as follows:
Nominal
Operation
BUEL lifting force acc. Stroke Options Frequency
voltage
to DIN 15430
refer to table
BL in dN - in 10 mm in V in Hz
below
o Example : BL 30-5 SW 400 V,50 Hz stands for:
o 300 N nominal lifting force acc. to DIN 15430
o 50 mm stroke
o Special equipment: Lowering valve and high temperature execution
o Connect to a supply voltage of 400 V 50 Hz
Index Available options

A Heater
C Enhanced corrosion-protection.
D Special mounting dimensions acc.to customers specifications
P Horizontal mounting position
R Analogue stroke indicator.
S Lowering valve
W High temperature execution
Y Cable glands at left side
Supply voltage, frequency
o The thruster is shipped ready to mount and tested.

o They are filled with hydraulic fluid.
o Never open the filler or overflow plugs without authorization as loss of oil will change the technical
values or disable some functions.
o BUEL®-thrusters have to be safely stored for the transport. Make sure neither the thruster nor other
components may be damaged.
o The transportation device has to be executed in a way that any danger for the shipped thrusters or
other components can be avoided.
o A safe loading to guarantee a safe transport is mandatory.
o The BUEL®-thruster should preferably be transported in vertical position

Product description
BUEL®- BG0
IMPORTANT!
The electrohydraulic thruster has a weight of up to 13

Kg, depending on the type. Always use proper lifting
devices and attach the brake at the head of the piston
rod.
Make sure the lifting ore does not damage the bearing.
o Store and / or transport the thruster dust- and waterproof with drying agent until installation.
o Protect the thruster against external damages during the complete storage- / transport-period.

o Hinges or joints
o Signs and plates

Mounting of the thruster
BUEL®- BG0
4 Mounting of the thruster
WARNING
4.1 Preparation
Check before mounting the thruster:
o Cleanliness and state of the mounting area

o Availability of correct power supply.
o Installation is secured
o Correct earthing
IMPORTANT!
The electrohydraulic thruster has a weight of up to 13 Kg,

depending on the type. Always use proper lifting devices and
attach the brake at the head of the piston rod.
Mounting position
o The BUEL®-thrusters are preferably mounted in vertical

position (piston rod on top).
o A deviation of +/- 20° from the vertical position is allowed.
o As an option the thruster may be mounted in horizontal
position.
o For other mounting positions please contact the manufacturer.

BUEL®- BG0
4.2 Mounting
CAUTION!
 As the BUEL®-thruster is movable, the terminal box connection

has to be flexible, too. Joint head
o Vertical mounting: Joint head on top.
o Horizontal or other mounting positions; terminal box on
top.
o Other mounting positions are possible but have to be
clarified with PINITSCH BUBENZER in advance.
 The mounting base of the BUEL®-thrusters can be positioned
in steps of 90° with a special tool.
 The thruster is mounted with two pin-connections. One at the Terminal box
point head, one at the mounting base.
 Make sure the pins are movable in the mounting base and
joint head.
 The pins have to be secured with washers and cotter pins on
both sides.
 The thruster has to be traversable.
Mounting base
 There must not be lateral forces at the piston rod.
 Misalignments of up to +/- 3° may be compensated.

BUEL®- BG0
DANGER!
Make sure the power supply is switched off and secured against switching on again.
NOTE!
If the unit is protected by a protective motor switch, insure that the thermal value which triggers
the switch is at least 1.5 times of the nominal lifting current (refer to type plate)!
IMPORTANT!
Connect a right-handed field at the terminals L1, L2, L3 in triangle.
The phases must not be interchanged during the operation of the unit.
 The BUEL®-thrusters are operated with a 3-phase current

voltage of 220 V - 690 V at 50 Hz or 60 Hz. Protective conductor
 The connection to the power supply is done at the terminals terminal
W2, U2, and V2 inside the terminal box of the BUEL®-thruster.
 Connect protective conductor terminal at socket with clamp.
 The possible diameter at the clamp for the supply cable is 9 –
17 mm.
 Keep terminal box clean.
 Make sure that gasket is correctly positioned and intact.
 Lock terminal box securely, tighten cable entry and seal it if
necessary.
 Please also refer to the wiring diagram inside the cover of the
terminal box. Terminals for
supply voltage
 For maritime applications the motor coil may be equipped with

an optional heating to prevent condensation.
 An additional heater for the thruster is also available for low
temperature applications.
 The heater is connected at specifically marked terminals inside
the terminal box.
 The choice of cable inlets is up to the customer.
 Possible heater voltages
110 V AC 50 Hz or 60 Hz
Terminals for
230 V AC 50 Hz or 60 Hz heater voltage

Setting of the thruster
BUEL®- BG0
5 Setting of the thruster
WARNING
5.1 Adjust setting time - Option S, only BL 30-5
WARNING
Changing the pre-set setting time of the thruster also changes the stopping distance of the
applied load!
Make sure the specified stopping distance of the brake installation is not exceeded. Also, refer to
the operating-manual of the brake, esp. the section “load test”.
 Unscrew closure stud G 3/8 at throttle valve SW 8.

 Flat screwdriver H2 vertical into the screw head of the throttle closure stud -
valve. throttle valve
 Turn the screw head of the throttle valve to adjust the setting Screw head
time continuously: throttle valve
 Clockwise = Increasing the setting time
 Counter clockwise = Reducing the setting time
 Adjusting range: 7 full turns
 The pre-set value is 0.5 seconds at nominal load and specified
operating conditions.
 Open and close brake several times to check setting.
 Screw in closure stud a G 3/8 and tighten it.

BUEL®- BG0
 In case the Buel® thruster is mounted horizontally in an EBH-

brake, the throttle valve is not accessible. In this case:
 Remove cotter pin and washer from pin.
 Push pin back far enough, so the throttle valve is accessible.
 Adjust valve as described.
 Push pin back in original position.
 Secure pin with washer and cotter pin.
 Open cotter pin.
.
WARNING
The correct setting of the thruster is essential for a safe operation of the brake!
Item
Function check
Stroke correct
Release time correct
Setting time correct

Operation
BUEL®- BG0
6 Operation
CAUTION!
CAUTION!
Danger of burning due to hot oil and / or hot surfaces
Let the thruster cool down at least to room temperature before commencing any work on the
thruster.
o BUEL®-thrusters work in intermittent duty independent of the operation mode of the brake.
State of thruster State of brake

BUEL® Thruster not energized Brake set
BUEL® Thruster energized Brake opens and remains open
BUEL® Thruster is being switched off Brake sets automatically
Power down or emergency stop Brake sets automatically
 In case of a power failure or after the EMERGENCY-STOP has been activated, the supply voltage of
the BUEL®-thruster is cut off by the installation.
 Due to the fail-safe principle the des BUEL®-thruster is idle and the brake automatically closes via
spring force.
 A controlled opening of the brake is now only possible by means of the manual release device of the
brake.
 In case of a power down the brake also sets automatically.
 The pre-set setting times are still valid.

Maintenance
BUEL®- BG0
7 Maintenance
DANGER!
DANGER!
When the thruster is dismounted the brake is not active. The overall braking force of the
installation is reduced!
WARNING!
CAUTION!
thruster.
NOTE
Also heed the corresponding sections of the operating instructions of the brake.
NOTE

Maintenance
BUEL®- BG0
 Being a closed hydraulic system the BUEL®-thruster is a low maintenance system. Check the
thruster during the regular maintenance schedule of the brake.
 Contact the customer support service in case of a leakage.
 Please refer to the maintenance section of the operating manual of the brake.
Maintenance tasks Interval [operating hours]
Visual check for leakages During the regular maintenance schedule of the brake
Check movability of BUEL® thruster During the regular maintenance schedule of the brake
Check for unusual noise emission During the regular maintenance schedule of the brake
Setting- and opening speed During the regular maintenance schedule of the brake
Correct stroke During the regular maintenance schedule of the brake
Check for corrosion During the regular maintenance schedule of the brake
Check correct earthing During the regular maintenance schedule of the brake
Replacement of hydraulic fluid 2 Million cycles / every 5 years
Check the thruster / brake system outside the regular inspection intervals if:
 A sensor indicates an incorrect stroke
7.2 Lubrication
 As long as the BUEL®-thruster is not disassembled no lubrication or greasing is needed or allowed.

Maintenance
BUEL®- BG0
7.3 Cleaning
WARNING!
Danger due to chemical substances
brake cleaner) and proper cleaning materials like cloth.
The cleaning must be carried out with proper tools and agents. Never use tools like high-pressure
cleaners or a wire brush.
WARNING!
The Installation has to be shut down during the cleaning process and has to be secured against
switching on again.
 Make sure the thruster is free from fat, oil, rust and other contaminations.
 Keep all movable parts clean

Maintenance
BUEL®- BG0
7.4 Check oil level
 Remove closure stud G 3/8 (SW 8) at the top of the thruster.

 Insert a measuring-tool e.g. screwdriver
 Check oil level.
 The oil level has to be 9.5 – 10 mm above the valve-disc (please refer to section 3.1) at room
temperature.
 Close upper closure stud.
 Wipe away remaining oil at thruster, if necessary.
7.5 Refilling
NOTE!
Always heed the information and advices on the handling given in the safety data sheet of the
hydraulic medium.
NOTE!
Make sure the correct hydraulic fluid is used. Please refer to specification.
Different temperature ranges may require special hydraulic fluids.
WARNING!
Never open the thruster when it is hot! Escaping hot oil may cause burns! Before repair or
refilling, let the unit cool down to room temperature!
WARNING!
Risk of environmental pollution

The BUEL®-thrusters are filled with synthetic high performance fluid Pentosin CHF 11S for a use in the
temperature range of -30°C to +60°C.
Lifetime: 2 Million cycles / 5 years

Maintenance
BUEL®- BG0
closure stud
 Disconnect thruster electrically
G3/8“
 Dismount BUEL®-thruster
 Please refer to the operating manual of the brake
 Provide a proper container for the hydraulic fluid.
 Loosen closure studs (SW 8 and SW 5) at the top of the
thruster.
 Let the hydraulic fluid flow into the container.
 Wipe away remaining oil at thruster, if necessary. closure stud
G1/8“ – BL 30-5
 Alternatively, the thruster may be turned upside down, being fixed at the mounting base.
 Loosen closure studs (SW 8 and SW 5) at the top of the thruster.
 Put thruster in an upright position and secure it against falling.

 Refill thruster with new hydraulic fluid according to specification.
 Refer to table below for the capacity of the thruster.
 Close upper closure studs.
 Remount BUEL®-thruster
 Reconnect BUEL®-thruster.
 Make sure brake is reset correctly before restarting.
CAUTION!
In case to much hydraulic fluid is filled in, it can be emitted under pressure, e.g. at the piston rod.
The function of the thruster can also be affected after a certain time.
Always make sure the correct amount of hydraulic fluid is used.
BL Capacity BL Capacity
22-5 0.94 l 30-5 1.00 l

Maintenance
BUEL®- BG0
7.6 Replacement of bearing at piston rod
 Remove cotter pin with punch.

 Push out bearing with aluminium or plastic tool.
 Check for cleanliness.
 Insert new bearing evenly into bore.
 Insert new cotter pin completely into bore.
7.7 Replacement of seals at piston rod
NOTE
Use soft tools like a brass-screw driver to remove the seals! Use soft tools e.g. made of brass.
Never use a hard standard tool, as this will damage the surface of the cylinder and lead to
leakages!
 Unscrew headless screw.

 Fix piston rod with open spanner.
 Loosen head with plastic hammer by turning it counter
clockwise.
 Unscrew head.

Maintenance
BUEL®- BG0
 Loosen 3 screws at the disc using Phillips screwdriver (H2).

 Remove disc carefully from recess by turning it and moving it
upwards.
 The disc is replaced as a complete unit including the seals.
 Remove O-ring from lower side of disc.
 Clean mounting area.
 Place protective cover onto piston rod.

 Make sure the flat faces fit.
 Apply a bit of grease to the O-ring.
 Insert new O-ring at lower side of disc.
 Mount new disc onto recess.
 Remove protective cover.
 Reinsert 3 screws into disc.
 Tighten screws with Phillips screwdriver (H2) (3 Nm).
 Screw head onto piston rod.

 Tighten with open wrench.
 Check alignment.
 Apply a bit of Loctite 242 onto headless screw.
 Screw headless screw into piston rod (2 Nm).

Troubleshooting
BUEL®- BG0
8 Troubleshooting
NOTE!
Please also refer to the troubleshooting-list of the brake.
Problem: BUEL® thruster does not open

Motor not connected correctly Check 4.3
Power supply malfunctioning Check supply voltage 4.3
Not enough hydraulic fluid Check filling level and refill, if necessary. 7.4 / 7.5
Motor-group damaged. Contact customer support
Problem: BUEL® thruster does not set

Supply voltage still switched on Check supply voltage 4.3
Problem: Setting time to long

Throttle valve maladjusted Adjust throttle valve 5.1

BUEL®- BG0
DANGER!
WARNING!
WARNING!
9.2 Dismounting of thruster
WARNING!
switching on again.

BUEL®- BG0
9.3 Disposal
WARNING!
regulations!
components.
o Always check which operating fluid is used in the thruster.
o Drain the tank acc. to section 7.4 and dispose of the oil according to the corresponding laws and
regulations.

Spare part list
BUEL®- BG0
10 Spare part list
NOTE!
The use of spare parts, not meant for this thruster, can lead to a malfunction of the thruster or
damage the thruster!
NOTE!
In case of ordering, please indicate the type and the serial no. of the brake which is located on the
type plate of the thruster!
Please note, that the brake has a separate type plate.
Pos. Nr. Item
1 Piston rod with joint head and cotter pin

1 Seal-kit for piston rod incl. protective rod
1000 ml Hydraulic fluid Pentosin CHF 11S

Appendix
BUEL®- BG0
11 Appendix
11.1 Data sheet
With joint-bearing
4x M6; T mm deep
BL Fmax [N] A B C D E F G H K L M N O* P S T U W
22-5 400 286 16 26 15 30 20 16 20 14 206 80 40 160 80 136 12 24 M4
30-5 450 370 16 34 15 30 20 16 18 16 210 80 40 160 80 136 12 24 M4

Appendix
BUEL®- BG0
NOTE!
The following values apply, unless another torque is given at a specific point in the manual.
These tightening torques apply for:

NOTE!
Used Nordlock-washers must not be used again!
8.8 10.9 12.9

M4 3.0 4.6 5.1 7
M5 5.9 8.6 10.0 8
M6 10.1 14.9 17.4 10
M8 24.6 36.1 42.2 13
M10 48 71 83 17 (16)
M12 84 123 144 19 (18)
M14 133 195 229 22 (21)
M16 206 302 354 24
M18 295 421 492 27
M20 415 592 692 30
M22 567 807 945 32 (34)
M24 714 1017 1190 36
M27 1050 1496 1750 41
M30 1428 2033 2380 46
M36 2482 3535 4136 55

Appendix
BUEL®- BG0
telephone number.
Plant Kirchen
Germany
Tel.: +49 (0) 27 41/94 88-0

Fax: +49 (0) 27 41/94 88-44

PB-Buel-BG0-en3.docx PINTSCH BUBENZER GmbH
Telefon +49 (0) 27 41/94 88-0
MADE IN GERMANY
Electrohydraulic Thruster
BUEL ® BL 35-5 to BL 600-8
Operating manual
- Translation -
State: 03/2018
Version: 9
Index
BUEL®
1 Basics ............................................................................................................................ 3
1.1 Foreword ....................................................................................................................................................... 3
1.2 Copyright ....................................................................................................................................................... 3
1.4 Conformity ..................................................................................................................................................... 4
1.8 Protective Equipment .................................................................................................................................... 7
2 Safety ............................................................................................................................. 8
2.1 Basics ............................................................................................................................................................ 8
2.4 Residual risks .............................................................................................................................................. 10

3.1 View of product............................................................................................................................................ 13
3.2 Function ....................................................................................................................................................... 14
3.3 Technical data ............................................................................................................................................. 15
3.4 Type plate .................................................................................................................................................... 16
3.5 Thruster labelling ......................................................................................................................................... 17
3.8 Tool-list ........................................................................................................................................................ 19
4 Mounting of the thruster ............................................................................................. 20

4.1 Preparation .................................................................................................................................................. 20
4.2 Mounting ...................................................................................................................................................... 21
5 Setting of the thruster ................................................................................................. 24

5.1 Adjust setting time - Option S ...................................................................................................................... 24
6 Operation ..................................................................................................................... 26

Index
BUEL®

6.3 Switches and sensors – Option EB ............................................................................................................. 27
6.4 Status-LEDs for operating conditions.......................................................................................................... 27
7 Maintenance ................................................................................................................ 28
7.2 Lubrication ................................................................................................................................................... 29
7.3 Cleaning ...................................................................................................................................................... 30
7.4 Refilling ........................................................................................................................................................ 31
7.5 Replacement of bearing at piston rod ......................................................................................................... 33
7.6 Replacement of seals at piston rod ............................................................................................................. 34

9.2 Dismounting of thruster ............................................................................................................................... 37
9.3 Disposal ....................................................................................................................................................... 38
10 Spare part list .............................................................................................................. 39
11 Appendix ...................................................................................................................... 40
11.1 Data sheet ................................................................................................................................................... 40

Basics
BUEL®
1 Basics
1.1 Foreword
operation and maintenance of the product.
They will help you:
1.2 Copyright
The Operating Instructions or even parts thereof may not be saved in a data processing system or
translated into another language.

Basics
BUEL®
product.
o in the case of incorrect commissioning, operation or upkeep,
and upkeep.
1.4 Conformity

Basics
BUEL®
DANGER!
Indicates a dangerous situation which leads to serious injury or death.
WARNING!
Indicates a dangerous situation which can lead to serious injury or death.
CAUTION!
Indicates a dangerous situation which can lead to minor or fairly serious injuries and
NOTICE!

Basics
BUEL®

Basics
BUEL®
The Operating Instructions constitutes an important part of the product. E g. if the product is installed in a
plant the Operating Instructions are to be made available to the operator of the plant. The plant operator
observed.

1.8 Protective Equipment

o A protective helmet and protective goggles have to be worn.
The safety measures necessary for all tasks concerning the hydraulic fluid can be found in the
corresponding safety-data sheet.

Safety
BUEL®
2 Safety
2.1 Basics
assets if:
NOTE
o Operating manual of the brake.
o Operating manual of the installation
o safety-data sheet of the hydraulic medium

Safety
BUEL®
The PINTSCH BUBENZER BUEL ® thruster is meant exclusively as an electrohydraulic thruster to create
a linear lifting movement with a defined lifting force and a defined stroke.
In case of a power failure the thruster is switched off. The thruster is designed for the operation in
combination with a spring-actuated brake. It is meant to open the brake electro-hydraulically.
warnings:
o on safety,
o on operation,
o All electric components of the BUEL®-thruster are mounted inside the housing and are
environmentally sealed.
o The only interface is the terminal box.
o Protective class of the terminal box: IP 65.
WARNING

Safety
BUEL®
2.4 Residual risks
product.
o draw-in points,
o parts such as the housing in particular can become hot after braking.
o In case of a power failure or after the EMERGENCY-STOP has been activated, the supply voltage of
the BUEL®-thruster is cut off.
o Due to the fail-safe principle the des BUEL®-thruster is idle and the brake automatically closes via
spring force.
o A controlled opening of the brake is now only possible by means of the manual release device of the
brake.
o In case of a power down the brake also sets automatically.
IMPORTANT!
The installation has to be secured against uncontrolled starting in case the supply voltage is
switched on again.
o The pre-set setting time of the brake does not change in case of an Emergency-stop or a power
failure.

Safety
BUEL®
regulations.
Before starting any work at all on the brake, make sure that the drive is switched off and protected against
switching on again.
Before starting any work at all on the brake, make sure that the electrical connection of the thruster is
switched off and protected against switching on again.
Electrical tasks must only be carried out by trained and instructed electricians.
The thruster must not be opened, while it is still hot. Let it cool down to at least room-temperature before
working on it to avoid burns.
necessary values.
The thruster may only be taken apart to the extent prescribed by these Operating Instructions. Any further
If unusual changes at the thruster are noticed, switch off the supply voltage immediately. Report the
Sales Service!

Safety
BUEL®
WARNING!


Product description
BUEL®
3.1 View of product
3
5
4
10
11
12
Pos. Item Pos. Item

1 Piston rod with joint head 7 Pump
2 Sealing-section for piston rod 8 Bearing-unit
3 Inductive sensor 9 Motor-unit
4 Piston 10 Terminal box
5 Hydraulic valves 11 Cable gland
6 Operating unit 12 Mounting base

Product description
BUEL®
3.2 Function
Pos. Item
1 Pressure limiting valve
2 Check valve
3 Way-valve
4 Way-valve
5 Throttle valve (Option S)
6 Piston
M Motor
P Pump
T Tank
MA Connection for external Measuring device
Release brake
 When the supply voltage is switched on, the redundant way-valves (3) and (4) are energized and
close of the return line back into the tank. The motor is switched on, too.
 The pump (P) draws the hydraulic medium out of the tank (T) and generates a pressure- and volume-
flow moving the piston upwards into the end-position.
 The pressure limiting valve (1) protects the pump from overload.
 After the inductive sensor emits a signal for the end position, the motor (M) is switched off.
 The check-valve (2) and the seated valves (3) and (4) maintain the pressure at the cylinder.
 It prevents the oil from flowing back through the pump (P).
 The brake remains open.
 The piston rod may lower itself due to micro-leakages.
 In this case the inductive sensor emits a signal to restart the pump for a short period to compensate
the pressure drop.
Set brake
 When the supply voltage is switched off, the two way-valves (3) and (4) are switched off
simultaneously and allow the oil to flow back into the tank (T).
 The hydraulic pressure is released in about 0.2 seconds and the piston rod is moved back into its
original position by external spring force.
 Option S: The volume flow can be adjusted continuously by a throttle valve (5), if necessary. This can
result in a longer setting time of the brake
 The redundant execution of the way-valves (3) and (4) helps a safe setting even when one valve
should be blocked.

Product description
BUEL®
3.3 Technical data
NOTE!
Please also refer to the data sheet in the appendix.
The technical data refers to an operation with a supply voltage of: 3 ~ 400 V, 50 Hz
Max. max. Weight

BL max. lifting current
Force Power (incl. oil)
35-5 600 0.35kW 0.6 A 16 kg
50-6 900 0.45 kW 0.7 A 16 kg
50-12 900 0.45 kW 0.7 A 16 kg
80-6 2000 0.6 kW 1.3 A 21 kg
80-12 2000 0.6 kW 1.3 A 21 kg
125-6 2500 0.65 kW 1.4 A 24 kg
125-12 2500 0.65 kW 1.4 A 24 kg
200-6 3600 0.80 kW 1.5 A 24 kg
200-12 3600 0.80 kW 1.5 A 24 kg
300-6 5000 0.9 kW 1.6 A 33 kg
300-12 5000 0.9 kW 1.6 A 33 kg
400-8 5500 1.0 kW 1.7 A 33 kg
400-10 5500 1.0 kW 1.7 A 33 kg
440-8 6500 1.1 kW 1.8 A 33 kg
450-8 7000 1.2 kW 2.0 A 33 kg
550-8 8000 1.25 kW 2.1 A 33 kg
600-8 8000 1.25 kW 2.1 A 33 kg
Operating conditions
Ambient temperature -30°C - + 60°C*
Protection class* IP 65 (IP 67)
Class of insulation F
Hydraulic medium Pentosin CHF 11S
Mounting position Vertical*
Duty cycle Intermittent duty.
S1 /S3 Up to 1000 c/h for 35-5 – 200-12
Up to 900 c/h for 300-6 – 600-8
* please contact PINTSCH BUBENZER for other applications

Product description
BUEL®
NOTE!
Different temperature ranges require special hydraulic fluids.
Pentosin CHF 11S

Colour Green DIN 10964
Density at 15 °C kg/m³ 830 DIN EN ISO 12185
Kinematic viscosity at -40°C mm²/s 1100 DIN EN ISO 3104
Viscosity-index 313 DIN ISO 2909
Flash point °C 156 DIN EN ISO 2592
Pourpoint °C -57 ISO 3016
Water endangering class WGK 2
Storage class 10
3.4 Type plate
o If you have any questions about the brake or when ordering spare parts, please give us the
complete brake type and the serial number according to the type plate.
o The typeplate is mounted at the terminal box.

Product description
BUEL®
3.5 Thruster labelling
o The BUEL thruster is labelled as follows:
Nominal
Operation
BUEL lifting force acc. Stroke Options Frequency
voltage
to DIN 15430
refer to table
BL in dN - in 10 mm in V in Hz
below
o Example : BL 80-6 SW 400 V,50 Hz stands for:
o 800 N lifting force acc. to DIN 15430
o 60 mm stroke
o Special equipment: Lowering valve and high temperature execution
o Connect to a supply voltage of 400 V 50 Hz
Index Available options

A Standstill-heater
C Enhanced corrosion-protection.
D Special mounting dimensions acc.to customers specifications
EB Inductive sensor – release control
L Low temperature execution with special oil
P Horizontal mounting position
R Analogue stroke indicator.
S Lowering valve
T Temperature sensor
W High temperature execution
Y Cable glands at left side
Supply voltage, frequency
o The thruster is shipped ready to mount and tested.

o They are filled with hydraulic fluid.
o Never open the filler or overflow plugs without authorization as loss of oil will change the technical
values or disable some functions.
o BUEL®-thrusters have to be safely stored for the transport. Make sure neither the thruster nor other
components may be damaged.
o The transportation device has to be executed in a way that any danger for the shipped thrusters or
other components can be avoided.
o A safe loading to guarantee a safe transport is mandatory.
o The BUEL®-thruster should preferably be transported in vertical position

Product description
BUEL®
IMPORTANT!
The electrohydraulic thruster has a weight of over 33

Kg, depending on the type. Always use proper lifting
devices and attach the brake at the head of the piston
rod.
o Store and / or transport the thruster dust- and waterproof with drying agent until installation.
o Protect the thruster against external damages during the complete storage- / transport-period.
o The thruster has a weight of more than 33 kg

o Hinges or joints
o Signs and plates

Product description
BUEL®
3.8 Tool-list
NOTE!
Please note, that you need a torque wrench to tighten some of the screws and bolts correctly.
Function Tool
Terminal-box Allen key 4 mm
Cable-glands Wrench 27 mm
Cable-clips Flat screwdriver - width 3 mm
closure stud at throttle-valve Allen key 5 mm
Throttle-valve Allen key 4 mm
Locking screw – piston-head/ up to size 200-12 Allen key 2 mm
Locking screw – piston-head/ from size 300-6 Allen key 2,5 mm
Split pins at bearing Punch 2 / 2,5 mm
Screws for seal-replacement Screwdriver PH2
Seal replacement Protective cover

BUEL®
4 Mounting of the thruster
WARNING
4.1 Preparation
Check before mounting the thruster:
o Cleanliness and state of the mounting area

o Availability of correct power supply.
o Installation is secured
o Correct earthing
IMPORTANT!
The electrohydraulic thruster has a weight of over 33 Kg,

depending on the type. Always use proper lifting devices and
attach the brake at the head of the piston rod.
Mounting position
o The BUEL®-thrusters are preferably mounted in vertical

position (piston rod on top).
o A deviation of +/- 30° from the vertical position is allowed.
o A thruster for a horizontal mounting position can be ordered.
o For other mounting positions contact the manufacturer.

BUEL®
4.2 Mounting
CAUTION!
 As the BUEL®-thruster is movable, the terminal box connection

has to be flexible, too. Joint head
 Vertical mounting: Joint head on top.
 Horizontal or other mounting positions; terminal box on top.
 Other mounting positions are possible but have to be clarified
with PINITSCH BUBENZER in advance.
Terminal box
 The mounting base of the BUEL®-thrusters can be positioned
in steps of 90° with a special tool.
 The thruster is mounted with two pin-connections. One at the
point head, one at the mounting base.
 Make sure the pins are movable in the mounting base and
joint head.
 The pins have to be secured with washers and cotter pins on
both sides.
 The thruster has to be traversable. Mounting base
 There must not be lateral forces at the piston rod.
 Misalignments of up to +/- 3° may be compensated.

BUEL®
DANGER!
NOTE!
If the unit is protected by a protective motor switch, insure that the thermal value which triggers
the switch is at least 1.5 times of the nominal lifting current (refer to type plate)!
IMPORTANT!
Connect a right handed field at the terminals L1, L2, L3
The phases must not be interchanged during the operation of the unit.
Terminal box
Fuse
3.15 A slow-blow
LED for the

surveillance of the
sensors
Terminals for
supply voltage
Terminal for heater or

inductive sensor

BUEL®
 The BUEL®-thrusters are operated with a 3-phase current

voltage of 220 V - 690 V at 50 Hz or 60 Hz.
 The connection to the power supply is done at the terminals
L1, L2, L3 and PE inside the terminal box of the BUEL®-
thruster.
 Connect according to wiring diagram on the previous page / on
the inside of the cover of the terminal box.
 The BUEL® -thruster is switched on / off via the main power
supply.
 The cable glands M25 on both sides of the terminal box or the
bottom side may be used for the connection to the power
supply.
 The possible diameter at the clamp for the supply cable is 9 –
17 mm.
 Make sure that gasket is correctly positioned and intact.
 Lock terminal box securely, tighten cable entry and seal it if
necessary.
 Also check the wiring diagram inside the cover of the terminal
box.
 For maritime applications the motor coil may be equipped with

an optional heating to prevent condensation.
 An additional heater for the thruster is also available for low
temperature applications.
 The heater is connected at the terminal “heating” (pins 1 – 2).
 1-1 and 2-2 are bridged.
 Possible heater voltages
110 V AC 50 Hz or 60 Hz
230 V AC 50 Hz or 60 Hz
 The standstill-heater is not meant for permanent operation.
Terminal for heater or
 It has to be switched on by the customer on case of longer inductive sensor
downtimes of the BUEL®-thruster.
 In case an inductive sensor (closer) is mounted to monitor the
upper end-position of the piston rod, the signal can be
connected at the pins 1 (+ 24V DC) and 2 (0 V).

BUEL®
5 Setting of the thruster
WARNING!
5.1 Adjust setting time - Option S
WARNING!
Changing the pre-set setting time of the thruster also changes the stopping distance of the
applied load!
Make sure the specified stopping distance of the brake installation is not exceeded. Also refer to
the operating-manual of the brake, esp. the section “load test”.
 Unscrew closure stud at throttle valve SW 5.

 Insert Allan-key SW 4 vertical into the screw head of the throttle closure stud -
valve. throttle valve
 Turn the screw head of the throttle valve to adjust the setting
time continuously:
Screw head
o Clockwise = Increasing the setting time
SW 4
o Counter clockwise = Reducing the setting time
o Adjusting range: 5 full turns
 The pre-set value is 0.3 seconds at nominal load and specified
operating conditions. Open and close brake several times to
check setting.
 Screw in closure stud and tighten it.

BUEL®
WARNING!
The correct setting of the thruster is essential for a safe operation of the brake!
Item
Function check
Stroke correct
Release time correct
Setting time correct

Operation
BUEL®
6 Operation
CAUTION!
CAUTION!
thruster.
o BUEL®-thrusters work in intermittent duty independent of the operation mode of the brake.
State of thruster State of brake

Thruster not energized Brake set
Thruster energized Brake opens and remains open
Thruster is being switched off Brake sets automatically
Power down or emergency stop Brake sets automatically
 In case of a power failure or after the EMERGENCY-STOP has been activated, the supply voltage of
the BUEL®-thruster is cut off by the installation.
 Due to the fail safe principle the des BUEL®-thruster is idle and the brake automatically closes via
spring force.
 A controlled opening of the brake is now only possible by means of the manual release device of the
brake.
 In case of a power down the brake also sets automatically.
 The pre-set setting times are still valid.

Operation
BUEL®
6.3 Switches and sensors – Option EB
CAUTION!
If sensors are mounted, it is not allowed to set them out of operation.
The data supplied by the sensors has to be processes in the installations control unit by the
customer.
An additional inductive sensor for the monitoring of the release control is available as an option.
Inductive Sensor with enhanced temperature range

Supplier: Hans Turck GmbH & Co. KG
Type: Bi2-EG08-AG41-X
DC 2-wire, 15...55 V DC
Closer, PNP-terminal
 Switching range 2.0 mm
6.4 Status-LEDs for operating conditions
 H1 –green LED
 H2 - yellow LED
H3
 H3 –red LED
 LED red, yellow, green off: Thruster idle H2

 LED yellow on: Motor type relay on
 LED yellow off: Motor type relay off
 LED green flashing: Normal operation H1
 LED red flashing: Motor switched off after 4 seconds via timer.

Maintenance
BUEL®
7 Maintenance
DANGER!
DANGER!
When the thruster is dismounted the brake is not active. The overall braking force of the
installation is reduced!
WARNING!
CAUTION!
thruster.
NOTE!
Also heed the corresponding sections of the operating instructions of the brake.
NOTE!

Maintenance
BUEL®
 Being a closed hydraulic system the BUEL®-thruster is a low maintenance system. Check the thruster
during the regular maintenance schedule of the brake.
 Contact the customer support service in case of a leakage.
 Please refer to the maintenance section of the operating manual of the brake.
Maintenance tasks Interval [operating hours]
Visual check for leakages During the regular maintenance schedule of the brake
Check movability of thruster During the regular maintenance schedule of the brake
Check for unusual noise emission During the regular maintenance schedule of the brake
Setting- and opening speed During the regular maintenance schedule of the brake
Correct stroke During the regular maintenance schedule of the brake
Check for corrosion During the regular maintenance schedule of the brake
Check correct earthing During the regular maintenance schedule of the brake
Replacement of hydraulic fluid 2 Million cycles / every 5 years
Check the thruster / brake system outside the regular inspection intervals if:
 A sensor indicates an incorrect stroke
7.2 Lubrication
As long as the BUEL®-thruster is not disassembled no lubrication or greasing is needed or allowed.

Maintenance
BUEL®
7.3 Cleaning
WARNING!
Danger due to chemical substances
brake cleaner) and proper cleaning materials like cloth.
The cleaning must be carried out with proper tools and agents. Never use tools like high pressure
cleaners or a wire brush.
WARNING!
The Installation has to be shut down during the cleaning process and has to be secured against
switching on again.
 Make sure the thruster is free from fat, oil, rust and other contaminations.
 Keep all movable parts clean

Maintenance
BUEL®
7.4 Refilling
NOTE!
Always heed the information and advices on the handling given in the safety data sheet of the
hydraulic medium.
NOTE!
Make sure the correct hydraulic fluid is used. Please refer to specification.
Different temperature ranges may require special hydraulic fluids.
WARNING!
Never open the thruster when it is hot! Escaping hot oil may cause burns! Before repair or
refilling, let the unit cool down to room temperature!
WARNING!
Risk of environmental pollution
The BUEL®-thrusters are filled with synthetic high performance fluid Pentosin CHF 11S for a use in the
temperature range of -30°C to +60°C.
Lifetime: 2 Million cycles / 5 years
 Disconnect thruster electrically
 Dismount BUEL®-thruster
o Please refer to the operating manual of the brake
joint head

Upper
 Loosen closure stud at the top of the thruster. closure stud
 Lay thruster on the side.
 Loosen lateral closure stud1/8”.
 Lay thruster on the side and let remaining fluid flow into
container. lateral
 Close lateral closure stud before refilling thruster. closure stud

Maintenance
BUEL®
 Alternatively the thruster may be turned upside down, being

fixed at the mounting base.
 Loosen closure stud at the top of the thruster.
Upper
closure stud
NOTE!
Use a funnel and fill in the hydraulic fluid slowly.
CAUTION!
In case to much hydraulic fluid is filled in, it can be emitted under pressure, e.g. at the piston rod.
The function of the thruster can also be affected after a certain time.
Always make sure the correct amount of hydraulic fluid is used.

 Put thruster in an upright position and secure it against falling. Upper
 Refill thruster with new hydraulic fluid according to closure stud
specification
 Use upper closure stud.
 Refer to table below for the capacity of the thruster.
 Close upper lateral closure stud.
 Remount BUEL®-thruster
 Reconnect BUEL®-thruster
 Make sure brake is reset correctly before restarting.
BL Capacity BL Capacity
35-5 0.35 l 300-6 0.55 l
50-6 0.35 l 300-12 0.60 l
50-12 0.35 l 400-8 0.55 l
80-6 0.40 l 400-10 0.55 l
80-12 0.40 l 440-8 0.55 l
125-6 0.40 l 450-8 0.55 l
125-12 0.40 l 550-8 0.55 l
200-6 0.40 l 600-8 0.55 l
200-12 0.40 l

Maintenance
BUEL®
7.5 Replacement of bearing at piston rod
 Remove cotter pin with punch.

o Size BL 35 - BL 80 – 1 pin
o Size BL 125 – BL 600 – 3 pins
 Push out bearing with aluminium or plastic tool.
 Check for cleanliness.
 Insert new bearing evenly into bore.

 Insert new cotter pin (s) completely into bore.

Maintenance
BUEL®
7.6 Replacement of seals at piston rod
NOTE
Use soft tools like a brass-screw driver to remove the seals! Use soft tools e.g. made of brass.
Never use a hard standard tool, as this will damage the surface of the cylinder and lead to
leakages!
 Unscrew headless screw.

 Fix piston rod with open spanner.
 Loosen head with plastic hammer by turning it counter
clockwise.
 Unscrew head.
 Loosen 3 screws at the disc using Phillips screwdriver (PH2).
 Remove disc carefully from recess by turning it and moving it

upwards.
 Remove rod seal from recess.
 Remove O-ring from lower side of disc.

Maintenance
BUEL®
 Place protective cover onto piston rod.

 Make sure the flat faces fit.
 Apply a bit of grease to the O-ring.

 Insert new O-ring at lower side of disc.
 Insert new rod seal into recess.
 Mount disc onto recess.
 Remove protective cover.

 Reinsert 3 screws into disc.
 Tighten screws with Phillips screwdriver (H2) (3 Nm).
 Screw head onto piston rod.

 Tighten with open wrench.
 Check alignment.
 Apply a bit of Loctite 242 onto headless screw.
 Screw headless screw into piston rod (3 Nm).

Troubleshooting
BUEL®
8 Troubleshooting
NOTE!
Also refer to section 6.4.
Please also refer to the troubleshooting-list of the brake.
Problem: BUEL® thruster does not open

Motor runs with wrong direction Re-connect supply voltage correctly 4.3
Power supply malfunctioning Check supply voltage 4.3
Not enough hydraulic fluid Check filling level and refill, if necessary. 7.4
Check LED
Sensor malfunctioning 6.4 / -
Contact customer support
Coil damaged. Contact customer support
Problem: BUEL® thruster does not set

Supply voltage still switched on Check supply voltage 4.3
Problem: Setting time to long

Throttle valve maladjusted Adjust throttle valve 5.1

BUEL®
DANGER!
WARNING!
WARNING!
9.2 Dismounting of thruster
WARNING!
switching on again.

BUEL®
9.3 Disposal
WARNING!
regulations!
components.
o Always check which operating fluid is used in the thruster.
o Drain the tank acc. to section 7.4 and dispose of the oil according to the corresponding laws and
regulations.

Spare part list
BUEL®
10 Spare part list
NOTE!
The use of spare parts, not meant for this thruster, can lead to a malfunction of the thruster or
damage the thruster!
NOTE!
In case of ordering, please indicate the type and the serial no. of the brake which is located on the
type plate of the thruster!
Please note, that the brake has a separate type plate.
Pos. Nr. Item
1 Piston rod with joint head and cotter pin

1 Seal-kit for piston rod incl. protective rod
1000 ml Hydraulic fluid Pentosin CHF 11S

Appendix
BUEL®
With joint head
11 Appendix
11.1 Data sheet
4 x M6; T mm deep
BL Fmax [N] A B C D E F G H K L M N O* P S T U W
35-5 600 370 16 34 15 30 20 16 18 16 250 80 40 160 80 136 10 24 M4
50-6 900 435 20 94 25 50 25 20 23 22 250 120 60 160 80 136 12 35 M5
50-12 900 515 20 114 25 50 25 20 23 22 250 120 60 160 80 136 12 35 M5
80-6 2000 450 20 66 25 50 25 20 23 22 250 120 60 160 80 136 13 35 M5
80-12 2000 530 20 86 25 50 25 20 23 22 250 120 60 160 80 136 13 35 M5
125-6 2500 645 25 69 30 60 31 25 35 25 250 90 40 160 80 136 13 45 M5
125-12 2500 705 25 129 30 60 31 25 35 25 250 90 40 160 80 136 13 45 M5
200-6 3600 645 25 69 30 60 31 25 35 25 250 90 40 160 80 136 13 45 M5
200-12 3600 705 25 129 30 60 31 25 35 25 250 90 40 160 80 136 13 45 M5
300-6 5000 645 25 78 30 60 31 25 35 25 270 90 40 180 90 152 12.5 45 M5
300-12 5000 705 25 138 30 60 31 25 35 25 270 90 40 180 90 152 12.5 45 M5
400-8 5500 645 25 78 30 60 31 25 35 25 270 90 40 180 90 152 12.5 45 M5
400-10 5500 645 25 78 30 60 31 25 35 25 270 90 40 180 90 152 12.5 45 M5
440-8 6500 648 25 81 30 60 31 25 35 25 270 90 40 180 90 152 12.5 45 M5
450-8 7000 645 25 78 30 60 31 25 35 25 270 90 40 180 90 152 12.5 45 M5
550-8 8000 665 25 98 30 60 31 25 35 25 270 90 40 180 90 152 12.5 45 M5
600-8 8000 665 25 98 30 60 31 25 35 25 270 90 40 180 90 152 12.5 45 M5

Appendix
BUEL®
NOTE!
The following values apply, unless another torque is given at a specific point in the manual.
These tightening torques apply for:

NOTE!
Used Nordlock-washers must not be used again!
8.8 10.9 12.9

M4 3,0 4,6 5,1 7
M5 5,9 8,6 10,0 8
M6 10,1 14,9 17,4 10
M8 24,6 36,1 42,2 13
M10 48 71 83 17 (16)
M12 84 123 144 19 (18)
M14 133 195 229 22 (21)
M16 206 302 354 24
M18 295 421 492 27
M20 415 592 692 30
M22 567 807 945 32 (34)
M24 714 1017 1190 36
M27 1050 1496 1750 41
M30 1428 2033 2380 46
M36 2482 3535 4136 55

Appendix
BUEL®
telephone number.
Plant Kirchen
Germany
Tel.: +49 (0) 27 41/94 88-0

Fax: +49 (0) 27 41/94 88-44

PB-Buel-en9.docx PINTSCH BUBENZER GmbH
Telefon +49 (0) 27 41/94 88-0
MADE IN GERMANY
Operating Manual for
Eldro Thruster

Postfach 123
Tel.: +49-2741 - 9488 - 0
Fax: +49-2741 - 9488 -44
GERMANY
PB70-0508-01/1
Operating manual
ELDRO - thruster
1 Safety regulations
Note: warnings and other security rules are presented like this throughout the manual:
All safety advises are marked by Symbols and frames!

Symbol / Pictograph Description
The thruster may only be used in the way described in chapter 2.3 “Description and proper 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 ELDRO thruster is part of an essential safety device.
Any misuse or insufficient handling or maintenance endangers life!
Also study the following manuals and Regulations:

 Operating manual of the brake
 Operating manual of the installation
 Safety precautions of the installation
 Valid Safety regulations
Before starting any work with the thruster:
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!
 Don’t use any mechanical devices to block the brake.

 Ensure, that the drive is disconnected from the electrical power supply.
 Ensure, that the brake is disconnected from the electrical power supply.
 Any electrical work is only to be done by a trained electrician.
 Only use original PINTSCH BUBENZER spare parts
 The thruster must not be disassembled.
Never open the thruster or the screw plug when it is hot! Escaping hot oil may cause burns!
Before repair or refilling, let the unit cool down to room temperature!
Page 2
Operating manual
ELDRO - thruster
2 Thruster
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 thruster. Furthermore these instructions should make sure that trained
and qualified personnel is able to handle the thruster 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 thruster or this manual, please contact PINTSCH BUBENZER quoting
the type and serial number of the thruster 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 thruster.
 Improper handling, setup, operation and maintenance of the thruster by the operating
company.
 Neglection of the regulations and notes in this manual concerning transport, setting up,
operation and maintenance of the thruster.
 Improper maintenance and repairs of the thruster.
 Improper monitoring of components, which are prone to wear.
 Catastrophes, external objects and forces and force majeure.
 Changes at the thruster without approval of PINTSCH BUBENZER.
The information in this manual has been checked thoroughly. Nevertheless we can’t accept liability
for errors.
2.3 Description and designated use
This manual describes the ELDRO thruster in connection with a elctrohydraulic brake of company
PINTSCH BUBENZER. The Eldro-Thruster is meant exclusively as a thruster for disc- or drum
brakes according to the specifications in your order. It serves to electro-hydraulically release a
brake. This version of the thruster is not suitable for use in areas with explosion hazards.
Any other use or any further change of the thruster 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!
As an option the ELDRO can be supplied with an integrated – non adjustable – brake spring. This
type is called C-ELDRO. In this case the brake must have no brake spring or be weight operated
Furthermore lifting- and lowering valves are available to open or close the brake slower. The
ELDRO may be equipped with a heater, that can either be used as an oil heater or a stand-still-
heater. To control the thruster a limit switch may be mounted.
Page 3
Operating manual
ELDRO - thruster
Nr. item
1 base mounting 6
2 Squirrel cage motor
3 Piston
5 7
4 Hydraulic fluid
5 Piston rod
6 Thruster ore 4
7 Oil filler
3
8 Hydraulic pump
9 terminal box
2
9
Fig. 1
When the motor (2) is switched on, the hydraulic fluid (4) inside the ELDRO is picked up and
pressed under the piston (3) by the pump (8). The piston-rod (5) is moved in arrow-direction. The
piton rod (5) pushes the thruster ore (6) upwards and the brake is released. As soon as the motor
(2) is switched off, the brake spring pushes the thruster ore (6) down. The piston (3) moves back
into its original position.
Page 4
Operating manual
ELDRO - thruster
2.4 Technical data
Note!
All technical values are average values. They apply for a run in thruster
filled with hydraulic fluid Shell Morlina 10 and an ambient temperature of
about 20°C / 68 °F.
Type Ed Lifting Stroke Braking Power con- Current Duty rating at Weight
force spring force sumption consumption S3-60% duty
(c-spring) at 400 V1) cycle
N mm N W A c/h kg
Ed 23/5 220 50 180 165 0,5 2000 10
Ed 23/5 BB 300 50 180 165 0.5 2000 10
Ed 30/5 300 50 270 200 0.5 2000 14
Ed 50/6 500 60 460 210 0.5 2000 23
Ed 80/6 800 60 750 330 1.2 2000 24
Ed 80/7 800 70 --- 330 1.2 2000 32
Ed 121/6 1250 60 1200 330 1.2 2000 39
Ed 201/6 2000 60 1900 450 1.3 2000 39
Ed 201/8 2000 80 --- 450 1.3 2000 39
Ed 301/6 3000 60 2700 550 1.4 1500 40
Ed 301/8 3000 80 --- 550 1.4 1500 40
Ed 301/8BB 4000 80 --- 550 1.4 1500 40
Ed 501/8 5000 80 --- 680 1,8 400 50
Ed 301/10BB 4000 100 --- 550 1.4 1500 40
Ed 50/12 500 120 --- 210 0.5 1200 26
Ed 80/12 800 120 --- 330 1.2 1200 27
Ed 121/12 1250 120 --- 330 1.2 1200 39
Ed 201/12 2000 120 --- 450 1.3 1200 39
Ed 301/12 3000 120 --- 550 1.4 900 40
Tye - Eg at 200V DC2)

Eg 50/6 500 60 460 350 1.6 1000 27
Eg 80/6 800 60 750 330 1.5 1000 27
Eg 121/6 1250 60 1200 330 1.5 1000 43
Eg 201/6 2000 60 1900 430 2.0 1000 43
Eg 301/6 3000 60 2700 470 2.2 800 43
Eg 50/12 500 120 --- 350 1.6 600 31
Eg 80/12 800 120 --- 330 1.5 600 31
Eg 121/12 1250 120 --- 330 1.5 500 44
Eg 201/12 2000 120 --- 430 2.0 500 44
Eg 301/12 3000 120 --- 470 2.2 400 44
1) U(400V)
Approximate calculation of the current consumption for non-standard voltages: Ix = ------------ I(400V)
U(x)
2) I(220V)
Page 5
Operating manual
ELDRO - thruster
Approximate calculation of the current consumption for non-standard voltages: Ix = ----------- U(220V)
U(x)
2.5 State of shipment and storage instructions
Note!
Depending on the type, the ELDRO thruster has a weight of up to 50 kg.
Always use a proper lifting device to transport the thruster!
Danger of injury!
 The thruster is shipped ready to mount and tested.

 Thrusters are shipped ready to use complete with hydraulic fluid. Refer to sticker (4) for grade
of fluid.
 Units are factory-set in star (Y) position.
 Never open the filler or overflow plugs without authorization as loss of oil will change the
technical values or disable some functions..
 Store and transport the thruster dust- and waterproof.

 Protect the thruster during the whole storage- and transport time against damage.

 Rod of the thruster
 Electrical components
 Signs and plates
If the thruster isn’t installed directly after delivery heed the following instructions:
 Store and / or transport the thrusters dust- and waterproof with drying agent until installation.
 Protect the brake against external damages during the complete storage- / transport-period.
Page 6
Operating manual
ELDRO - thruster
3 Set-up
Warning!
3.1 Mounting
 As the Eldro thruster is swivel-mounted, it must be connected with

flexible cable. 6
 Vertical mounting:
o piston rod (6) on top.
 Horizontal and all intermediate positions:
o Data plate (101) facing up.
 For other mounting positions contact the manufacturer.
 The mounting bases of types Ed 50 to Ed 301 can either be rotated
through 90°.
 The swivel-mounting must not be obstructed. 10
 No lateral forces may act on the piston rod..
Fig. 2:
Valve adjustment
 Markings: "H" = Lifting valve, "S" = Lowering valve
 Refer to data-plate (10).
 Remove plug "H" (11) or plug "S" (12).
 To adjust lifting and/or lowering times
 Rotate set screw (13 for 11) or (14 for 12). 11 15 12
o Clockwise rotation: Increase the floating
time.
o Counter clockwise rotation: Decrease the
floating time.
o Regulating distance max. 20 rotations.
 The valves are factory-set to 5 sec. time delay.
 Fasten plug after adjustment is finished.
11 / 12
13 / 14
Fig. 3:
Page 7
Operating manual
ELDRO - thruster
Danger!
The electrical connection and all other electrical tasks must only be done
by a trained electrician!
Important!
If the unit is protected by a protective motor switch, insure that the thermal
value which triggers the switch is at least 1.5 times of the standby current
(refer to type plate)!
 Follow terminal diagram inside terminal box cover when connecting unit.
 Insure that gasket is correctly positioned and intact.
 Lock terminal box securely, tighten cable entry and seal it if necessary.
AC-Eldros:
 The motor can be converted from delta ( ) to star (Y) connection.
Standard-terminal box:
1 – Protective Earth terminals

2 – Jumper
3 – Motor connection terminals
Fig. 4:
3.3 ELDRO with Heating
Depending on the application of the heater and the supply voltage (120 / 230 V) there are different
connection diagrams.
When used as a oil heater, that starts up when the ambient temperature drops below -25°C / -
13°F:
 refer to fig. 5, independent of the supply voltage.
When used as a stand still heater, that starts up when the pump motor is switched off:
 refer to fig. 5, for 120 V supply voltage.
 refer to fig. 6, for 230 V supply voltage.
Page 8
Operating manual
ELDRO - thruster
1 – Heater connection terminals

2 – Jumper
3 – Motor connection terminals
4 – Pg-union for the heater cable
5 – Protective Earth terminal
6 – Pg-union for the motor cable
Fig. 5:
Supply voltage
Standby Voltage 240 V 3 Phasen
Terminal block Eldro with heating 120 V

Fig.6:
3.4 ELDRO with High speed lowering circuit
Important!
The high speed lowering circuit needs a stronger fuse than the standard
ELDROs. Mount a circuit breaker type D-10A.
Siemens 5SY4310-8. Refer to wiring diagram (fig. 7).
This thruster is equipped with a high speed lowering circuit. It allows for a 15% faster setting time.
Supply Voltage 380-480 V 3Ph / PE
Fig. 7: ELDRO-Brake
Page 9
Operating manual
ELDRO - thruster
4 Maintenance
Warning!
 Being an enclosed System, the ELDRO-thrusters are low maintenance. Check the thruster for
leakages regularly. In case of a leakage an authorized specialist has to be called.
 For further maintenance-instructions refer to the operating manual of the brake.
ELDRO- thruster are supplied for a temperature range from:

-25°C to+50°C and filled with hydraulic oil Morlina 10 of class HL10 DIN 51524.
-10°C to+60°C and filled with hydraulic oil Morlina 22 of class HL22 DIN 51524.
+5°C to+80°C and filled with hydraulic oil Morlina 46 of class HL46 DIN 51524.
Different temperature ranges require special fluids. This "long-life"-filling is not subject to wear or
contamination during operation, as long as the thruster is in perfect condition.
In case of refilling after repair, all other makes of class HL 10 DIN 51524 (-25°C to +50°C) / HL22
DIN 51524 (-10°C to 60°C) / HL46 DIN 51524 (+5°C to +80°C) may be used.
All bearings in the ELDRO thruster receive an original lubrication of grease with the long life grease
type K-L3n to DIN 51825 (for example SHELL Alvania R3). For other temperature ranges a special
grease is used
ELDRO thrusters in explosion-proof design are filled with a hardly inflammable hydraulic fluid
This fluid meets the requirements of the EN-Commission.
In case of refilling on site, the thruster has to be filled in vertical position up to the overflow screw or
to the filling limit of the charging connection, depending on the thruster type.
In order to prevent possible inclusions of air, run the unit through several strokes.
Then check oil level again and top up if necessary.
Finally, tighten charging connection and overflow screw.
Eldro Type Filling quantity Eldro Type filling quantity Eldro Type filling quantity
(litres) (litres) (litres)
Ed 23/5 1.6 Ed 301/8 9.2 Eg 80/6 4.2
Ed 23/5 BB 1.6 Ed 301/8 BB 9.2 Eg 121/6 9.4
Ed 30/5 1.9 Ed 301/10 BB 9.2 Eg 201/6 9.4
Ed 50/6 4.2 Ed 501/8 BB 11 Eg 301/6 9.4
Ed 80/6 4.2 Ed 50/12 5.5 Eg 50/12 5.5
Ed 80/7 4.2 Ed 80/12 5.5 Eg 80/12 5.5
Ed 121/6 9.4 Ed 121/12 9.4 Eg 121/12 9.4
Ed 121/8 9.4 Ed 201/12 9.4 Eg 201/12 9.4
Ed 201/6 9.4 Ed 301/12 9.2 Eg 301/12 9.4
Ed 201/8 9.4 Ed 185/16 9.4
Ed 301/6 9.2 Eg 50/6 4.2
Average values, which differ for thrusters with valves and/or springs.
Page 10
Operating manual
ELDRO - thruster
When the thruster is put out of service, the following instructions have to be heeded to help
avoiding dangers to life, material and environment:
The thruster must only be put out of service and disposed by trained and qualified personnel.
Always heed the applying laws and regulations!
Important!
Because of the weight of the thruster always use proper lifting devices!
Danger of injury!
Warning!
A sudden startup of the installation endangers the life of the working
Danger!
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.
Warning!
Never open the thruster or the screw plug when it is hot! Escaping hot oil
may cause burns! Before repair or refilling, let the unit cool down to room
temperature!
Page 11
Installation Manual for
ELHY Thruster

Tel.: +49-2741 - 9488 - 0
Fax: +49-2741 - 9488 -44
GERMANY
PB72-0614-01/2
Operating Manual
ELHY - thruster
1 Safety regulations
Note: warnings and other security rules are presented like this throughout the manual:
All safety advises are marked by Symbols and frames!

Symbol / Pictograph Description
The thruster may only be used in the way described in chapter 2.3 “Description and proper 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 ELHY thruster is part of an essential safety device.
Any misuse or insufficient handling or maintenance endangers life!
Also study the following manuals and Regulations:

 Operating manual of the brake
 Operating manual of the installation
 Safety precautions of the installation
 Valid Safety regulations
Before starting any work with the thruster:
Warning!
 Don’t use any mechanical devices to block the brake.

 Ensure, that the drive is disconnected from the electrical power supply.
 Ensure, that the brake is disconnected from the electrical power supply.
 Any electrical work is only to be done by a trained electrician.
 Use only genuine PINTSCH BUBENZER spare parts.
 The thruster must not be disassembled.
Never open the thruster or the screw plug when it is hot! Escaping hot oil may cause burns!
Before repair or refilling, let the unit cool down to room temperature!
Page 2
Operating Manual
ELHY - thruster
2 Thruster
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 thruster. Furthermore these instructions should make sure that trained
and qualified personnel is able to handle the thruster 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 thruster or this manual, please contact PINTSCH BUBENZER quoting
the type and serial number of the thruster 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 thruster.
 Improper handling, setup, operation and maintenance of the thruster by the operating
company.
 Neglection of the regulations and notes in this manual concerning transport, setting up,
operation and maintenance of the thruster.
 Improper maintenance and repairs of the thruster.
 Improper monitoring of components, which are prone to wear.
 Catastrophes, external objects and forces and force majeure.
 Changes at the thruster without approval of PINTSCH BUBENZER.
The information in this manual has been checked thoroughly. Nevertheless we can’t accept liability
for errors.
2.3 Description and designated use
This manual describes the ELHY thruster in connection with a thruster brake of company
PINTSCH BUBENZER. The ELHY-Thruster is meant exclusively as a thruster for disc- or drum
brakes according to the specifications in your order. It serves to electro-hydraulically release a
brake. This version of the thruster is not suitable for use in areas with explosion hazards.
Any other use or any further change of the thruster 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!
As an option the ELHY can be supplied with an integrated brake – non adjustable – brake spring.
This type is called C-ELHY. In this case the brake must have no brake spring or be weight
operated. Furthermore lifting- and lowering valves are available to open or close the brake slower.
Page 3
Operating Manual
ELHY - thruster
Nr. item
1 base mounting 6 7
2 Squirrel cage motor
3 Piston 5
4 Hydraulic fluid
5 Piston rod
6 Thruster ore 4
7 Oil filler
8 Hydraulic pump
3 8
9 Terminal box
2
9
Fig. 1
When the motor (2) is switched on, the hydraulic fluid (4) inside the ELHY is picked up and pressed
under the piston (3) by the pump (8). The piston-rod (5) is moved in arrow-direction. The piton rod
(5) pushes the thruster ore (6) upwards and the brake is released. As soon as the motor (2) is
switched off, the brake spring pushes the thruster ore (6) down. The piston (3) moves back into its
original position.
Page 4
Operating Manual
ELHY - thruster
2.4 Technical data
Note!
All technical values are average values. They apply for a run in thruster
filled with transformer oil Shell Diala S3 ZX-I10 and an ambient temperature
of about 20°C / 68 °F.
Type Ed Lifting Stroke Braking spring Power con Current consumption Weight
force force (c-spring) -sumption at 400 V1)
N mm N W A kg
EB 120-40 120 40 120 130 0,4 7.5
EB 220-50 220 50 220 160 0.4 9.3
EB 300-50 300 50 270 140 0.3 9.6
EB 500-60 500 60 500 200 0.4 13.1
EB 800-60 800 60 800 260 0.5 19.0
EB 1250-60 1250 60 1250 380 0.6 20.6
EB 2000-60 2000 60 2000 500 0.7 32.8
EB 3000-60 3000 60 3200 550 0.9 39.0
EB 500-120 500 120 500 200 0.4 14.8
EB 800-120 800 120 800 380 0.5 23.0
EB 1250-120 1250 120 1250 380 0.6 24.2
EB 2000-120 2000 120 2000 500 0.7 32.8
EB 3000-120 3000 120 --- 550 0.9 39.0
1) U(400V)
Approximate calculation of the current consumption for non-standard voltages: Ix = ------------ I(400V)
U(x)
Page 5
Operating Manual
ELHY - thruster
2.5 State of shipment and storage instructions
Note!
Depending on the type, the ELHY thruster has a weight of up to 44 kg.
Always use a proper lifting device to transport the thruster!
Danger of injury!
 The brake is shipped ready to mount and tested.

 The brake is shipped with spring under tension, if a thruster is mounted.
 Thrusters are shipped ready to use complete with hydraulic fluid. Refer to sticker (4) for grade
of fluid.
 Never open the filler or overflow plugs without authorization as loss of oil will change the
technical values or disable some functions.
 Store and transport the thruster dust- and waterproof.

 Protect the thruster during the whole storage- and transport time against damage.

 Rod of the thruster
 Electrical components
 Signs and plates
If the thruster isn’t installed directly after delivery heed the following instructions:
 Store and / or transport the thrusters dust- and waterproof with drying agent until installation.
 Protect the brake against external damages during the complete storage- / transport-period.
Page 6
Operating Manual
ELHY - thruster
3 Set-up
Warning!
3.1 Mounting
 As the ELHY thruster is swivel-mounted, it must be connected with 6

flexible cable.
 Vertical mounting:
o piston rod (6) on top.
 Horizontal and all intermediate positions:
o Data plate (10) facing up.
 For other mounting positions contact the manufacturer.
 The swivel-mounting must not be obstructed.
 No lateral forces may act on the piston rod..
Fig. 2:
10
Valve adjustment
The adjustment is done while the thruster is standing upright, even when
it will be mounted in lying position.
 Markings: "H" = Lifting valve, "S" = Lowering valve
 Refer to data-plate (10).
 Remove screw "H" (11) or plug "S" (12).
 To adjust lifting and/or lowering times
 Rotate set screw (13 for 11) or (14 for 12).
o Clockwise rotation: Increase the floating time.
o Counter clockwise rotation: Decrease the floating time.
o Regulating distance max. 6 revolutions.
 The valves are factory-set to 3 revolutions.
 Fasten screw after adjustment is finished.
13 / 14 11 / 12
11 / 12 13 / 14 11 / 12
13 / 14
Fig. 3: EB120-40 EB220-50 EB300-x – EB 3000-x
Page 7
Operating Manual
ELHY - thruster
Danger!
Important!
If the unit is protected by a protective motor switch, insure that the thermal
value which triggers the switch is at least 1.5 times of the standby current
(refer to type plate)!
Follow terminal diagram inside terminal box cover when connecting unit.
 Insure that gasket is correctly positioned and intact.
 Lock terminal box securely, tighten cable entry and seal it if necessary.
 Phase sequence can be chosen when connecting to mains.
PE L1 M25
PE L1 M25
L2
L3
L3 L2
Fig. 4: 3-Pole terminal board 6-Pole terminal board
PE: Protective earth

L1, L2, L3: Mains, 3 Phase (Phase sequence can be chosen when connecting)
M25: Connection
V2 W1 V2 W1
L1 L1
U2 V1 U2 V1
L2 L2
L3 L3
W2 U1 W2 U1
Fig. 5: Star-connection at 6-pole terminal board Delta-connection at 6-pole terminal board
Page 8
Operating Manual
ELHY - thruster
4 Maintenance
Warning!
Warning!
temperature!
 Being an enclosed System, the ELHY-thrusters are low maintenance. Check the thruster for
leakages regularly. In case of a leakage an authorized specialist has to be called.
 For further maintenance-instructions refer to the operating manual of the brake.
ELHY- thruster are supplied for a temperature range from:

-25°C to+50°C and filled with transformer oil Shell Diala S3 ZX-I.
-40°C to+40°C and filled with silicone oil Dow Corning 200 Fluid 10ct.
Attention!
For the use with silicone oil the ELHY is equipped with a special pump. It is
not allowed to switch between transformer- and silicone-oil, otherwise the
thruster will be damaged!
Different temperature ranges require special fluids. This "long-life"-filling is not subject to wear or
contamination during operation, as long as the thruster is in perfect condition.
All bearings in the ELHY thruster receive an original lubrication of grease with the long life grease
type K-L3n to DIN 51825 (for example SHELL Alvania R3). For the other temperature ranges a
special grease is used.
In case of refilling on site, the thruster has to be filled in vertical position up to the overflow screw or
to the filling limit of the charging connection, depending on the thruster type.
In order to prevent possible inclusions of air, run the unit through several strokes.
Then check oil level again and top up if necessary.
Finally, tighten charging connection and overflow screw.
ELHY Type Filling quantity ELHY Type filling quantity ELHY Type filling quantity
(litres) (litres) (litres)
EB 120-40 1.2 l EB 1250-60 4.3 l EB 800-120 6.0 l
EB 220-50 2.6 l EB 2000-60 9.0 l EB 1250-120 6.0 l
EB 300-50 1.8 l EB 3000-60 10.1 l EB 2000-120 9.0 l
EB 500-60 2.6 l EB 500-120 3.5 l EB 3000-120 10.1 l
EB 800-60 4.3 l
Average values, which differ for thrusters with valves and/or springs.
Page 9
Operating Manual
ELHY - thruster
When the thruster is put out of service, the following instructions have to be heeded to help
avoiding dangers to life, material and environment:
The thruster must only be put out of service and disposed by trained and qualified personnel.
Always heed the applying laws and regulations!
Important!
Because of the weight of the thruster always use proper lifting devices!
Danger of injury!
Warning!
A sudden startup of the installation endangers the life of the working
Danger!
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.
Warning!
temperature!
Page 10
Zulässige Mindestdicke für Bremsscheiben:
Originaldicke minus 3mm bei Bremsscheibendicke > 20mm
Originaldicke minus 2mm bei Bremsscheibendicke ≤ 20mm
≤
Minimum permissible thickness for brake discs:

Original thickness minus 3mm for brake discs with a thickness > 20mm
Original thickness minus 2mm for brake discs with a thickness ≤ 20mm
IG0400 Seite 1 von 2
IG0400
IGA2005-ARKA Inductive sensors
Made in Germany
Product characteristics
Inductive sensor
Metal thread M18 x 1
Cable
Sensing range 5 mm; [f] flush mountable
Electrical data
Electrical design AC/DC
Operating voltage [V] 75...250 AC / 20...250 DC
Protection class II
Reverse polarity protection yes
Outputs
Output function normally open
Voltage drop [V] < 5.5
Minimum load current [mA] 4
Leakage current [mA] <4
Current rating
- Current rating (continuous) [mA] 100
- Current rating (peak) [mA] î: 0.9 A (20 ms / 0.5 Hz)
Short-circuit protection Yes (non-latching)
Overload protection yes
Switching frequency [Hz] 25 AC / 50 DC
Monitoring range
Sensing range [mm] 5
Real sensing range (Sr) [mm] 5 ± 10 %
Operating distance [mm] 0...4.05
Accuracy / deviations
Correction factors mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / aluminium approx. 0.4 /
copper approx. 0.3
Hysteresis [% of Sr] 1...15
Switch-point drift [% of Sr] -10...10
Environment
Ambient temperature [°C] -25...80
Protection IP 67
Tests / approvals
EMC EN 61000-4-2 ESD: 4 kV CD / 8 kV AD
file:///D:/NotesData/VSTemp/IG0400.hta 03.03.2015
EN 61000-4-3 HF radiated: 3 V/m

EN 61000-4-4 Burst: 2 kV
EN 61000-4-6 HF conducted: 3V
EN 55011 (Emission): class B
MTTF [Years] 397
Mechanical data
Mounting flush mountable
Housing materials threaded sleeve: brass white bronze coated; active face: PBT; end cap: PC / TPE
Weight [kg] 0.132
Displays / operating elements
Output status indication LED yellow
Electrical connection
Connection PVC cable / 2 m; 2 x 0.34 mm²; Ø 4.9 mm
Wiring
Core colors
BN brown
BU blue
Accessories
Accessories (included) 2 lock nuts
Remarks
Pack quantity [piece] 1
ifm efector, inc. 782 Springdale Drive, Exton, PA 19341 — We reserve the right to make technical alterations without prior notice. — US — IG0400-06 — 23.04.2010
IG0403
IGA2005-BRKA Inductive sensors
Made in Germany
Inductive sensor
Metal thread M18 x 1
Cable
Sensing range 5 mm; [f] flush mountable
Electrical data
Operating voltage [V] 90...230 AC / 24...230 DC (45...65 Hz AC)
Protection class II
Outputs
Output function Normally closed
Leakage current [mA] < 0.9 (250 V AC) / < 0.8 (24 V DC)
Current rating
Short-circuit protection pulsed
Range
Correction factors
mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / Al approx. 0.4 / Cu
approx. 0.3
Environment
Protection IP 67
Tests / approvals
EN 61000-4-3 HF radiated: 10 V/m (80...2000 MHz)
EN 61000-4-4 Burst: 2 kV
EN 61000-4-5 Surge: 1 kV / (line to line, Ri: 42 Ohm)
EN 61000-4-6 HF conducted: 10 V (0.15...80 MHz)
MTTF [Years] 394
Mechanical data
Mounting flush mountable
Housing materials threaded sleeve: Brass white bronze coated; active face: PBT; end cap: TPE / PC
Weight [kg] 0.132
Wiring
Core colours
BN brown
BU blue
Accessories
Accessories (included) 2 lock nuts
Remarks
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen — We reserve the right to make technical alterations without prior notice. — GB — IG0403-00 — 28.08.2009
IN0136 Seite 1 von 2
IN0136
IN-2003-BRKA Inductive sensors
1: threaded insert M3, depth 5.8 mm, max. tightening torque 1.2 Nm (screw fixing class 8.8) when brass insert in contact with
counterpart.
Made in Germany
Inductive sensor
Rectangular, plastics
Cable
Sensing range 3 mm; [nf] non-flush mountable
Electrical data
Operating voltage [V] 90...250 AC / 24...250 DC (45...65 Hz AC)
Protection class II
Outputs
Output function normally closed
Leakage current [mA] < 0.9 (250 V AC) / < 0.8 (24 V DC)
Current rating
Short-circuit protection Yes (non-latching)
Monitoring range
Correction factors mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / aluminium approx. 0.4 /
copper approx. 0.3
Environment
file:///D:/NotesData/VSTemp/IN0136.hta 03.03.2015
IN0136 Seite 2 von 2
Protection IP 67
Tests / approvals
EN 61000-4-3 HF radiated: 10 V/m
EN 61000-4-4 Burst: 2 kV
EN 61000-4-5 Surge: 1 kV (line to line, Ri: 42 Ohm)
EN 61000-4-6 HF conducted: 10 V
MTTF [Years] 399
Mechanical data
Mounting non-flush mountable
Housing materials housing: PBT; end cap: TPE
Weight [kg] 0.098
Wiring
Core colors
BN brown
BU blue
Remarks
ifm efector, inc. 782 Springdale Drive, Exton, PA 19341 — We reserve the right to make technical alterations without prior notice. — US — IN0136-00 — 06.01.2015
file:///D:/NotesData/VSTemp/IN0136.hta 03.03.2015

Standard Dokumentation + SD SB16 En1!1!00

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Standard-Documentation disc brake SB 16

Dimension sheets disc brake SB 16 SB 16 mit BUEL-en

2018 PINTSCH BUBENZER GmbH

PINTSCH BUBENZER GmbH

ca. 250 ca. 160

Right-hand execution Left-hand execution

*) Average static coefficient of friction

The coefficient of friction is subject to fluctuations depending

ca. 200 ca. 160

150 80 Right-hand execution Left-hand execution

270 *) Average static coefficient of friction

for standard material combination

Operating manual- Translation

3 Product description .................................................................................................... 13

4 Mounting of the brake ................................................................................................. 18

5 Set-up of the brake...................................................................................................... 22

©2018 PINTSCH BUBENZER GmbH

5.5 Load test ...................................................................................................................................................... 29

9 Putting out of service and disposal ........................................................................... 49

10 Spare parts .................................................................................................................. 52

©2018 PINTSCH BUBENZER GmbH

©2018 PINTSCH BUBENZER GmbH

1.3 Guarantee and liability

©2018 PINTSCH BUBENZER GmbH

1.5 Presentation of hazard warnings

©2018 PINTSCH BUBENZER GmbH

Symbols of hazard warnings

Warning of a danger point

Warning of dangerous voltage

Warning of automatic start

Warning of cut and crush injuries

Warning of hot surfaces

Warning of environmental pollution

Warning of falling loads

©2018 PINTSCH BUBENZER GmbH

1.6 Notices and obligations of the plant operator

1.7 Personnel training

Assembly, commissioning, operating and upkeep/maintenance personnel must be adequately qualified

1.8 Protective equipment

During all work on the product

©2018 PINTSCH BUBENZER GmbH

©2018 PINTSCH BUBENZER GmbH

2.2 Use in accordance with the intended purpose

2.3 Use not in accordance with the intended purpose

©2018 PINTSCH BUBENZER GmbH

2.4 Residual risks

For all jobs on the brake, make sure that

2.5 Procedure in the event of Emergency STOP or power failure

©2018 PINTSCH BUBENZER GmbH

2.6 Safety notes for assembly, start-up and maintenance

Electrical jobs may only be carried out by trained electricians!

©2018 PINTSCH BUBENZER GmbH

2.7 Notes on waste disposal

Due attention is to be paid to the environmentally friendly disposal of consumables, lubricants,

Electrical waste is to be collected separately and passed on for recycling.

©2018 PINTSCH BUBENZER GmbH

3.1 View of product

©2018 PINTSCH BUBENZER GmbH

Switches and sensors

Pos. Item Pos. Item

©2018 PINTSCH BUBENZER GmbH

3.3 Technical data

With organic With sintered

Maximum running speed 50 m/s 90 m/s