Kobelt 5022-A Owner'S Operation, Installation & Maintenance Manual Download Page 1

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KOBELT MANUFACTURING CO. LTD MNL-5022-A.docx (rev B)

5022-A DISK BRAKE

AIR APPLIED VERSION

Owner’s Operation, Installation &
Maintenance Manual

Summary of Contents for 5022-A

Page 1: ...KOBELT MANUFACTURING CO LTD MNL 5022 A docx rev B 1 5022 A DISK BRAKE AIR APPLIED VERSION Owner s Operation Installation Maintenance Manual...

Page 2: ...2 Brake Discs 9 2 3 Caliper brakes 11 2 3 1 Mechanical 11 2 3 2 Piping 11 3 Commissioning 13 3 1 Air Gap 13 3 2 Function Test 13 3 3 Burnishing 13 3 4 Torque Test 14 4 Operation 15 4 1 Functional Requ...

Page 3: ...MANUFACTURING CO LTD MNL 5022 A docx rev B 3 5 3 2 Stroke Adjustment 18 5 3 3 Brake Linings 19 5 4 Recommended Spares 21 6 Warranty 22 7 Appendix A Technical Drawings 23 8 Appendix B Parts List Drawi...

Page 4: ...instructions concerning a service or operation that may be hazardous if performed incorrectly or carelessly The associated risk levels are stated below This symbol indicates an imminently hazardous s...

Page 5: ...this manual If these guidelines are not followed and damage occurs the warranty will be voided 1 2 3 Hazards Equipment Starts Automatically Brake systems frequently are controlled remotely and may ac...

Page 6: ...typical Kobelt caliper brake with all the major components identified All of the Kobelt caliper brakes can be fitted with either air applied hydraulic applied spring applied with air released or spri...

Page 7: ...ference only They are based on properly bedded and burnished linings acting on a rotor at 20o C and manufactured to required specifications 2 Requires a minimum 4 34 in 110 mm wide face Technical data...

Page 8: ...KOBELT MANUFACTURING CO LTD MNL 5022 A docx rev B 8 1 5 MODEL CODE KEY...

Page 9: ...e seals Remove the plugs prior to connection to the piping Brake discs are shipped with a light rust inhibitor applied to the surfaces Remove the rust inhibitor using solvent and a cloth prior to inst...

Page 10: ...1016 0 043 1 1 0 056 1 4 0 069 1 8 0 082 2 1 45 1143 0 049 1 2 0 063 1 5 0 078 2 0 0 092 2 3 To reduce the size of the mounting bolt clearance hole it is recommended to offset the bolt circle on the...

Page 11: ...from step 6 Use ANSI shims that straddle the mounting bolts 8 Insert the mounting bolts from underneath the pedestal using appropriate flat washers The nut must be on top of the brake foot The mountin...

Page 12: ...turns from finger tight Use brass pipe fittings as steel fittings are too heavy and may split the port Do not over tighten the fitting in the actuator port as damage to the actuator may occur For ope...

Page 13: ...nsure that the brakes are operational 3 3 BURNISHING Burnishing is required in order to achieve rated brake torque The process of burnishing removes minor contaminants from the rubbing surfaces and im...

Page 14: ...burnish one brake at a time Three important points to consider when burnishing are i The temperature of the disc must be closely monitored Excessive heat will damage the friction linings ii The durati...

Page 15: ...drate wood alcohol to prevent freezing of the air system 4 2 SERVICE LIMITS 4 2 1 Disc Temperature The Kobelt brake lining achieves maximum friction at 300o F Over 300o F the brake begins to fade or e...

Page 16: ...he table below the discs must be balanced Under no circumstances must the running speed exceed the value given in the right hand column Table 4 Maximum Disc Speeds Part Number Nominal OD inch mm Max S...

Page 17: ...mption When the running clearance has reached 0 04 1 mm the brake must be adjusted back to 0 01 0 25 mm per shoe Refer to section 5 3 2 For pressure applied brakes maintain the proper running clearanc...

Page 18: ...mum Thickness Allowances Brake Disc Minimum Thickness Disc Series Original Thickness in mm Minimum Thickness in mm 2 4 XX 2 00 50 8 1 90 48 5 When re machining the disc surface equal amounts must be t...

Page 19: ...ises by turning inward to allow for the extra thickness of a new lining 5 3 3 Brake Linings The linings must be replaced before the rivets make contact with the disc Remove worn linings from the shoe...

Page 20: ...1 Loosen screws B 2 Apply brakes onto the disc 3 Ensure link A has no tension on it Adjust if necessary 4 Tighten screws B When reinstalling the shoes and pivot blocks reinstall the shoe pin first to...

Page 21: ...service work on a Kobelt unit be performed by a factory authorized service representative Please contact the nearest Kobelt authorized distributor for assistance The table below itemizes which kit sp...

Page 22: ...cant Applicant must immediately contact Kobelt and describe the issue in writing by letter fax email or other electronic conveyance Kobelt will then assess the cause of the defect and determine warran...

Page 23: ...KOBELT MANUFACTURING CO LTD MNL 5022 A docx rev B 23 7 APPENDIX A TECHNICAL DRAWINGS...

Page 24: ...KOBELT MANUFACTURING CO LTD MNL 5022 A docx rev B 24...

Page 25: ...KOBELT MANUFACTURING CO LTD MNL 5022 A docx rev B 25 8 APPENDIX B PARTS LIST DRAWINGS 5022 A...

Page 26: ...9 2 5022 0011 BALANCING LINK PART 1 5022 CALIPER 2 1 2 5021 0226 LINK PIN 5 16 UNC X 7 8 LG 2 11 2 5022 0112 BALANCING LINK PART 2 5022 CALIPER 2 12 4 1002 0808 SCREW SKT HD CAP 10 UNC x 1 2 LG SS 2 1...

Page 27: ...KOBELT MANUFACTURING CO LTD MNL 5022 A docx rev B 27 5022 AW...

Page 28: ...7 8 LG 2 9 2 5022 0011 BALANCING LINK PART 1 5022 CALIPER 2 1 2 5021 0101 SIDE MOUNT BRACKET 5021 CALIPER 2 11 2 5022 0112 BALANCING LINK PART 2 5022 CALIPER 2 12 4 1002 0808 SCREW SKT HD CAP 10 UNC...

Page 29: ...12 ACTUATOR 3 2 6112 0003 DIAPHRAGM WASHER 6112 ACTUATOR 4 2 6112 0002 CENTRE HOUSING 6112 ACTUATOR 5 2 6112 0001 END CAP 6112 ACTUATOR 6 6 1201 0146 SPRING COMPRESSION 640 OD X 065 WIRE X 2 95 L 7 2...

Page 30: ...A docx rev B 30 5022 LS ITEM QTY PART NUMBER DESCRIPTION 1 1 5022 0007 BRAKE PAD 1 2IN K5 2 1 5022 0005 BRAKE SHOE 3 19 1033 1007 RIVET 1 4 X 7 16 10 7 BRASS Heiko Epkens Digitally signed by Heiko Ep...

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Kobelt 5022-A, Owner'S Operation, Installation & Maintenance Manual

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