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伊顿盘式辅助刹车使用操作保养说明书英文版

伊顿盘式辅助刹车使用操作保养说明书英文版
伊顿盘式辅助刹车使用操作保养说明书英文版

Airflex? DBBS Brake Assemblies

Installation, Operation and Maintenance Manual DBB 8110

DBBS Brakes General Information

Warning

Forward this manual to the person responsible for Installation,

Operation and Maintenance of the product described herein. Without access to this information, faulty Installation, Operation or Maintenance may result in personal injury or equipment damage.

Caution

Use Only Genuine Airflex? Replacement Parts

The Airflex Division of Eaton Corporation recommends the use of genuine Airflex replacement parts. The use of non-genuine Airflex replacement parts could result in substandard product performance, and may void your Eaton warranty. For optimum performance, contact Airflex:

In the U.S.A. and Canada: (800) 233-5890

Outside the U.S.A. and Canada: (216) 281-2211

EATON Airflex? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012 2

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 20123

1.0 INTRODUCTION ............................................................................................................................................................06 1.1 Description ........................................................................................................................................................06 1.2

How It Works (06)

2.0 INSTALLATION (06)

2.1 Alignment ..........................................................................................................................................................06 2.2 Mounting ...........................................................................................................................................................07. 2.3 Air Supply System .............................................................................................................................................08 3.0 O P ERATION . (09)

3.1 Pressure and Speed Limits ...............................................................................................................................09 3.2 Initial Operation .................................................................................................................................................09 3.3 Periodic Inspection ............................................................................................................................................11 4.0 MAINTENANCE . (11)

4.1 Wear Limits .......................................................................................................................................................11 4.2 Wear Adjustment ..............................................................................................................................................11 4.3 Friction Disc Replacement ................................................................................................................................17. 4.4 Cylinder Seal Replacement ...............................................................................................................................19 4.5

Spring Replacement (20)

5.0 ORDERING INFORMATION / TECHNICAL ASSISTANCE ..........................................................................................22 6.0 PARTS LISTS .. (23)

6.1

Basic Assemblies (23)

DBBS Brakes

T able of Contents

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

4DBBS Brakes

Index of T ables

Index of Figures

Table No. Table Title Page No.

1 Item Descriptions

5 2 Alignment Requirements

7.3 Brake Sizes Requiring Rigid Support

7.4 Fastener Description and Assembly Torque 85 Maximum Disc Speeds 96 Wear-in Parameters

97. Wear Limits for DBBS Components 138 Wear Gap Values 149 Power Head Weights 14

Figure No. Figure Title Page No.

1 DBBS Cross Section and Item Numbers 5

2 Proper vs Improper Alignment of DBBS 7.

3 Clutch/Brake Overlap

114 Dust/Wear Grooves & Wear Step in Friction Discs 125 Wear Adjustment Gap Location 14 6 DBBS Single Disc 157. DBBS Two Disc 158 DBBS Three Disc 159 DBBS Four Disc

1510 Solid Wear Spacer (stored) Location 1611 Split Wear Spacer (removal) 17.12 Cylinder Seal Orientation 19

DBBS Brakes Table 1

Item Description

ITEM DESCRIPTIO

N

2 Mounting Flange 6 Stud

8 Friction Disc

12 Clamp Tube

14 Pressure Plate

16 Spring Housing

17. Flat Washer

18 Locknut

19 Cylinder

20 Hex Head Screw

21 Inner Lip Seal

22 Spring Item Description

ITEM DESCRIPTIO

N

23 Outer Lip Seal

27. Spacer Tube

28

G ear

29 Wear Spacer 31 Reaction Plate 34 Release Spring

52 Inner Spring

53 Spring Retainer

57. Flat Head Screw

58 Disc

105 Brass Pipe Plug

Figure 1 (2 Disc DBBS)

EATON Airflex? DBB 8110 Brake Assembly E-CLCL-TT001-E December 20125

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

6

Throughout this manual there are a number of

HAZARD WARNINGS that must be read and adhered to in order to prevent possible personal injury and/or damage to equipment. Three signal words

“DANGER”, “WARNING”, and “CAUTION” are used

Danger

Denotes the most serious hazard, and is used when serious injury or death WILL result from misuse or failure to follow specific instructions.

Used when serious injury or death MAY result from misuse or failure to follow specific instructions.

Used when injury or product / equipment damage may result from misuse or failure to follow specific instructions.

It is the responsibility and duty of all personnel involved in the installation, operation, and

maintenance of the equipment on which this device is used to fully understand the ! Danger ! Warning and ! Caution procedures by which hazards are to be avoided.

1.1 Description 1.1.1

The Airflex Model DBBS brakes were designed for heavy-duty industrial applications where spring set (power off) braking is required.

1.1.2

All Airflex DBBS brakes are supplied with long wearing, Non-Asbestos Friction material and solid cast, rotating discs.

1.1.3

Airflex DBBS brakes are available in four basic sizes and can be supplied as single, dual, triple or quadruple disc units. The model number identifies the number of discs and the disc diameter. For

example, 225DBBS indicates the brake uses two 25 inch diameter discs. When size, such as 25DBBS is referred to in this manual, it means that the

information given applies to all DBBS models using 25 inch diameter discs; i.e. 125DBBS, 225DBBS, etc...

1.1.4

This manual includes metric equivalents usually shown in parentheses ( ) following the U.S.

measurement system value. Be sure to use the correct value.

1.2

How It Works

1.2.1

Referring to Figure 1 and Table 1, the gear (28) is mounted on the shaft which is to be stopped. The brake assembly is attached to the machine frame or reaction bracket. As air pressure is applied through the ports in the cylinder (19), the cylinder and pressure plate (14), which are attached to each

other with screws (20), flat washers (17.) and spacer tubes (27.), move away from the mounting flange (2), which is connected to the machine frame or reaction bracket. The pressure plate compresses the springs (22) (52) against the stationary spring housing (16) and the clamp force is removed from the discs (58) which ride on the gear. The shaft is then free to rotate.

1.2.2

As air pressure is exhausted, the springs (22) force the pressure plate (14) toward the mounting flange (2), clamping the rotating discs (58) between the stationary friction discs (8) which are attached to the pressure plate (14) and mounting flange (2). On two, three and four disc models, a reaction plate (31), to which friction discs are mounted, and an additional disc are clamped between the pressure plate and mounting flange.

2.0 Installation

Danger

Prior to installation of the DBBS brake, make sure that the machinery will remain in a secured position. Failure to do so could result in serious personal injury or possibly death.

2.1 Alignment 2.1.1

For proper operation and service life, the DBBS brake must be mounted concentric and at right angles to the shaft within the limits shown on Table 2.CAUTION

Proper alignment is necessary to assure that the discs (58) will track properly. Improper alignment will result in excessive wear to the friction discs (8), discs (58) and gear (28). See Figure 2.

DBBS Brakes

1.0 Introduction

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 20127

2.1.2

To aid in obtaining accurate readings, a rigid bracket should be fabricated for mounting a dial indicator when checking alignment.

2.1.3

Bearing or machinery manufacturers may require different alignment tolerances. Use the tightest of those recommended.

2.2 Mounting

Support brackets for external stud support may be required for specific brake models. See Table 3 for models requiring support brackets. Consult Eaton

Airflex Engineering for design parameters. Warning

Failure to properly support studs as noted in Table 3 may result in drastic loss of torque, brake damage and brake failure.

2.2.1

Ensure that the shaft is clean and free of nicks or burrs and that the key fits properly in the shaft and

gear. Tap the key into the shaft keyway.

2.2.2

On multiple disc brakes, before installing the gear onto the shaft, slide it into the brake assembly to align the splines on the discs. Air pressure must

be applied to the brake to release the discs for

alignment. Once the gear passes through all discs, exhaust the air to clamp them into position and remove the gear.

Warning

Maximum allowable air pressure is 120 psig (8.2 bar) for sizes 20DBBS, 25DBBS and 38DBBS. Maximum allowable air pressure is 150 psig (10.3 bar) for the 50DBBS. Application of pressure exceeding maximum allowable may result in damage to the brake.

2.2.3

Apply a light coat of anti-seizing compound to the shaft.

2.2.4

To install the gear, heat uniformly to approximately 250°F (121°C), prior to pressing the gear onto the shaft. Making sure the dimension between the gear and brake mounting surface (“A”) is held at 1.00” (25.4) for sizes 20DBBS, 25DBBS and 38DBBS and 2.00” for size 50DBBS. See Figure 1.

Do not allow the gear temperature to exceed 350°F (17.6°C). Overheating the gear will adversely affect the hardness and wear life.

2.2.5

Apply a light coat of Castrol Molub-Alloy 936SF Heavy grease or equivalent to the gear teeth and slide the brake assembly onto the gear.

Note

For reference, Eaton Airflex part number for the specified grease is 000153X1182.

TABLE 2

Alignment Requirements

Concentricity Perpendicularly (Parallel, TIR) (Angular, TIR) of of Shaft and Mounting Flange

Element to shaft* Size

(Inches (mm)) (Inches (mm))

20DBBS 0.010 (0,25) 0.010 (0,25)25DBBS 0.010 (0,25) 0.012 (0,30)38DBBS 0.010 (0,25) 0.019 (0,48)50DBBS 0.010 (0,25) 0.025 (0,64)

*Perpendicularity measured near the O.D. of the mounting flange.

TABLE 3

Brake Sizes Requiring Rigid Support Bracket *

No. of Discs

20DBBS

25DBBS

38DBBS

50DBBS

3 x

4 x x x x

* Customer must provide a RIGID support on the cylinder end of the brake. Consult Eaton Airflex

Engineering for design parameters.

CORRECT

INCORRECT

Figure 2

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

82.2.6

While supporting the brake, connect an air supply and apply enough pressure to release the brake.

Attach the mounting flange (2) to the brake mounting surface using the appropriate fasteners. Torque the fasteners to the specified value. See Table 4. Note

Mounting holes in the 325DBBS and 425DBBS brakes are larger than the 125DBBS and 225DBBS sizes. Be sure to use the correct size fasteners.

Use only the proper number and grade fasteners

shown in Table 4. Use of commercial grade fasteners where Grade 8 fasteners are specified may result in failure of the fasteners and a sudden and drastic

reduction in brake torque.2.3

Air Supply System

Maximum allowable air pressure is 120 psig (8.2 bar) for sizes 20DBBS, 25DBBS and 38DBBS. Maximum allowable air pressure is 150 psig (10.3 bar) for the 50DBBS. Application of pressure exceeding maximum allowable may result in damage to the brake components.

2.3.1

Cylinder port size is 1/2”-14 NPT for sizes 20 and 25DBBS brakes, 3/4”-14 NPT for size 38DBBS brakes and 1”-11-1/2 NPT for size 50DBBS brakes.2.3.2

Since the air control arrangement will vary from one application to the next, a specific description cannot be presented here. Following are some general guidelines for installing the air control components.

2.3.2.1 Use full size piping consistent with the control valve

size. All piping should be free of metal chips, cutting compound, and any other foreign matter. Pipe ends should be reamed after cutting to eliminate possible restrictions.2.3.2.2 Keep the number of elbows to a minimum to ensure

consistent response.2.3.2.3 Spool type solenoid valves are not recommended.

Use poppet type valves and locate them as close as possible to the brake.

If the DBBS brake is being used on a mechanical power press, special valving may be required.

2.3.2.4 If the DBBS is being used on a cyclic application,

an air receiver tank should be installed in the air supply line and isolated (check valve) from other air consuming equipment.2.3.2.5 The final connection to the brake inlet ports must be

made with flexible hose.2.3.2.6 The DBBS brake does not require lubricated air;

however the solenoid valve may. Consult the valve manufacturer.2.3.2.7. A pressure switch should be located in the air supply

line to the brake and interlocked with the equipment electrical controls.

Before modifying air supply lines, adding inline components or adding pressure switch interlocks, ensure brake will function in a safe manner.

TABLE 4

Fastener Description and Assembly Torque, lubed, ft.-lb. (Nm)

Item No. & Description

Specification

20DBBS

25DBBS*

38DBBS

50DBBS

18

Size 3/4-10NC-3 1-1/8 7.NC-3 1-3/8 - 6NC3 1-3/8 - 6NC3Self Locking Nut Torque 150 (203) 500 (67.7.) 7.50 (1015) 7.50 (1015)20 Size 3/4 - 10NC-2 1-1/8 - 7.NC-2 1-3/8 - 6NC-2 1-3/8 - 6NC-2

Gr. 8

Gr. 8

Gr. 8

Gr. 8

Hex Head Screw Torque 150 (203) 500 (67.7.) 7.50 (1015) 7.50 (1015)Mounting Screw* Size 5/8 - 11NC-2 5/8 - 11NC-2 1-8 NC-2 1-3/8 - 6NC-2

Gr. 8

Gr. 8

Gr. 8

Gr. 8

Torque 17.0 (230) 17.0 (230) 680 (920) 17.80 (2409)

* The 325DBBS and the 425DBBS require larger mounting screws. The mounting screw required for both sizes is a 3/4”-10NC-2. Tightening torque is 280 lb-ft (380 Nm) lubed.

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 20129

3.0 Operation

3.1 Pressure and Speed Limits

3.1.1

Maximum allowable pressure is 120 psig (8.2 bar) for sizes 20DBBS, 25DBBS and 38DBBS. Maximum allowable air pressure is 150 psig (10.3 bar) for the 50DBBS.

Maximum applied pressure is 120 psig (8.2 bar) for

sizes 20DBBS, 25DBBS and 38DBBS. Maximum allowable air pressure is 150 psig (10.3 bar) for the 50DBBS. Operation at pressures exceeding

maximum may result in damage to the DBBS components.

3.1.2

Maximum freewheeling disc speeds are shown on Table 5.

Operation at disc speeds exceeding the maximum allowable, as shown on Table 5, may result in personal injury or product/equipment damage.

3.2 Initial Operation

3.2.1 Wear-in/Burnishing

3.2.1.1 In order to improve initial operation and brake torque,

it is suggested that the non-asbestos friction material used in the DBBS brakes be worn-in prior to normal operation to improve contact of the mating friction surfaces.

Machine operation should be monitored closely until the friction couple wears in.

3.2.1.2 The shaft on which the brake discs are mounted

should be free to rotate to allow for run-in. On drawworks applications, disconnect the wire rope from the drawworks drum to allow operation as described in the following paragraphs.

TABLE 5

Maximum Disc Speeds

Size Max. Free

Wheeling Speed RPM

20DBBS 220025DBBS 17.0038DBBS 95050DBBS 600

TABLE 6

DBBS Wear-in Parameters

Maximum Free

Maximum Standard

Slip Brake

Wheeling Maximum

Temp at Wear-in Quantity Power Brake Torque Brake Number of Speed Pressure Slip Time Speed Temp at Start End of Slip Cycles of Power Target Target Size

Discs

(rpm) psi (bar

(sec)

(rpm)

of Slip °F (°C)

°F (°C) Required

Springs

HP (Kw)

in-lb (N-m)

1

29 (22) 15318 (17.30)20DBBS 2

120

60 (4.1) 60 2,200 120 (49) 250 (121) 15 18 58 (44) 30636 (3461) 3 87. (65) 45954 (5192) 4 116 (87.) 6127.2 (6923) 1

52 (39) 27.450 (3101)25DBBS 2

120 65 (4.5) 60 1,7.00 120 (49) 250 (121) 15 24 104 (7.8) 54900 (6202) 3 156 (117.) 82350 (9304) 4 208 (156) 109800 (12405) 1

116 (87.) 121848 (137.66) 38DBBS 2

60 60 (4.1) 60 950 120 (49) 250 (121) 15 48 231 (17.3) 242646 (27.415) 3 347. (259) 364495 (41182) 4 463 (346) 486343 (54949) 1

169 (120) 17.8000 (20111) 50DBBS

2

338 (252) 356000 (40222) 3

60 88 (6.1) 60 600 120 (49) 250 (121) 15 112 507. (37.8) 534000 (60333) 4

67.6 (504) 7.12000 (80445)

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

103.2.1.3 Release the brake by applying full release pressure

through the ports in the cylinder (19) to allow the brake to freely rotate.

Maximum applied pressure is 120 psig (8.2 bar) for

sizes 20DBBS, 25DBBS and 38DBBS. Maximum allowable air pressure is 150 psig (10.3 bar) for the 50DBBS. Minimum releasing pressure for low

pressure brakes is 60 psig (4.1 bar).

3.2.1.4 Run the motor to achieve a brake disc speed listed in

Table 6. Rapidly exhaust the air pressure in the brake to the pressure listed in Table 6. Slip the brake for the time specified in Table 6, but DO NOT ALLOW

THE BRAKE TO SLIP FOR MORE THAN THE TIME SPECIFIED.Caution

Slipping the brake at increased time intervals, speeds, pressure or temperatures other than

specified may result in damage to brake components.Caution

Brake pressures listed in Table 6 are for the standard compliment of power springs in the DBBS brake. The standard quantity is listed in Table 6. If a brake contains less than the standard compliment of

springs, consult Eaton/Airflex engineering for proper brake pressure to wear-in the brake and spring quantity if unknown for the specific brake.

3.2.1.5 After the brake has engaged/slipped for up to the

maximum slip time specified in Table 6, quickly apply full air pressure to completely release the brake. Smoke rising from the brake should be expected. Freewheel the brake discs at speeds up to the maximum freewheeling speed in Table 6 to allow the brake discs to cool to a temperature at or below 120°F (49°C) use of fans or clean, dry compressed air can be used to accelerate the cooling process.Caution

Use proper safety precautions when using forced ventilation.

Note

The brake pressure listed in Table 6 should provide a dynamic torque target value as listed and resultant power target at the brake speed listed. Since new friction torque will be lower at the start of wear-in procedure, pressure may need to be lowered to achieve the target torque. An adequate control and torque monitoring system must be used if pressure values less than those listed are used for wear-in. Target torque should be monitored to correspond to values listed.

3.2.1.6 Monitor the brake discs temperature during

slipping and cooling. Do not allow the brake discs temperature to exceed 250°F (121°C).3.2.1.7. Repeat steps 3.2.1.3 through 3.2.1.6 for the number

of cycles shown in Table 6 to allow for adequate wear-in of the brake. Allow the brake disc to completely cool to ambient temperature prior to

testing the torque capacity of the brake or returning it to service.3.2.2

If the brake engagement appears harsh, a flow

control valve may be installed in the brake air supply line. When using a flow control valve, install so free flow is to the brake and restricted flow is away from the brake.

Excessive restriction of the brake exhaust air will result in long stopping times and inconsistent

stopping position. Consult Eaton Airflex Engineering with questions.

3.2.3

If the DBBS brake is used in combination with a clutch, clutch/brake overlap may occur which will result in excessive heat generation and motor

overload. Overlap may be detected by monitoring the drive motor current at the beginning and end of each machine cycle. A current surge at the beginning of the cycle usually indicates clutch overlap which can be corrected by restricting the air flow to the clutch or increasing the air pressure to the brake. A current surge at the end of the machine cycle usually indicates brake overlap (see Figure 3) which can be corrected by installing and adjusting a flow control valve in the brake air supply line, as indicated in 3.2.2.

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

11

3.3 Periodic Inspection

3.3.1

As the friction material wears, the brake torque will be reduced somewhat and adjustment of the stopping position controls (flow control or limit switch) will be necessary. See the Maintenance section for the friction material wear limit and replacement procedure.

3.3.2

Periodically inspect the brake for proper operation

particularly if excessive heating of the disc (58) has

been experienced or is suspected of having occurred.

See ‘WARNING’ below. Excessive heating of brake components can be caused by disc dragging, excessive E-Stops, low air pressure, warping of the discs, or operating the brake beyond its designed capability.

If the brake is subjected to heat, the discs (58) may

shrink causing a condition whereby the discs will get

stuck to the gear, limiting the axial movement. This

condition will cause failure of the brake to develop

full torque. Warning Failure to develop full torque can cause drastic

equipment failure, personal injury and/or death.

3.3.3 Periodically check for air leakage in the area of the

piston seals (21, 23). For replacement, refer to the

Maintenance section.

3.3.4 Periodically observe the discs with the brake released. Causes of dragging discs may include wear or contamination of the gear or disc splines, disc imbalance, warped discs, or excessive shaft float.

3.3.5

Pneumatic and electrical control interlocks should be periodically checked for correct settings and operation.

3.3.6

Periodically remove the brass drain plug (105) and purge condensation from the cylinder. Replace the brass drain plug with sealant and check for air leaks.

4.0 Maintenance

Prior to performing any maintenance on the DBBS brake, make sure the equipment is in, and will remain in, a safe condition. Never service a brake supporting a load.4.1

Wear Limits

4.1.1

Wear limits for the DBBS components are shown on Table 7.. If any wear limit has been reached or exceeded, that component must be repaired or replaced.

4.2

Wear Adjustment

Note Refer to Figure 4 for illustration of the friction

material wear groove for the size 20DDBBS, 25DBBS and 38DBBS brakes and friction material wear step in the size 50DBBS brakes. Refer to Figure 6, Figure 7., Figure 8 & Figure 9 for an illustration of the wear gaps on all DBBS sizes. On single and multiple disc

units, the friction material must be replaced when

worn to the bottom of the groove on the friction

material or to the bottom of the step on the friction lining on the size 50 brakes. Multiple disc brakes, however, are manufactured with wear spacers that allow for wear adjustment when the ‘Gap Required for Adjustment’ has been reached per the values

in Table 8. Typically, multiple disc brakes have a

quantity of wear spacers equal to the number of

discs minus 1. For example: a 450DBBS brake has 4

discs and 3 wear spacers. The exception to this rule is the 420DBBS that has additional ‘thinner’ spacers that will require four (4) adjustments. The number of wear spacers will dictate the number of adjustments before the brake requires complete disassembly for friction disc replacement. Spacers are removed to correct for wear. One set of spacers is removed for

each wear adjustment.

Figure 3

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

12

Figure 4

4.2.1

To determine when adjustment is required, make sure the brake is engaged then measure the gap between the spring housing (16) and the pressure plate (14) as shown in Figure 5. Measure the ‘Y’ gap between the pressure plate (14) and the reaction plate (31), the ‘Y’ gap between the reaction plate (31) and the mounting flange (2) and the ‘Y’ gap between the reaction plates (31) as shown in Figure 5, 6, 7., 8 and 9. If the measured gaps meet or be outside (larger or smaller) the limits shown on Table 8 AND none of the friction discs are worn to the bottom of the wear groove or the step on size 50 brakes, adjust the brake. It is also recommended to check the DBBS components for wear as shown in Table 7.. If any wear limit has been reached or exceeded, that component must be repaired or replaced.

If a wear adjustment is not made, the brake torque

may deteriorate to the point where the equipment will not stop properly.

Remove, retain or support discs as needed so that they do not fall off the gear during maintenance.

Note

Prior to August 2012, multiple disc DBBS units were manufactured with solid wear spacers (29), requiring brakes to be fully disassembled in order to make wear adjustments. Multiple disc units manufactured from August 2012 and later, use the split wear spacers and adjustment can be conducted without full disassembly. Check the date code on your brake to verify the date of manufacture.

4.2.2 Wear Adjustment with Solid Wear Spacers

Note

A Procedures for adjusting a two disc brake are listed below as an example.

4.2.2.1 Disconnect the air supply lines from the brake. Wipe

down the brake and match mark all components from the mounting flange (2) to the cylinder (19) prior to disassembly. Match marking all components will ensure that the components are reinstalled in the orientation and location from which they were removed.4.2.2.2 While supporting the cylinder (19), loosen the

locknuts (18) ONE TURN AT A TIME and in an alternating (crosswise) pattern to prevent binding of the cylinder on the studs. Continue to loosen the locknuts until the force of the release springs (34) is relieved, allowing for access to the wear spacers (29). It may be necessary to push the reaction

plate(s) (31) away from the mounting flange so that the release springs can be moved to gain access to the wear spacers.

Note

Once the assembly is loose, the wear spacers (29) can be rotated to confirm that they are the ‘Solid Wear Spacers’ and the disassembly can proceed per 4.2.2.3 below. The split spacers are identified by the presence of a slot running across the thickness of the spacer. If the wear spacers have the slot, then they have been replaced with a split spacer kit and the DBBS can be adjusted without complete disassembly. See Section 4.2.3 for wear adjustment with split wear spacers. See figure 11 for an illustration of the split wear spacer.

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 201213

TABLE 7

Wear Limits for DBBS Components (Ref. Figs. 1 & 2 and Section 4.2)

Item

Description

Wear Limit

Remarks

Fully Worn at Bottom of dust groove. See Figure #4. Friction Material must also

be replaced if contaminated Brake has adjustment provision #8 Friction Disc Friction Material with oil or grease. See Section 4.2

Wear will be in the form of

#14 Pressure Plate

elongation of the holes. Original and

Maximum wear is hole diameters are shown on the #31 Reaction Plate Reaction Holes 0.031 in. (0.80 mm) table below

Maximum wear is Wear will be in the form of notch or #12 Clamp Tube Reaction Area 0.015 in. (0.38mm) step on the side of tube.

Maximum wear is Wear will be in the form of notch or #12Clamp Tube Reaction Area 0.015 in. (0.38mm) step on the side of tube.

Wear will be in the form of grooves

Maximum wear is where the seals contact the #19 Cylinder Seal Area 0.005 in. (0.13mm) cylinder wall.

Wear will be in the form of grooves

Maximum wear is where the seals contact the #19 Cylinder Seal Area 0.005 in. (0.13mm) cylinder wall.

Original free height shown on the

Maximum free height shown table below. Springs must be #22, 34, & 52 Spring Spring Free Height on the table below. replaced on complete sets.

Backlash is measured at the pitch

diameter. Replace the disc and

Maximum total backlash is gear together. If step is worn in #28 & 58 Gear & Disc Gear Backlash 0.060 in. (1,5mm). gear, gear must be replaced.

Original thickness for sizes 20 and Maximum wear is 25 is 1.00 in (25,4mm), for size 38

0.045 in. (1,12mm) and 50 it is 1.25 in. (31,7.5mm).

Friction Wear per surface 0.090 in. Wear will be in the form of circular #58 Disc Surfaces (2,24mm) total

grooves on the iron surface.

Item Reference Description Element Size

20DBBS 25DBBS 38DBBS 50DBBS

Original Reaction Hole 14 & 31 Diameters in Pressure 1.34 1.69 2.06 2.38 Plate and Reaction Plate (34,11) (42,9) (54,4) (60,33)

Original Free Height 2.84

2.57.

3.64

4.25 34 inch/(mm) (7.2,1) (65,3) (92,4) (108,0)

Minimum Free Height 2.65

2.40

3.40

4.12 inch/(mm) (67.,3) (61,0) (86,4) (104,7.)

Original Free Height 4.56

5.18

6.65 9.00 22 inch/(mm) (115,8) (131,6) (168,9) (228,6)

Minimum Free Height 4.25

4.90

6.3

7.

8.7.5 inch/(mm) (108,0) (125,5) (161,8) (222,3)

Original Free Height n/a

5.23

6.7.8 n/a 52 inch/(mm) n/a (132,8) (17.2,2) n/a

Minimum Free Height n/a

4.95

6.50 n/a inch/(mm)

n/a

(125,7.)

(165,1) n/a

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

14

The locknuts (18) must be loosened gradually to prevent damage to the brake components.

4.2.2.3 Remove the locknuts (18) and washers (17.) and slide

the cylinder (19), spring housing (16) and pressure plate (14) off of the studs (6) as an assembly. Set aside in a clean area making sure not to damage the friction disc (8) or friction block on size 50 brake, on the pressure plate. See TABLE 9 for weight of sub assembly.

Note

If a stud (6) should happen to come loose, remove it completely and clean the threads on the stud and the threads in the mounting flange. Apply Loctite ? Loc-Quic ? Primer Grade “T” to the stud threads. After the threads have dried, assemble to the mounting flange using Loctite #262. The end of the stud must not extend past the mounting surface on the mounting flange.

TABLE 8

Wear Gap Values, - Inches (mm)

(X-Gap) Gap (Y -Gap)

*X-Gap Required for Y -Gap gap required for Disc Size Qty. of New Gap Adjustment New Gap Adjustment Inches

Discs

inch (mm)

inch (mm)

inch (mm)

inch (mm)

1 - - - - 20DBBS

2 0.14 (3,6) 0.64 (16,3) 2.14(54,4) 1.64 (41,7.)

3 0.21 (5,3) 0.7.1 (18,0) 2.1

4 (54,4) 1.64 (41,7.)

4 0.28 (7.,1) 0.66 (16,6) 2.14 (54,4) 1.64 (41,7.)

1 - - - -25DBBS

2 0.18 (4,6) 0.68 (17.,3) 2.14(54,4) 1.64 (41,7.)

3 0.27. (6,8) 0.7.7. (19,5) 2.1

4 (54,4) 1.64 (41,7.)

4 0.36 (9,1) 0.86 (21,8) 2.14 (54,4) 1.64 (41,7.)

1 - - - -38DBBS

2 0.2

3 (5,9) 0.65 (16,5) 2.39 (60,7.) 1.97. (50,1) 3 0.30 (7.,6) 0.7.2 (18,2) 2.39 (60,7.) 1.97. (50,1)

4 0.40 (10,1) 0.82 (20,8) 2.39 (60,7.) 1.97. (50,1)

1 - - - -50DBBS

2 0.31 (7.,9) 0.7.32 (18,6) 2.39 (60,7.) 1.97. (50,1)

3 0.47. (11,9) 0.888 (22,5) 2.39 (60,7.) 1.97. (50,1)

4 0.62(15,8) 1.044 (26,5) 2.39 (60,7.) 1.97. (50,1)

* Value shown is GAP after wear adjustment. New or rebuilt brakes may vary slightly from this value due to tolerances.

TABLE 9

POWER HEAD WEIGHTS

Brake Size Approximate Total Weight

Lbs (kg)

20DBBS 27.1 (597.) 25DBBS 543 (1195) 38DBBS 1585 (3487.) 50DBBS 3994 (87.87.)

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 201215

Figure 6

Figure 9

Figure 7

Figure 8

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

16

Loctite#262 must be shaken prior to application.

Caution

Loctite #262 may irritate sensitive skin. Refer to the product label for safety precautions.

4.2.2.4 Remove the outboard disc (58), the reaction plate

(31) and the release springs (34) and set aside.

Note

For 3 disc brakes remove one additional disc,

reaction plate and set of springs during disassembly.

Note

For 4 disc brakes remove two additional disc,

reaction plate and set of springs during disassembly.

4.2.2.5 Slide the clamp tubes (12) and one set (layer) of wear

spacers (29) off of the studs. Reinstall the clamp tubes only. For all sizes of DBBS brakes clamp tubes (12) are placed over every stud (6).

4.2.2.6 Place the release springs (34) onto the clamp tubes

(12) and slide the reaction plate (31) onto the clamp tubes. Note

For 2,3 & 4 disc brakes, sizes 20, 25 & 38 DBBS, release springs (12) are equally spaced on 4 clamp tubes.

Note

For 2,3 & 4 disc brakes, size 50DBBS, release springs (12) are placed on every clamp tube.

4.2.2.7. Slide the second disc onto the gear.

4.2.2.8 Place the release springs (34) onto the clamp tube

(12) and slide the pressure plate/cylinder assembly onto the clamp tubes. 4.2.2.9 Lubricate the threads on the ends of the studs with

30 wt. oil or anti-seizing compound and install the locknuts (18), washers (17.) and the wear spacers (29) removed in 4.2.2.5. The wear spacers are “stored” under the locknuts for use after replacing friction discs (8). See Figure 10.

Note

It is recommended to dispose of the solid wear spacers and use split spacers when replacing the friction discs.

4.2.2.10 While supporting the weight of the cylinder/

spring housing/pressure plate assembly, tighten the locknuts (18), ONE TURN AT A TIME and in a crosswise pattern, until the spring housing is seated against the clamp tubes. Torque the locknuts to the appropriate value. See Table 4.

The locknuts (18) must be tightened gradually to prevent damage to the brake components.4.2.3

Wear Adjustment with Split Wear Spacers

Note

To determine the type of wear spacers (29) installed in the brake, refer to section 4.2.3.4 that directs to loosen the locknuts (18) until the force of the release springs is relieved. Once the assembly is loose, the wear spacers can be rotated to confirm that they are the ‘Split Spacers’. The split wear spacers are identified by the presence of a slot running across the thickness of the spacer. If the wear spacers do

Figure 10

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

17

Figure 11

not have the slot then they are solid wear spacers and the DBBS must be disassembled per 4.2.2 in order to make adjustments.

Be sure to follow 4.2.3.4 instructions complete to

prevent damage to the brake components

4.2.3.1

Disconnect the air supply lines from the brake. Wipe

down the brake and match mark all components from the mounting flange (2) to the cylinder (19)

prior to disassembly. Match marking all components will ensure that the components are reinstalled in the orientation and location from which they were removed.

4.2.3.2 Wear adjustment can be conducted without full

disassembly of the Multi-disc DBBS brake. The wear adjustment spacers are slotted to allow for easy removal with a chisel. See Figure 11. 4.2.3.3

Wear spacers shall be removed in complete sets only

(one from each stud location). Mark the spacers to be removed to avoid confusion during removal.

Removal of spacers in quantities other than complete sets (layers) will result in severe damage to DBBS components during reassembly and could cause the brake to not function properly.

4.2.3.4 Loosen the locknuts (18) one at a time and in an

alternating (crosswise) pattern to prevent binding of the cylinder on the studs. Continue to loosen the locknuts until the force of the release springs is relieved, allowing for access to the wear spacers. It may be necessary to push the reaction plate(s) away from the mounting flange so that the release springs can be moved to gain access to the wear spacers.

The locknuts (18) must be loosened gradually to prevent damage to the brake components.Caution

Remove discs as needed so that they do not fall off the gear during maintenance.

4.2.3.5 Using a narrow chisel wedged into the slot in the

wear spacer, pry the wear spacer until it fractures and is clear to be removed from the stud. Repeat for the remaining spacers in the set that is to be removed (one spacer from each stud position). See Fig 11.

Removing Split Wear Spacers with Chisel

Be sure to collect all wear spacers when removed. Spacers lodging in between brake components could prevent the brake from properly engaging or releasing.

4.2.3.6 While supporting the weight of the cylinder/piston

assembly, tighten the locknuts (18) ONE TURN AT A TIME and in a crosswise pattern until the cylinder is seated firmly against the clamp tubes. Torque the locknuts to the appropriate value. See Table 4.The locknuts (18) must be tightened gradually and evenly to prevent damage to the brake components.

4.2.3.7. Restore any piping or covers removed prior to

operating the brake.4.3

Friction Disc Replacement

Use only genuine, Airflex friction material. Use of material not of Airflex origin may result in

unpredictable brake performance and/or excessive wear of the brake components.

DBBS Brakes

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

18

Friction disc replacement is required when the friction material is worn to the bottom of the wear groove or step for size 50 brake, as indicated in Figure 4, or if oil or grease has contaminated the surface. In Figure 4 note the location of the wear grooves on the friction disc on sizes 20, 25 & 38 versus the step on the edge of the friction block for size 50 brakes.

4.3.1

Reference section 6.3 for Friction Disc Kit part numbers.

4.3.2 Disconnect the air supply lines from the brake.

4.3.3

Remove the brake and place it on a level working surface, with the mounting flange facing down.4.3.4

Loosen the locknuts (18) ONE TURN AT A TIME and in an alternating (crosswise) pattern until the spring force is relieved. Remove the locknuts, washers (17.) and wear spacers (if stored).

Caution

The locknuts (18) must be loosened gradually to prevent damage to the brake components.

Refer to Table 9 for power head weights before lifting the power head. Provide properly rated lifting devices. Failure to use the properly sized and rated lifting devices can cause equipment damage and personal injury. Note

The term ‘power head’ refers to the subassembly consisting of the spring housing, cylinder, and pressure plate.

4.3.5

Lift the cylinder, spring housing, and pressure plate off of the studs as an assembly. Set the assembly aside on a level working surface, with the cylinder facing down.

Note

If a stud (6) should happen to come loose, remove it completely and clean the threads on the stud and the threads in the mounting flange. Apply Loctite Primer Grade “T” to the stud Threads. After the threads

have dried, assemble to the mounting flange using Loctite #262. The end of the stud must not extend past the mounting surface on the mounting flange.

Caution

Loctite #262 must be shaken prior to application.Caution

Loctite #262 may irritate sensitive skin. Refer to the product label for safety precautions.

4.3.6

On multiple disc brakes, remove the reaction plate (31), release springs (34), clamp tubes (12) and the remaining disc(s)(58).

4.3.7.

Inspect the brake components for wear or damage. Replace as required. For wear limits of components, see Table 7..

4.3.8

Remove the socket head screws and friction discs or blocks and discard.

Note

It may be necessary to use heat to soften the Loctite to ease screw removal. Use a pinpoint torch, heating only the socket area of the screw.

4.3.9

Smooth the friction mounting surfaces of any burrs or raised areas with a course, flat polishing stone, and clean the tapped holes of any residual Loctite or other contamination. Check screw fit and chase the threads if necessary being sure to final clean the tapped holes of any residual contamination.Caution

Before installing screws, make sure that the screw threads and threaded holes are clean to ensure that the new screws will lock properly.

4.3.10 Position the new friction discs (friction blocks on the

50DBBS) on the mounting surfaces. Apply Loctite #262 to the threads of the screws (57.), install and torque the screws to 20 ft.-lb.

Loctite #262 must be shaken prior to application.

DBBS Brakes

Loctite #262 may irritate sensitive skin. Refer to the

product label for safety precautions.

Note

When replacing friction material, it is suggested that

discs (58) also be replaced to ensure good surface

contact.

4.3.11 Position a disc (58) on the mounting flange/friction

disc assembly. Center the disc on the friction

material.

4.3.12 On multiple disc units, install wear spacers (29),

clamp tubes (12), release springs (34), the reaction

plate, and remaining reaction springs over the studs.

Position the remaining disc (58) on the reaction plate/

friction disc assembly. Center the disc on the friction

material and align the disc splines with those on the

first disc.

Note

It is suggested that the Wear Spacers (29) be the

Split Wear Spacer type.

4.3.12.1 Wear Spacers (29) are installed in sets onto each

stud. The number of wear spacers must be equal on

each stud.

4.3.12.2 Clamp tubes (12) are installed onto each stud and

rest upon the wear spacers (29).

4.3.12.3 Release springs (34) are installed over the clamp

tubes (12) as outlined in Section 4.2.2.6

The position of the release springs can vary with

different brake sizes. If unsure of assembly position,

consult Eaton Airflex Engineering. The springs on

either side of the reaction plate must be assembled

on the same stud, over the clamp tubes. Improper

assembly will result in cocking of the reaction plate

and uneven brake release. Refer to section 4.2 and

6.1 for wear spacer quantity.

4.3.13 Lubricate the threads on the ends of the studs with

30 wt. oil or Never Seez? anti-seizing compound.

4.3.14 Hoist the cylinder, spring housing and pressure plate

assembly into position. Noting the position of the air

inlets to the mounting flange, lower the assembly

over the studs and clamp tubes.

4.3.15 Assemble the washers (17.) and locknuts (18) onto

the studs. Tighten the locknuts, ONE TURN AT A

TIME and in a crosswise pattern, until the spring

housing is seated against the clamp tubes. Torque

the locknuts to the appropriate value. See Table 4.

The locknuts (18) must be tightened gradually to

prevent damage to the brake components.

4.3.16 Re-install the brake per 2.0, ’Installation’.

4.4 Cylinder Seal Replacement

4.4.1 Reference section 6.2 for Cylinder Seal Kit part

numbers.

4.4.2 Disconnect the air supply lines and remove the

screws (20), washers (17.) and spacer tubes (27.)

attaching the cylinder (19) to the pressure plate (14).

4.4.3 Carefully slide the cylinder (19) off of the spring

housing (16).

Do not use compressed air to remove the cylinder

(19) from the spring housing.

4.4.4 Remove the cylinder seals (21, 23) from the spring

housing (16) and thoroughly clean the seal grooves in

the spring housing.

4.4.5 Insert new seals (21) (23) into the grooves, noting the

orientation of the seals per Figure 12.

DBBS Brakes

Figure 12

EATON Airflex? DBB 8110 Brake Assembly E-CLCL-TT001-E December 201219

EATON Airflex ? DBB 8110 Brake Assembly E-CLCL-TT001-E December 2012

204.4.6

Carefully examine the seal surfaces in the cylinder (19). If the surfaces have worn to the point as

indicated on Table 7., the cylinder must be replaced.4.4.7.

Lubricate the seal surfaces in the cylinder (19)

with Molykote ? 55M Grease and carefully slide the cylinder onto the spring housing (16). Take special care to avoid damaging the seal lips.

4.4.8

Attach the cylinder (19) to the pressure plate (14) with the screws (20), washers (17.) and spacer tubes (27.) removed in 4.4.2. Use Loctite Loc-Quic Primer Grade “T” to clean and prepare the screw threads and install with Loctite #262. Using a crosswise pattern, torque the screws to the value shown on Table 4.

Loctite #262 must be shaken prior to application.

Loctite #262 may irritate sensitive skin. Refer to the

product label for safety precautions.4.5

Spring Replacement

4.5.1

Spring Replacement for 20 DBBS & 25 DBBS Brakes

Warning

Make sure that the machinery and related loads are properly secured or supported to prevent shaft rotation prior to releasing, removing or performing maintenance on the DBBS brake assembly.

4.5.1.1 Disconnect the air supply lines and loosen the

locknuts (18), ONE TURN AT A TIME and in a crosswise pattern, until the spring force has been relieved.4.5.1.2 Match mark the pressure plate and spring housing to

one another.

4.5.1.3 Remove the locknuts (18) and washers (17.) and

carefully remove the cylinder/spring housing/pressure

plate assembly. Transport to a clean work area.

The locknuts (18) must be loosened gradually to prevent damage to the brake components.

4.5.1.4 Loosen the screws (20) gradually ONE TURN AT

A TIME, following a crosswise pattern until the remaining spring force is relieved. Remove the screws and washers (17.).4.5.1.5 Carefully lift the cylinder and spring housing off of the

pressure plate, exposing the springs (22). Note

If the cylinder (20) is removed from the spring

housing (16), refer to Section 4.4 for inspection of the seals, replacement (if necessary) and reassembly of the cylinder/spring housing/pressure plate assembly.

Note

Before removing the old springs, make note of the number u sed and the position that they are in so that the new springs may be installed similarly for proper brake functioning.

4.5.1.6 Noting their orientation, remove the spring retainer

plates (53), exposing the springs.4.5.1.7. Remove the springs and check the free height. If the

free height of any spring is less than the value shown on Table 7., or any springs are cracked or broken, the entire complement of springs must be replaced.4.5.1.8 Re-install the springs into the pockets in the pressure

plate.No spring retainer plate (53) should cross over the ribs in the spring housing (16).

4.5.1.9 Place a spacer tube (27.) in position over each tapped

hole in the pressure plate (14), align the match

marks and carefully lower the spring housing/cylinder assembly onto the springs, making sure the springs engage the bosses in the spring housing.

4.5.1.10 Clean the threads on the hex head screws (20) and

install the hex head screws and flat washers (17.).

Using a crosswise pattern, tighten the screws one

turn at a time until the spacer tubes are clamped

between the cylinder and pressure plate.4.5.1.11 Remove the hex head screws (20) one at a time.

Clean and prepare the screw threads and apply Loctite LocQuic ? Primer “T” to the screw threads.

DBBS Brakes

威利普LEDESC控制系统操作说明书

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Mar 6, 2009 2009年3月6日
? 2007 Eaton Corporation. All rights reserved.

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? ? ? ? ? 1911年由J.O. Eaton建立 全球总部位于美国俄亥俄州的克里夫兰 总裁兼执行长 - Alexander M. Cutler 2008年销售额150亿美元 全球82,000名员工,分布于125个国家
? ? ? ? ?
Founded in 1911 by J.O. Eaton World Headquarters in Cleveland, Ohio USA Chairman & CEO - Alexander M. Cutler $15 billion sales in 2008 82,000 employees in 125 countries
2

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电气设备 Electrical 液压设备 Fluid Power
Markets We Serve
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? ?
全球领先的多元化工业产品制造商 A global diversified industrial manufacturer 在下列行业全球领先: ? 电源质量和控制设备 ? 流体动力系统 ? 汽车发动机空气管理 A leader in Electrical power quality and control Fluid power systems Automotive engine air management
? 商用车智能动力传动系统和安全系统 Intelligent drivetrain and safety systems for trucks and heavy vehicles
3

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