Related Manuals for Kobelt 5022-SA
Summary of Contents for Kobelt 5022-SA
- Page 1 5022-SA DISK BRAKE SPRING / AIR VERSION Owner’s Operation, Installation & Maintenance Manual KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
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Page 2: Table Of Contents
4.2.3 Pressure ........................17 4.2.4 Disc speed ....................... 17 Maintenance ....................... 18 Preventative Maintenance ..................18 Inspection ........................18 5.2.1 Pad Wear ........................ 18 5.2.2 Seals ........................18 5.2.3 Actuator Test ......................18 KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) - Page 3 Release Limit Switch ....................21 5.3.4 Spring Actuators...................... 21 5.3.5 Brake Linings ......................21 Recommended Spares....................22 Warranty ........................24 Appendix A: Technical Drawings ................... 25 Appendix B: Parts List Drawings ................... 27 KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
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Page 4: Introduction
• Do not carry out any modifications to the product. • Only use authentic Kobelt spare parts. • Observe all local regulations, directives and laws during the installation of this product. • All installation, commissioning and maintenance work must only be conducted by qualified personnel. -
Page 5: Hazards
Brakes contain numerous pinch points which can cause serious injury. Ensure all power sources are locked out prior to performing work. High Pressure Fluids: Kobelt lever brakes use high pressure hydraulics. Ensure all pressure is exhausted and the pressure source locked out prior to performing work. Hot Surfaces: Disc brakes are capable of making the surfaces of the brake disc dangerously hot when burnishing or during braking events. -
Page 6: Product Description
The diagram below shows a 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 spring applied with hydraulic released actuators depending on the required service. - Page 7 102 lbs [46.3 kg] 1) Requires a minimum 4.34 in [110 mm] wide face Technical data and specifications are also available from our datasheet posted on www.kobelt.com the technical drawings in Appendix A. KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
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Page 8: Model Code Key
1.5 M ODEL KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) -
Page 9: Installation
International tolerance class. Allowable run out is proportional disc O.D. Parking brakes and emergency brakes with stopping times of 10 seconds or less are considered light duty. Ventilated discs are exempted from this requirement KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) - Page 10 The cooling air pumped through the disc must be exhausted away from the outer diameter of the disc to allow fresh, cool air to enter the inner vent opening of the disc. KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
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Page 11: Caliper Brakes
All piping must be cleaned prior to connection to the actuators. Welded carbon steel piping must be pickled to remove the scale produced by welding. The connections to the brake actuators must be made by hoses of suitable rating to accommodate the movement of the brake levers. KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) -
Page 12: Instrumentation
2.3.3 Instrumentation Kobelt caliper disc brakes may be equipped with sensors and switches, such as the 6212-MSKIT. The 6212-MSKIT is a brake release indicating switch kit. The connection to the switch must be made by cable or flexible conduit and a ½ NPT cable or conduit gland. To access the switch terminals, remove the two captive screws holding on the back cover. -
Page 13: Commissioning
3.2 F LUSHING Kobelt spring applied, air released disc brakes may be used in low pressure hydraulic applications. Before subjecting the brake system to full hydraulic pressure, the brake lines must be flushed to an ISO 4406 cleanliness rating of 19/17/14. -
Page 14: Function Test
Disc temperature must not exceed 700°F (371°C) or permanent degradation of the lining may occur. KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) -
Page 15: Torque Test
Before putting equipment into service, confirm that full rated braking torque has been achieved through load testing or a torque test against the drive motors. If full brake torque has not been achieved, continue burnishing. KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) -
Page 16: Operation
In applications where the brakes cycle infrequently with significant changes in ambient temperature it may be necessary to provide a thermal relief to protect the actuators from over pressurization due to thermal expansion. KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) -
Page 17: Control
4.2 S ERVICE IMITS 4.2.1 Disc Temperature The Kobelt brake lining achieves maximum friction at 300 F. Over 300 F the brake begins to fade or experience diminishing friction. The maximum operating temperature of the brake linings is 700 F [371 C]. -
Page 18: Maintenance
Occasionally it may be necessary to test the actuator springs as a means of trouble shooting. The easiest method is to measure the hold-off and release pressure of the actuator. The release pressure is defined as the minimum pressure required to fully retract the actuator whereas KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) -
Page 19: Pin Wear
Brake Disc Minimum Thickness Disc Series Original Thickness Minimum Thickness in [mm] in [mm] 2-4-XX 2.00 [50.8] 1.90 [48.5] When re-machining the disc surface, equal amounts must be taken off of each face. KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) -
Page 20: Service
This is to prevent premature seal wear and reduce seal friction. All Kobelt calipers, during assembly, are pre-greased on the shoe pin and saddle pin with a Lithium based NLGI 2 grease. These pins must be re-greased no less than once annually. -
Page 21: Release Limit Switch
The linings must be replaced before the rivets make contact with the disc. Remove worn linings from the shoe by drilling out the rivets with a ¼” drill. Install new linings with the proper rivets. KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) -
Page 22: Recommended Spares
‘C’. Tighten screws ‘C’ to 200 in-lbs [ 22.7 Nm]. ECOMMENDED PARES The spare parts kept on hand will depend on the severity of the service. As a minimum Kobelt recommends keeping the following parts for each brake in service: 1. One Lined set of brake shoes 2. - Page 23 Disc Thickness -175 5022-1750 1.750 in -150 5022-1500 1.500 in -125 5022-1250 1.250 in -100 5022-1000 1.000 in Friction Code Lined Shoe Friction Material 5022-LSN4 non-sparking 5022-LSC4 low COF (.12-.15) 5022-LSE4 mid COF (.25-.28) KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
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Page 24: Warranty
If any part is found to be defective, Kobelt will replace said part FOB the Kobelt factory provided that any such defective part is returned by the Buyer with freight and applicable forwarding charges prepaid by the Buyer. -
Page 25: Appendix A: Technical Drawings
A: T PPENDIX ECHNICAL RAWINGS KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) - Page 26 KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
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Page 27: Appendix B: Parts List Drawings
B: P PPENDIX ARTS RAWINGS 5022-SA KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) - Page 28 SPRING APPLIED ACTUATOR, 6212 1002-1216 SCREW, SKT HD CAP, 3/8-16 UNC X 1, SS 1002-1112 SCREW, SKT HD, 5/16-18 X 3/4, 18-8 6112-0010-L PIN, LONG, 6112 ACTUATOR 1026-0312 COTTER PIN 3/32 X 3/4 SS KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
- Page 29 5022-SAW KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
- Page 30 SPRING APPLIED ACTUATOR, 6212 1002-1216 SCREW, SKT HD CAP, 3/8-16 UNC X 1, SS 1002-1112 SCREW, SKT HD, 5/16-18 X 3/4, 18-8 6112-0010-L PIN, LONG, 6112 ACTUATOR 1026-0312 COTTER PIN 3/32 X 3/4 SS KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
- Page 31 COMPRESSION SPRING; HEAVY 6212-0016 SPRING GUIDE; HEAVY 1022-0216 JAM NUT; 5/8-11, 18-8 1001-1136 SCREW, HX HD CAP, 5/16-18 X 2-1/4, 18-8 1001-1112 SCREW HEX HEAD, 5/16-18 x 3/4, 18-8 6212-RK SEAL KIT, 6212 ACTUATOR KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A)
- Page 32 5022-LS KOBELT MANUFACTURING CO. LTD MNL-5022-SA.docx (rev A) Heiko Epkens Digitally signed by Heiko Epkens Date: 2023.08.10 13:59:57 -07'00'...