Operating/Instruction Manual for ICAN Disc Brake IB30 Series

(DWG. No. CT-44663-B-2)

Revised June 2008

Ican Company Ltd.

1-5,1-chome, Shintomi, Chuo-ku, Tokyo JAPAN 104-0041 Tel: +81-3-3552-7781 Fax:+81-3-3555-0681 DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series

CONTENTS

Page 1

SAFETY PRECAUTIONS...................................................................................................... 2 CAUTIONS. ........................................................................................................................... 3 INTRODUCTION. .................................................................................................................. 3 SECTION 1 : SECTION 2 : SECTION 3 : SECTION 4 : SECTION 5: SECTION 6 : SECTION 7 : SECTION 8 : SECTION 9 : PARTS LIST and Spares ordering. ........................................................... 4 Initial mounting procedure. ...................................................................... 6 Thruster electrical connections. .............................................................. 8 Thruster reserve stroke checking and adjusting.................................... 9 Initial setting. ........................................................................................... 11 Running in procedure ............................................................................. 13 Brake torque setting................................................................................ 14 Brake Limit Switches (Options, if any) .................................................. 15 Manual release lever ............................................................................... 16

SECTION 10 : Maintenance............................................................................................. 17 SECTION 11 : Brake Lining (Pad) Replacement............................................................ 18 SECTION 12 : Thruster Mounting Position and maintenance...................................... 19 SECTION 13 : Anti Corrosion Measures ........................................................................ 21 SECTION 14 : Safety Instructions (Periodic)................................................................. 22 SECTION 15 : Spare Parts............................................................................................... 23 Fig. A IB30 Overview and Dimensions ........................................................................... 24 Periodic Inspection Sheet ................................................................................................. 25

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series

SAFETY PRECAUTIONS

Page 2

1. IMPORTANT SAFETY PRECAUTIONS:

Warning: Heavy duty high torque braking requires that the following basic rules and principles are followed: By definition the brake is a machine element designed to control the speed of rotating shaft(s) connected to the machine and/or to stop the machine on command by exerting pressure from the friction shoes to the disc. Machine speed control is carried out by the absorption of the mechanical energy of the moving parts. This mechanical energy is transformed into heat energy at the frictional surfaces and is then dissipated by heat transfer. Always confirm the following essential requirements before operating machinery: 1) the mechanism of pressing the frictional shoes on the brake disc is normally actuated, and 2) the friction coefficient between the friction lining of the shoes and the disc is within the design value limits. (The coefficient will change depending on the conditions such as an existence of oil, foreign material between the friction surfaces, extreme friction surface temperatures, among others.) CAUTION 1 In the absence of either or both essential conditions 1) and/or 2) above, the brake will not function properly (i.e. according to specifications); consequences of such malfunctions can include partial or total loss of control of the equipment, free drop of cargo, and loss of life or injury. CAUTION 2 At normal operating temperatures, direct contact between human skin and brake disc, brake pads, or other adjoining components can result in severe burns. Temperature due to heat generation depends on the frequency of braking actions; consequently, excessively frequent operation will generate extreme heat, which might result in excessive deformation of the elements and change material quality, leading to possible interference of normal brake performance. CAUTION 3 When the brake is released, the shaft of the machine is able to rotate freely, i.e. the machine will rotate out of control suddenly if torque remains or is exerted on either shaft. This can lead to possible free drop of cargo, and loss of life or injury. Limited Warranty It is essential that the users of the brake understand the above principles thoroughly, take reasonable precautions to avoid accidents in advance. Do not operate or work on this brake unless you have thoroughly read and understand the instructions, precautions and warnings included in this Operating Instruction Manual and on brake warning plates. Failure to follow these instructions or warnings could result in injury or death. Given the difficulty of predicting every possible variable and risk associated with the operation and maintenance of heavy duty disc brakes, the manufacturer receive no claims that the warnings and cautions necessary to avoid all possible mishaps or accidents are contained herein, nor does the manufacturer assume any liability for same. Operators and Service personnel are obligated to try to find out a dangerous state, based on the real understanding of the principle of the brake. Outside the limited manufacturers warranty, responsibility for proper care and maintenance of brakes rests with operator and service company. Ican warrants to the original purchaser, only that the Product manufactured will be free from defects in design, materials, and workmanship for one year from the date on which the Product is delivered to the original purchaser. EXCEPT AS STATED IN THIS LIMITED WARRANTY ICAN DOES NOT MAKE AND DISCLAIMS ALL EXPRESS OR IMPLIED WARRANTIES INCLUDING, BUT NOT LIMITED TO, ITS FITNESS FOR A PARTICULAR PURPOSE, ITS DESIGN, CONDITION OR WORKMANSHIP. Icans obligation under this warranty is limited to replacing or restoring (at Icans election) any Product that is returned intact to it, or to one of its authorized service stations with transportation charges prepaid, within the warranty period, and that it is disclosed, to Icans satisfaction, to be defective after its examination. The end user is responsible for maintaining and replacing serviceable items such as lining, Automatic Wear Adjustment device(s), et al. This warranty shall not apply to any product that has been subject to misuse or abuse, negligence or accident, or has been installed or used not in accordance with operating instruction manual furnished with the product by Ican. ICAN WILL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY CHARACTER AS A RESULT OF A BREACH OF ITS LIMITED WARRANTY, INCLUDING WITHOUT LIMITATION: INCONVENIENCE, TRANSPORTATION COSTS, LOSS OF PROFITS, PROPERTY DAMAGE OR LOST PRODUCTION, LOSS OF LIFE OR PERSONAL INJURY, WHETHER SUFFERED BY THE ORIGINAL PURCHASER OR ANY THIRD PARTY. Icans maximum liability under any circumstances will be the purchase price of the product paid by the original purchaser. Ican neither assumes nor authorizes any person to assume for it any other or greater liability in connection with the sale of its products. Any provision in this limited warranty, including any provision limiting or excluding legal remedies or warranties or fitness for purpose, is not applicable where expressly prohibited by local law, but only to the extent so prohibited. Any action for breach of this warranty regardless of the legal theory of the action must be brought within one year after the date of the breach.

2. SPARE PARTS
Cautions: Only original ICAN SPARE AND REPLACEMENT PARTS guarantee correct functioning. Please remember to indicate the serial number of the brake when ordering ICAN spare and replacement parts. (see Section 15. p.23)

3. PROHIBITED OPERATING PROCEDURES

To Avoid Danger: Do not loosen or otherwise tamper with brake spring. Always set brake torque as specified on the name plate of the brake, whose torque scale is based on friction coefficient of =0.4. Do not spread, spray, or allow any oil and/or grease on the friction surface of disc and linings; if either grease or oil is present, please use brake only after completely removing oil or grease to avoid sudden reduction of brake torque. During normal operation, do not operate manual release device of brake. (For proper operation of manual release, see Section 9 p.16) of Operating Instruction Manual) During normal operation, do not turn the main spindle adjusting nut (3)anti-clockwise, (for use of main spindle adjusting nut, see Section 9 p.16 of Operating Instruction Manual) Do not touch rotating disc, hub and/or couplings to avoid serious injury. Apply protecting cover for all disc(s) to prevent accidental contact with rotating parts. Do not drop foreign material/objects on the rotating disc because centrifugal force of rotating disc will turn such material objects into dangerous projectiles. Do not enter or approach area directly under the lifted material (e.g. container) to avoid accidental injury or death resulting from sudden abnormal function of brake. Do not apply paint or any coating to name plate or other warning/caution plates, etc.

4. SAFETY FACTOR
Danger: Brake torque for any motion is required to have a safety factor against actual load torque. If a high enough safety factor does not exist, dropped cargo or serious accidents can occur. Ican therefore recommend a safety factor of the brake torque shall be more than 2.0 times of actual load torque on the brake shaft.

5. VISUAL INSPECTION
Cautions: Please conduct a visual inspection on the following: To confirm proper performance of automatic wear adjustment device (AWA). (one time per week) To confirm brake lining clearance exist on both sides of disc to avoid unbalanced lining wear. (one time per week) To confirm required reserve stroke of thruster (SR) remains during braking condition to avoid sudden partial or total (to zero!!) reduction of brake torque. (one time per week) To confirm that thickness of brake lining exceeds specified wear limit. (one time per month; see Section 11 p.18 of Operating Instruction Manual) To confirm that brake disc is free from any grease or oil to avoid sudden partial or total reduction of brake torque. (one time per week) To confirm whether bolts or screws, are loose due to vibration, or if pins, retaining rings, collar stop of AWA are separated or missing to avoid possible malfunctioning of brake. (one time per month)

6. ANTI-CORROSION MEASURES
Warning: Moving hinges are made of materials that do not easily corrode under normal conditions; however, these hinges may corrode in extreme environments, and can interfere with the smooth movement and can also reduce brake torque. To avoid serious accident due to abovementioned these parts must be inspected every 12 months and if this instance has occurred, please remove rust and feed lubricant immediately. As indicated elsewhere, to avoid serious accident due to reduction of brake torque, do not apply any oil or grease to the friction surface of disc and linings when applying grease.

7. PAINTING
WARNING: When applying subsequent coats of paint to the brake, ENSURE THAT NO PAINT IS SPILLED ON THE AWA SPINDLE, THRUSTER, MOVING PARTS, BRAKE DISC, and OR BRAKE PAD. To keep smooth movement for hinge of brake lever, do not apply painting thickness more than 150m around the hinges. The brake must be cleaned and any loose or damaged paint removed and the surface treated and repainted every 12 months.

8. STORAGE REQUIREMENTS
Important: If the brake is not operated for an extended period of time, a) suitable protective coating should be applied to all moving parts; b) brake disc friction surfaces should be treated with a suitable anti-corrosive; c) brake disc must be cleaned carefully before the brake is used again.

Brake must be handled or lifted by crane as shown in the right picture The brakes are delivered ready for installation. The lining pressing force has been tested by manufacturer and the torque is normally set before delivery.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series

Page 3

CAUTIONS.
Before starting any work on the brake secure the drive against any accidental rotation and ensure the power supply is isolated. There are high precision parts on these brakes and to ensure their long life please carry out the correct handling, safety and maintenance procedures. Routine maintenance and periodic inspections should be carried out by suitably trained personnel. Do not touch the electrical connections or carry out any maintenance without first checking the power source is isolated Where ACD is fitted axial movement of the brake disc must be within +/- 0.3 mm. If axial movement is above this value the ACD will malfunction and must be replaced with an MCD. Keep your hands away from the brake during operation. Danger. Do not operate or work on this brake unless you have thoroughly read and understood the instructions and cautions included in this Operating Instruction Manual and on the brake warning plates. Any problems caused by not following this manual will invalidate the warrantee. Failure to follow these instructions and cautions could result in injury or death. This manual is to be read by suitable qualified personnel.

INTRODUCTION.
The IB30 Series brake has 2 automatic adjustment devices care must be taken with these parts as to ensure no damage is done, as this will result in their malfunction ACD (Automatic Centering Device) The procedure required to disengage this is covered in Section 2. AWA (Automatic Wear Adjustment) The procedure required to disengage this is covered in Section 2 MCD (Manual Centering Device) If the ACD is not fitted the centering must be done periodically using the MCD, Manual Centering Device The MCD shown below consists of a bolt with a lock nut, when this is fitted the centering can be manually adjusted by releasing the lock nut and turning the screw. periodic centering must be carried out if this MCD is fitted. After the initial mounting and operation procedures have been completed the lock nut must be tightened.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 1 : PARTS LIST and Spares ordering.
The following part numbers can be used for Spare part ordering.

Page 4

Important: When ordering spare parts include the brake type and serial No which is indicated on the name plate on each brake. To guarantee the correct function of this unit only original ICAN replacement and spare parts must be used. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16A 17 18 19 20 21 22 23 30 32 35 40 1 (1) (1) (1) (1) (1) 1 2 1 1 2 1 QTY 1 1 1 1 1 1 1 4 PART Spring tension adjusting nut Brake spring Adjusting nut for brake lining (pad) clearance and reserve stroke Thruster Spring plate Cover for ACD (Not shown)

Automatic centering device (ACD) Brake pad mounting bolt(s) (2 x 2 = 4 pcs.) Tappet Lower Pin Braking torque scale Automatic wear adjustment (AWA) (Complete Assembly) Lock nut for set screw Set screw Collar stop Manual Centering Bolt (MCD) Lock Nut for MCD Brake shoes Key(s) (for brake lining (pads)) Brake pad with lining Threaded sleeve for main spindle Bushing Kit ( 1 brake set all bushes) Limit Switch for Brake Release (Option) Limit Switch for Lining Wear (Option) Lock screw for Manual Release Lever (Option) (Not shown) Manual Release Lever (Option) Limit Switch for Manual Release (Option) (Not shown) Lock nut for Spring spindle (Not shown) (Not shown)

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series

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DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 2 : Initial mounting procedure.

Page 6

Confirm that the mounting holes of the brake and center height comply with the dimensions Allowable height ("h" See Fig.A on page.24) deviation is 1 mm. Disengage the ACD and AWA as follows The ACD must first be disengaged as follows. Remove the cover for ACD (6). Remove the rack for ACD by removing fixing bolt (7E) and then remove the rack (7B). Unscrew ACD adjusting nut (7A) (see below) to allow brake lever to move freely for adjustment. Note: Brakes are delivered with the Automatic Centering Device (ACD) disengaged. The rack (7B) and screw (7E) for ACD is packed in a plastic bag tied to the brake on delivery.

MCD Loosen the locknut(16A), and unscrew the bolt(16). The AWA must be disengaged as follows Loosen lock nut for set screw (13). Unscrew (screw out) set screw (14). Pull out collar stop (15) until the free-wheel with tappet (12) can be rotated freely by hand.

ACD AWA

MCD

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series

Page 7

To enable the brake to slide over the disc, the clearance between the brake linings (19) must be increased, this is done by opening the brake using the AWA main spindle adjusting nut (3) and turning it Anti-clockwise. Note: Before sliding in the brake over the disc ensure all protective grease/paint has been removed from the disc and that the disc is clean and dry. Set the brake over the disc into its mounting position. Position brake with a distance L between the outer lining edge and outermost edge of brake disc as shown in Table 1 below.

Table 1 Brake Type Distance L(mm) IB3013 4 IB3020 5 IB3025 5 IB3028/315 5

Put the mounting bolts in position but do not tighten. Close the brake on to the disc by screwing the AWA adjusting nut (3) clockwise until the full brake force is applied. Check the brake is positioned correctly and centered as drawing below. mounting bolts. Then tighten the

TOP VIEW

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 3 : Thruster electrical connections.
Follow terminal diagram inside terminal box lid when connecting unit. Possible cable connections to the 6 or 9 pole terminal block(s) are as follows. FOR 6-POLE TERMINAL BLOCK: G-1 STAR CONNECTION OR H-1 DELTA CONNECTION FOR 9-POLE TERMINAL BLOCK: G-2 STAR CONNECTION OR H-2 DELTA CONNECTION

Page 8

The ground cable entry size is Pg.21. Conductor sizes of up to 4c x 2.5 mm2 are applicable. Terminal blocks are either 6-pole or 9-pole. The protective conductor terminal is M4. The earthing screw (M5) is located outside the terminal box, just under the ground cable entry port.

( 400 / 380V )

( 230 / 220V )

( 440 / 400V )

( 220 / 200V )

It is not necessary to consider phase sequences. This means that both clockwise and anticlockwise rotation is acceptable. Keep terminal box clean. Ensure that terminal box gasket is correctly positioned and intact. Lock terminal box securely and tighten cable entry pressure screw. Seal if necessary

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 4 : Thruster reserve stroke checking and adjusting.

Page 9

The Reserve Stroke Gauge is a simple yet very accurate means of checking and confirming the correct Reserve Stroke "SR. Note: If the green marker on the piston rod goes into the Red section the brake force will be reduced to Zero.

To Adjust
Caution: Before adjusting thruster stroke, ACD and AWA must be disengaged. (See Section 2) 1. Find bottom end stroke position of the thruster by rotating adjusting nut (3) anti-clockwise continuously until there is no longer any downward movement of the piston rod. This is zero brake force. Rotate adjusting nut (3) clockwise until piston of the thruster moves 10 mm from the bottom end stroke position. (This is the reserve stroke "SR) The brake now has full force. Replace the ACD and check the air gap. Replace the AWA and check the brake for smooth and correct operation.

2. 3.

The correct stroke position of both SR and SL as shown in Table 2 below. However, both height position of thruster cap green stroke maker within green gauge of indicator is also acceptable. 4. Set AWA and ACD to engage. (See Section 5) Table 2 THRUSTER TYPE #25, #33 #55, #88, #140, #220, #330 #338 #339

Reserve Stroke ("SR") 10 mm 10 mm 10 mm 10 mm

Working Stroke ("SL") 40 mm 50 mm 70 mm 80 mm

Maintenance of proper reserve stroke (SR) means maintenance of proper torque.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series

Note :

Page 10

If the reserve stroke requires adjusting outside normal maintenance procedures e.g. Brake lining replacement. This will indicate that the AWA is not operating correctly. To correct this problem do the following. 1. Clean up and check the spindle thread is not seized and the collar and one way clutch is moving smoothly. 2. AWA assembly needs to be replaced into new. Contact Ican or representatives.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 5: Initial setting.
1. 2. Ensure the electrical connections to the thruster. (See Section 3.)

Page 11

Check the gauge on the spring unit for the correct Torque setting, this is factory set, if it needs adjusting (See Section 7.) Open the brake with the thruster, check the air gap between linings and disc evenly adjust if necessary using the adjusting nut (7A) on top of ACD spindle or MCD (16). (See Section 2.) CAUTION: DO NOT turn screw or unscrew the adjusting nut of ACD (7A) while the rack(7B) is fitted. Both ACD spindle and MCD bolt shall be carefully handled for disc entering adjustment.

3.

4. 5. 6.

Check the Thruster is operating smoothly. Check the thruster reserve stroke. (See Section 4.) Engage ACD with ensuring the ACD rack is correctly positioned as shown Fig.2 on page 12. If the MCD is fitted tighten the locknut (16A). Engage AWA with ensuring the AWA free-wheel tapet is engaged in the collar.

7.

IMPORTANT: If any brake adjustments are required, the ACD and AWA must be disengaged before work. 8. 9. Carry out the running in procedure. (See Section 6.) Adjust the limit switches during running procedure (See Section 9.)

For ACD and AWA setting, please refer to procedures on next page 12 .

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series

ACD Setting

Page 12

a. Ensure that air gap between linings and disc is evenly. b. Slide in the ACD rack (7B) at the top of rack support (7C) toward instruction allow shown on Fig.1 below. The rack plate must be correctly positioned as plate backside straight surface firmly fit and aligned to the post of support (See Fig.2). The ACD main spindle with pinion can freely rotate toward rack sliding-in direction (e.g. anticlockwise). c. Set and tighten hexagonal-head bolt (7E) with paying attention to rack plate doesnt be in skew. d. Replace the ACD cover (6) and screw its tightening bolt into original position. Note: Failure to replace the rack or incorrect fitting will result in uneven wear of the brake linings and may cause damage to the disc, brake lining and shoe. Once the Rack is fitted the disc centering is now operated automatically and the nut (7A) must not be turned manually.

7A 7C 7B

ACD (with No rack)

Fig.1 ACD rack Sliding In

No Gap

7A

7B

7E
Incorrect setting !!!

Fig.2 ACD rack set (TOP VIEW) AWA Setting a. Ensure that thruster reserve stroke (SR) is correctly positioned. b. Rotate AWA free-wheel until the Tapet (9) is positioned in the center of the Collar stop (15) placing location. c. Replace the Collar stop (15) with ensuring the Tapet (9) is within the Collar bore and tighten the set screw (14) with locking nut (13). Note: Failure to replace the Tapet and collar stop will result no function of lining auto wear and may cause serious damage as brake slippage or dropping the cargo.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 6 : Running in procedure
Running in procedure under load. Release the brake after each cycle for 1 minute to allow it to cool down 1. 2. 3. 4. 5.

Page 13

Load the drive with half of the rated load. Run the drive on half rated speed and carry out 10-15 emergency stops. Repeat the procedure several time gradually increasing the speed up to the maximum. Check the reserve stroke of the Thruster and adjust if necessary. (See Section 4) Remove linings and check for sufficient contact of the surfaces. At least 70% of surface contact must be obtained through running in.

Caution. Take care not touch the hot brake and disc during this operation.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 7 : Brake torque setting

Page 14

The brake torque is normally set at delivery. However, when torque adjustment is required, adjust the torque according to the simple procedure as follows.. 1. Release lock nut (40), rotate spring tension adjusting nut (1) until the top edge of the blue mark on the spring plate (5) coincides with the specified torque settings on the braking scale (11). 2. Fix the setting torque using the lock nut (40). When tongued washer is provided on the spring tension adjusting nut (1) , bend to lock the nut (1).

Caution.
If brake torque is set at value higher than scale value, danger exists that brake will not open properly. The brake torque is factory set using a digital load cell and is very accurate. The scale on the brake is for checking and is not 100% accurate. Therefore we do not recommend any torque adjustment unless it is absolutely necessary.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 8 : Brake Limit Switches (Options, if any)
LIMIT SWITCH CONNECTIONS
The cable shall be flexible cable or flexible cable conduit. It must be flexible enough to enable brake movement(s) required for brake operation. The Switch Connection circuit for both 3.4.1 and 3.4.2 is indicated.
1 4 NC NO

Page 15

3 2 NO NC

(A) Brake open Limit switch Please refer to the drawings below. The brake must be open for this adjustment. 1. Unscrew both bolts (28) and open brake completely by actuating the thruster. 2. Move striker (27) from upside downwards to a position such that roller lever (26) activates the close signal of limit. 3. Move striker (27) upwards to a position such that the roller lever (26) activates the "open signal" of the "Brake Open" limit switch (25). 4. And more move striker to slide up 2mm. This is the correct position. 5. Tighten fixing bolt (28). (B) Brake Lining Wear Limit switch Please refer to the drawing below. The brake must be closed for this adjustment. 1. Unscrew fixing bolts (22). 2. Adjust supporting plate (21) with limit switch (24) to set distance Z as shown in Table 3 below. 3. Tighten switch bolts (22). 4. The distance Z corresponds to new linings. The limit switch is activated when the remaining thickness of the lining(s) decreases to 5.0 mm (for IB30-20/25/28/315) or 2.0 mm (for IB30-13). BRAKE TYPE IB30-13 IB30-20 IB30-25 IB30-28 IB30-315 SET DISTANCE "Z" 45 mm 45 mm 71 mm 71 mm 75 mm (C) Manual Release Limit Switch Please refer the drawing Fig.3 of Section 9 page 16. The manual release lever must be released freely for this adjustment. 1. Unscrew the Lock screw (30) for the Lever (32) free. 2. Loosen the roller lever fixing bolt (37) of the limit switch (35) and adjust this lever angle enabling to detect manual lever close position (with striker (36)). 3. Tighten roller lever fixing bolt (37).

(A) Brake Open" Limit Switch

(B) Brake Lining Wear" Limit Switch

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 9 : Manual release lever
The manual release lever (see below) is intended only for use in case of a power failure.

Page 16

Operate the lever very slowly and carefully to release the brake. Use extra caution in the case of lowering operation with a load. The manual lever shall be lifted up to 90 degrees from original position (until the position of roller catcher on the cam) and shall not exceed this angle. Before operating the lever (32) remove the lock screw (30). Replace the Lock screw (30) before re-commissioning the brake.

Fig.3 Manual Release Device

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 10 : Maintenance
Checking the brake is best done when the brake is operating normally. The following visual checks should be carried out every 100 to 150 Hours.

Page 17

1. Check the reserve stroke on the thruster. (See Section 4) Adjust if necessary Note: If the reserve stroke needs adjusting check the smooth operation of the AWA device. and apply a small amount of grease to the AWA spindle thread and keep clean. Please see Caution Page 10. 2. Check for any oil leaks from the thruster and the thruster is operating smoothly. Repair/overhaul or replace if necessary. Note: Replacement of operating fluid in the thruster must be carried out as an integral part of each overhaul procedure. Overhaul intervals shall be every 5,000,000 cycles or every 10,000 operating hours, based on intermittent operation of S3, 60% duty. 3. Check air gap between linings and disc. Adjust if necessary using MCD or by removing the ACD rack (7B) from the ACD and turning bolt (7A). (See Section 2&5).

4. Check the thickness of the brake linings. (See Section 11) replace if necessary Note: If the linings are wearing unevenly check the ACD rack is correctly fitted or check the MCD has been adjusted and the lock nut is tight. 5. Check the condition of the disc it should be clean and dry and free of any grease or oil. If the disc is found to be contaminated with oil or grease the whole area should be degreased and new brake linings fitted. (See Section 11) Check the disc surface is not scored, glazed or damaged or has worn down by more than 5mm. Replace or skim if necessary. 7. Check the electrical connections and cables are good and the limit switches are correctly positioned. 8. Check for any loose bolts/unusual noise.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 11 : Brake Lining (Pad) Replacement

Page 18

The automatic centering device (ACD) must first be disconnected. Next, the automatic wear adjustment device (AWA) must be disengaged. 1. Remove the ACD Rack

2. Disengage automatic wear adjustment device (AWA).

19

3. Open brake by rotating nut (3) anti-clockwise. 4. Detach the two screws (8) from the brake shoe (17). 5. Tilt brake lining carrier with lining (19) towards brake disc to detach and remove the carrier from the key (18). Remove the lining carrier by pulling upwards.

18

6. If sintered linings are to be used, clean the friction surface of the new lining carrier with a detergent. If other lining materials are to be used, the friction surface of the new lining carrier should be cleaned with emery paper.
C1

7. Insert new lining carrier by sliding it into position over the key and then fasten it to the brake shoe (17) using screws (8). 8. Reset the brake into the correct operation condition and carry out initial setting and the running in procedure. (See Section 5 & 6) Type Initial thickness (C1) of Lining (mm) Minimum thickness (C2) of Lining (mm) IB30-13 9.5 2 IB30-20 9 5 IB30-25 15 5

17

IB30-28/315 15 5

CAUTION
Before starting any work on the brake secure the drive against any accidental rotation and ensure the power supply is isolated.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 12 : Thruster Mounting Position and maintenance.

Page 19

The Thruster must be installed vertically and piston rod shall be located perpendicular to the base of the brake (standard installation). For horizontal installation of thruster, please contact ICAN COMPANY LTD. It is not necessary to consider phase sequences. clockwise rotation is acceptable. This means that both clockwise and anti-

Keep terminal box clean. Ensure that terminal box gasket is correctly positioned and intact. Lock terminal box securely and tighten cable entry pressure screw. Seal if necessary Note: The thruster is already mounted into the brake on delivery.

The thrusters are delivered ready for operation and are filled with the appropriate hydraulic fluid. Thrusters for use in a ambient temperature range of -25 to +50 deg. C are supplied ready-filled with Shell Tellus C10 or Shell Morlina oil 10 class fluid. Other temperature ranges require special hydraulic fluids. This "long life" fluid is not subject to wear or contamination when the thruster is operation, as long as the unit is in proper working order. All thruster bearings are provided with initial lubrication. (This means that thrusters are to a degree are maintenance free).

Thruster Operating Fluid Maintenance

1. Replacement of operating fluid is not normally required. Replace fluid when overhauling or repairing thruster. 2. Volume of hydraulic fluid to be filled into standard thrusters as follows:

Type of thruster Volume of oil(l)

#25 1.6

#33 1.9

#55 4.2

#88 4.2

#140 9.4

#220 9.4

#330 9.2

#338,339 9.2

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series

Level of operating fluid.

Page 20

Level of operating fluid

Plug 34

a) To remove air from thruster fluid and/or prevent possible entry of air, run the unit through several strokes. Then check oil level again and fill again to the top as necessary. b) Type / Brand of Operating Fluid: Shell Tellus C10 or Shell Morlina oil 10. Note: Replacement of operating fluid must be carried out as an integral part of each overhaul procedure. Overhaul intervals shall be every 5,000,000 cycles or every 10,000 operating hours, based on intermittent operation of S3, 60% duty.

For the exposed piston rod, thruster type of #25, #33, #55 and #88, please keep the rod clean, and apply spray lubricants or grease on the rod during the brake is released under routine maintenance. See sketch.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 13 : Anti Corrosion Measures

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Yearly the brake should be cleaned and any loose or damaged paint should be removed and the area treated with a rust inhibitor and the paint touched up.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 14 : Safety Instructions (Periodic)

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Please Note: All work on brakes or brake systems has a direct influence on the safety of your equipment. Our operating instructions should be strictly adhered to.

1. The following should be inspected regularly:

the proper functioning of the brake system brake shoe liftoff between disc and lining brake lining wear the condition(grease, oil, rust & etc.) of the brake disc the brake thruster reserve stroke (SR) smooth movement of the brake linkage setting of brake spring tension the adjustment of limit switches, hand release devices, and other options. possible wear of the automatic lining wear of the automatic wear adjustment (AWA)

2. Before commencing any work on the brake, determine if the brake or the brake spring tension needs to be released. In this case, ensure that:
the drive cannot move when releasing the brake / brake spring tension no mechanical tools are used to lock the brake in released condition, as these may be forgotten and left in the brake after the work has been completed. the brake is re-set to the required values after work is completed, i.e. the spring tension, the thruster SR reserves stroke and the brake shoe liftoff (brake lining clearance).

3. Your brake / brake system must be checked outside the special inspection :
a prolonged braking time occurs an emergency braking action has occurred. a limit switch indicates lining wear or lack of releasing stroke. the equipment has not been operated for an extended period of time oil leaks out (only in the case of electro-hydraulic or hydraulic brakes).

4. For service and repair work, observe the following points:

use original Ican Co., Ltd. spare parts only the use of non-original brake linings can cause the brake to malfunction and thus constitutes a safety hazard. replace brake linings when worn down to a minimum thickness of lining(C2). additional painting of the brake and/or coupling may lead to soiling and the restricted mobility of the brake pivot points and to contamination of the brake disc / brake drum surface. This will also impair the brake's safety. Brakes with automatic wear adjustment plus automatic centering device must also be inspected regularly, as it can show signs of wear itself if the brake is operated frequently. IMPORTANT NOTE: Although IB30 is fitted with an AWA (Automatic Wear Adjustment), it is not maintenance free, we recommend lining clearance/ wear and reserve stroke of thruster should be checked under routine maintenance.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series SECTION 15 : Spare Parts

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1. THRUSTERS Seals & Gaskets are available. Please contact us and state brake type and Serial No. 2. 2. BRAKE LININGS

NOTE: PLEASE STATE NAME PLATE DETAILS WHEN ORDERING SPARE PARTS.

DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series Fig. A IB30 Overview and Dimensions

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DWG No. CT-44663-B-2 (Revised June 2008)

Operating/Instruction manual for ICAN Disc Brake IB30 Series Inspection Sheet
INSPECTION ITEM BRAKE MECHANISM
1. 2. 3. 4. GENERAL SETTING BRAKE TORQUE BOLTS AND NUTS RETAINING RINGS MOVEMENT OF AWA, CONDITION OF COLLAR STOP Exterior inspection Visual Visual/ Physical Visual Is the movement smooth ? Is the torque set initial value ? Any bolts loosened ? Is the Free-wheel rotates smoothly ? Is the Tappet set at Collar Stop properly ? Is any wearing occurred ? See Section 10 See Section 7 To be re-tightened. To be adjusted, cleaned up and/or replace newone. (Recommended stock item)

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METHOD

POINTS TO BE CHECKED

CORRECTIVE MEASURES

THRUSTER
5. LIFTING LOWERING OPERATION Visual / Physical/ Measuring Visual Visual / Measuring Visual/ Physical Visual Is operation smooth? (Noise, Overheating, if any ?) Any oil leakage ? To be kept in allowable ranges. To be replaced newone. (Recommended stock item) To be replaced packings/ seals or new thruster. (Recommended stock item) 7. ADJUSTMENT OF RESERVE STROKE BOLTS AND NUTS OIL VOLUME AND CONDITION See Section 4 To be tightened. Change oil.

6.

LEAKING OF OIL

8. 9.

Any bolts loosened ? Check Oil. Not contaminated.

BRAKE PADS
10. THICKNESS OF LINING 11. GAP BETWEEN LINING AND DISC SURFACE 12. SETTING BOLTS 13. LINING Visual / Measuring Visual / Measuring Visual/ Physical Visual Check the thickness. (Is worn out uniformly ?) Check both gaps evenly ? To be replaced newone. (Recommended stock item) See Section 5 To be tightened. To be replaced newone. (Recommended stock item)

Any bolt loosened ? Check the color. Is there any crack occurred ?

DISC
14. NO GREASE, OIL AND RUST 15. BOLTS AND NUTS 16. THICKNESS OF DISC 17. DISC SURFACE Visual Visual/ Physical Visual / Measuring Visual Check the disc is free from any grease, oil, rust or contamination. Any bolts loosened ? Check the thickness. (Is worn out uniformly ?) Check the color. Is there any crack occurred ? Oil and grease to be removed and the disc surface to be cleaned up. To be tightened. Repair or renew. Repair or renew.

DWG No. CT-44663-B-2 (Revised June 2008)