Operation & Maintenance Manual of Disc Brake

# 223, 80 f eet , Ou ter Ring Road, Nagarab havi, 6t h Block, 2nd St age
BANGALORE - 560 072. INDIA. Ph one : +91-80-23 484179 / +91-80-232108 50

Fax : +91 -80 -23 481305 E-mail : inf o@kat eel.com Web: ht tp :/ / www.kat eel.com
KATEEL HYDRAULIC FAILSAFE DISC

BRAKE
MODEL: K-DAF/70-MS
1
Introduction
Safety
Unpacking the brake
Mounting
Cleaning the brake disk
Handling the brake
Mounting the brake
Inspecting the alignment of the brake
Connecting the hydraulics
Bleeding the brake
Bedding in of the brake
Mounting the brake pads
Adjusting the brake
Before using the brake
Removing the brake
Servicing the brake
Trouble shooting
Spare parts drawings and lists
2
Introduction
KATEEL Brakes’ range of high quality brakes offers a equipment designer a system of
braking that meets the highest safety and reliability for heavy braking applications..
Kateel Brakes is capable to deliver the complete braking solutions including Hydraulic
power pack and electronic control panel with smooth braking as optional.
Safety
Hydraulic power pack:

• Do not operate the hydraulic aggregate before correctly filling the reservoir/oil tank
with oil
• Do not adjust valves or pressure switches to higher operating pressure than
specified in the manual
• Do not change the size or type of components
• Do not use hydraulic fluids not recommended in this manual Brakes:
• Do not operate the brake before removing the air from the hydraulic system by
bleeding and then re-filling with oil
• Do not use higher operating pressures than specified on the nameplate of the
brake/or in the manual
• Do not change the size or type of spring pack
• Do not use the brake pads when they are worn to the minimum thickness as shown
in the manual
• Do not operate the brake if there is dirt or corrosion on brake disc or on brake pads
• Do not try to adjust the brake or remove it, before securing the brake disc from
rotating
• Do not work on a spring applied brake without locking/securing the piston by
using the air gab bolt/nut
Kateel products are designed and can be mounted any rotating brake disc for both
Dynamic and parking application.
Do not:
 Operate the brake before bleeding, after refilling with oil.

 Use higher operating pressure than specified on the sign on the brake.
 Change the size or type of spring pack without consulting KATEEL BRAKES.
 Use tools or any other equipment, which is not recommended by KATEEL
BRAKES.
3
 Use the brake pads, when they are worn to the minimum thickness, as shown in
the manual.
 Use brake pads, which are not recommended by KATEEL BRAKES.
 Try to adjust the brake, or remove it, before securing the brake disc from
rotating.
 Use other spare parts, than original spare parts from KATEEL BRAKES.
 Operate the brake if there is dirt on disc or brake pads.
Note:
The customer is responsible for , that the air gap between the brake pads and the brake
disc never exceeds the air gap recommended from KATEEL BRAKES
Always use a torque wrench for mounting bolts, to make sure that the torque obtained
is the torque described in the manual.
It is the responsibility of the customer that the brake pads and the brake disc always
are clean, and free from dirt, grease or oil.
Always be sure that the brake disc is locked and not able to rotate, before the adjusting
of the air gap is started.
Always use spare parts from KATEEL BRAKES
Unpacking the brake
1. Please check that all the parts listed on order have been delivered.
2. A tool kit is needed to be able to install the brake correctly. If a such has been
ordered it should be included in the delivery. The same tool kit can be used for
several brakes of the same type.
3. Any indicators that may have been ordered are not mounted on the brake but
packed separately to avoid damage during transportation and mounting of the
brake.
4. The brake pads have also been packed separately and should not be unpacked
until immediately before mounting them.
5. All loose parts should be visually inspected to check they are intact after
transport, and they should be removed before the brake is lifted from the
transport crate.
4
6. The brake is marked with a label, which should be checked against the ordered
items. The sign contains information on the type of brake, the serial number and
the necessary working pressure of the brake.
7. If anything is missing from the delivery according to the ordered items, or if

anything is damaged please contact the supplier immediately.
Mounting
Cleaning the brake disc
Before the installation of the brake calipers the disc must be washed clean with white
spirit and thereafter with thinners or trichlor ethylene. Any residual oil or anti-
corrosion preparation will reduce the friction coefficient markedly.
Handling the brake
The Mono-spring K-DAF/70-MS brake is equipped with a top plate with holes and
should only be lifted by means of placing a hook through them
In any case, do not fit any hook or tie any rope, chain or strap around switches,
valves, accumulator, gauges etc. in order to avoid damaging these parts.
The total weight of the caliper is approx.100 kilos.
Mounting the brake
1. Remove the indicator set, if fitted, by loosening and removing the allen
screw on the indicator mounting bracket.
2. When the brake is to be lifted for mounting, mount an eye bolt on the back of the
passive caliper half.
3. The brake can be lifted using these eye bolts.
4. Ensure that the mounting flange is cleaned of dirt and oil.
5
5. Lift the brake to the mounting flange and mount the lowest and innermost bolt
without tightening.
6. Tip the brake backwards.
7. Unscrew the cover on the adjusting screw.
8. Remove the threaded plug in the upper pressure connection and connect a hand
pump or hydraulic unit. Check the position of the adjusting screw,(Xmax.=93mm).
9. Apply min. release pressure mentioned in the name plate, max..180 bar.
10. When the piston is completely lifted, screw the flange nut into the end of the
center bolt, with the hand.
11. The hydraulic pressure can now be released.
12. Remove the hand pump. Plug the pressure connection on the caliper again.
13. Unscrew the adjusting screw approx.2turns (anti-clockwise)with the spanner

(adjusting tool) to allow sufficient space between the pads so the brake can later
be swung up round the brake disc.
14. Mount the brake pads so that the curved side of the pad is placed towards the
caliper and at the same time is parallel to the periphery of the disc.
15. check the mounting flanges and disc for dirt and grease.
16. Tip the brake into its place and fit the 4 bolts in the bottom plate. (M20,grade 8.8-
Mv=350Nm)
17. The hydraulic unit can now be mounted to the brake.
6
18. Check the position of the brake, continue to adjust the air gap.
Inspecting the alignment of the brake
1. Make sure that the piston is completely lifted and the pads are not in contact
with the disc.
2. Check that the pads can move freely.
3 . important !
The axial movement of the brake disc must not exceed 0,5 mm.
Connecting the hydraulics
The brake is provided with two pressure connections BSP 3/8”. The connection at the
lowest position shall always be used as pressure connection when connecting the brake
to the hydraulic system. The highest pressure connection can be used, depending on
the design of the hydraulic system.
Donot apply hydraulic pressure to the caliper before you have checked that X<93
mm.
Bedding in of the brake
7
To obtain the rated coefficient of friction between the pads and the brake disc, it
is essential that the pads are bedded to the disc surface. Instructions for this
process are packed together with pads.
Mounting the brake pads
1. Brake pads of composite material-for example BE pads-are delivered packed in

sealed plastic.
2. Be careful to protect the pads from grease and oil which would significantly.
Impair the friction coefficient. If any grease or oil comes in contact with the pad,
the pad must be discarded.
3. Always keep the pads in the packet for as long as possible.
4. Brake pads of sintered metal are less sensitive to oil and can be cleaned with
solvent and re-used.
5. When mounting the pads, first remove the two inside screws from the end of the
pad.
Note: The pads should be inserted with the rounded edge orientated so that it
follows the curvature of the disc. Re-fit the two screws and tighten them as
specified.
6. If the hub diameter is too large (disc diameter minus 300mm), the brake pads
can be mounted from the side. Remove the mounting screws and insert the pads
as described above. Re-fit the two screws and lighten them as specified.
Adjusting the brake
1. The air gap is the space between the brake pads and the brake disc, when the
piston is completely lifted back against the adjusting screw.
2. This total air gap must be adjusted to 1 mm at installation and must NEVER
exceed 3mm, i.e. 1 mm wear on each pad . when the air gap is > 3 mm the
caliper must be adjusted.
3. Remove the indicator set, if fitted, by removing the allen screw on the mounting.
4. Check the position of the adjusting screw, Xmax. ≤93, and apply release pressure
to the caliper, see test certificate or sign.
8
5. Mount the flange nut and release the oil pressure.
6. Turn the adjusting screw clockwise using the spanner (adjusting tool) until both
pads are in contact with the disc. Then turn the adjusting screw a half turn
backwards (180° anti-clockwise). There will now be 1 mm air gap (the thread of
the adjusting screw has a pitch of 2mm).
7. Check by measuring with, for example, a 1mm feeler gauge that the air gap
between the disc and the pad is exactly 1mm. if the positioning system is
mounted, the 1mm air gap must be adjusted to 0,5mm air gap on each side of
the brake disc, see data sheet.
8. Apply release pressure to the caliper, ref name plate.
9. Remove the flange nut, and release the oil pressure
10. Re-mount the cover and O-ring.
Before using the brake
Please check that the disc has been blocked mechanically while the following points are
checked:
Please make sure you check:
1) That the disc and the pads are clean, containing no dirt after mounting
2) The bolts and hydraulic connections have been tightened using the right torque
3) That the electrical installations have been connected correctly
4) That the brake set for the correct air gap
9
5) That the brake opens and closes correctly, and with the right reaction times
6) That the indicators function correctly
Please make sure the brake is closed and that the hydraulic pressure has been
removed.
Free the disc from the mechanical blocking.
The brake is now ready for use .please note that the pads needs to be bedded in for a
while before the full effect of the brake is obtained.
Removing the brake
1. Apply hydraulic pressure, see test certificate or sign.
2. Remove the cover, and mount the flange nut (see mounting of the brake)
3. Relieve the pressure
4. Remove 3 of the bolts in the ground plate and loosen the 4th.
5. The brake can now be turned around the 4th bolt and brake pads be removed.
6. Apply hydraulic pressure again, remove the flange nut and re-fit the cover.
7. Remove hose and pipe connections. The brake can be removed safely from the
mounting place by removing the 4th bolt.
Servicing the brake
Replacing the brake pads.
The brake pads must be replaced when each pad has been worn 5mm.
All brake pads for the brake consist of a steel back plate and a friction material. The
brake pad has a total thickness of 24mm, i.e. all brake pads must be replaced at the
latest when the thickness of friction material +back plate is minimum 19mm.
1. Unscrew the cover.
10
2. Check the position of the adjusting screw (Xmax=93mm). Apply max. Release
pressure to the caliper (see test certificate or sign.)
3. When the piston is fully lifted, mount the flange nut on the center bolt.
4. Release the oil pressure.
5. Turn the adjusting screw anti –clockwise using the spanner (adjusting tool), as
far out as possible, i,e. until the adjusting screw comes into contact with the O-
ring.
6. It is possible to change the pads just by removing the 2 innermost allen screws
on each pad, if there is >90mm space between the hub of the disc and the mono
spring bracket.
7. Otherwise disconnect the hydraulic lines from the brake.
8. Loosen the mounting bolts in the brake pad holders.
9. Remove the pad retraction springs (if fitted).
10. Replace the worn brake pads with new pads, and replace the pad retraction
springs if fitted.
11. Check the mounting surfaces and the disc for dirt, grease, oil etc.
12. Re-connect the hydraulic unit to the brake.
NOTE: All pipes and hoses shall be undamaged and thoroughly free of dirt. (See
“Connecting the hydraulics”).
13. Adjust the air gap between the new brake pads and the brake disc.
Follow the section “Adjusting the brake”
14. Remember the bedding in of brake pads.
Checking the spring package.
If you want to check the spring pack visually before it has reached its calculated service
life, it can be carried out as follows:
1. Remove the spring pack (See “Dismantling the hydraulic unit”).
11
2. The positioning of each individual cup spring in relation to each other is very
important and must be carefully checked.
Never mount a spring pack if there is any doubt as to the positioning!
3. Distance shims, if any, must be placed towards the adjusting screw.
4. Check each individual cup spring and distance shim visually. The whole spring
package must be replaced by a new pack, if just one cup spring is broken or
scratched.
Replacing the spring Package.
The spring pack must ALWAYS be replaced after the 60,000 operation.
Replacing the spring pack (See “Dismantling the hydraulic unit”)
The positioning of each individual cup spring in relation to each other is very important
and must therefore be carefully checked. Distance shims, if any, must be placed
towards the adjusting screw.
Lubricate the springs and the adjusting screw thoroughly when fitting.
NOTE: A spring package must NEVER be mounted and be discarded when:
1. There is any doubt as to the positioning of the cup springs,

2. A single cup spring is broken or scratched.
Dismantling the hydraulic unit.
General
The greatest possible cleanliness must be observed when working on a hydraulic

system of any type.
Each part must be washed in solvent (paraffin, trichloretylene) and dried before
being Lubricated and fitted. Parts must be stored in, and assembly work must be
carried out in a clean & dust free environment. Dirt shortens the service life of the
seals considerably and may also damage the hydraulic unit. The surface of the
piston and the yoke which works against the seals is highly polished. Check that
they are not damaged and handle them carefully to avoid damaging the surface in
any way. A damaged piston will immediately ruin the seals.
12
1. Apply release pressure (See the name plate) to the caliper and mount the flange
nut.
2. Release the oil pressure.
3. Turn the adjusting screw anti-clockwise using the spanner (adjusting tool), until
X=93mm
4. Loosen the mounting bolts in the bottom plate of the Monospring brake and tip
the brake backwards around the lowest and innermost bolt.
5. Remove the pads, and tip the brake back into place.
6. Apply release pressure (See the name plate) to the caliper and remove the flange
nut.
7. Release the oil Pressure.
8. Dismantle and plug the hydraulic connections.
9. Store the flange nut together with the spanner as part of the tool kit
10. Remove the 2 allen screws and the top plate.
11. Remove the 4 mounting bolts and remove the whole caliper half. The caliper half
must be taken to a workshop prepared for hydraulic work.
12. Remove the adjusting screw from the yoke.
13. WARNING! Before removing the adjusting screw, be sure there is no pressure on
the caliper.
14. Remove the spring pack.
15. Push the piston including center bolt back wards.
16. Remove the wiper and the seals.
17. Wash the parts thoroughly, dry and lubricate them.
18. Mount the new seals and the wiper. The dust lip on the wiper must be placed
outwards. The piston seals consist of an O-ring and a sealing ring. There is also
an O-ring together with the wiper. Place the O-ring in the groove first. Then form
the sealing ring in a U-form and place them in the groove with the O-ring.
13
Squeeze out any kink. Use your fingers only. Be very careful with the edges on
the piston rod seals-even a tiny scratch can ruin the seals.
19. Push the piston as into the yoke as possible. The adjusting screw can be used as
a tool.
20. Fit the spring pack. (See “Replacing the Spring Package”) using the spanner,
until is max 93 mm out of the yoke.
21. Turn the adjusting screw clockwise, using the spanner, until it is max. 93 mm
out of the yoke.
22. The caliper is ready for re-installation and adjustment (See “Mounting”).
Lubrication and Storage
LUBRICATION:
Lubrication is required only when dismantling the hydraulic unit and when replacing
the spring pack
Seal –surfaces lubricated with hydraulic oil. Spring, threads etc. lubricated with MoS2.
Storage
The brake is externally treated before delivery with an anti-corrosion film which is
sufficient for indoor storage for 12 months.
If the caliper is to be stored for periods longer than 12 months. It must be worked 20
times at full stroke each 12 months.
IMPORTANT
The anti-corrosion protection must be re-applied as necessary after transport and

handling if stored for more than 12 months.
Any kind of work carried out on the brake, which are not mentioned in this manual
should be regarded as repair. In such cases please contact M/s. KATEEL supplier.
14
Trouble shooting
FAULT CAUSE ACTION

The brake applies Slowly Air in the hydraulic Bleed system at Highest
point and at Brake
Air gap between brake pad Adjust air gap.
and disc too large.
Abnormal throttling in the Check that all the correct
hydraulic system, valve in position
wrong position.
Abnormal throttling in the Clean and check pipes
hydraulic system, dirt hoses and valves
Oil in lines between brake Check that the oil is the
and tank has too high recommended grade and
viscosity not too cold.
(too thick).
Long braking time or Load too heavy or speed too Check the braking distance
insufficient braking force high load and speed Values
Air gap too large Adjust the air gap
Oil, paint or grease on Wash disc with
brake disc or pad trichloroethylene
All brakes not connected Check valves where
applicable
Incorrect or damaged Replace whole spring pack.
spring Not individual cup springs
Leakage. Worn seals Replace seals. Check
sealing surfaces
Uneven wear on pad The brake is incorrectly Check the alignment and
aligned the bracket
Excessive disc throw or Replace the brake disc and
shaft check the shaft deflection.
Abnormally heavy wear on Increased brake utilization Check that the load speed
brake pad and frequency do not
exceed permissible values
Insufficient air gap . Adjust the air gap
The brake does not lift Check the oil Pressure
properly
Check The movements of
pads and pistons and the
position of cup springs and
guides.
15
PART LIST.
16
17
18
19
20
21

Operation &amp; Maintenance Manual of Disc Brake

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# 223, 80 f eet , Ou ter Ring Road, Nagarab havi, 6t h Block, 2nd St age

BANGALORE - 560 072. INDIA. Ph one : +91-80-23 484179 / +91-80-232108 50

KATEEL HYDRAULIC FAILSAFE DISC

Unpacking the brake

Cleaning the brake disk

Handling the brake

Mounting the brake

Inspecting the alignment of the brake

Connecting the hydraulics

Bleeding the brake

Bedding in of the brake

Mounting the brake pads

Adjusting the brake

Before using the brake

Removing the brake

Servicing the brake

Spare parts drawings and lists

Hydraulic power pack:

 Operate the brake before bleeding, after refilling with oil.

Always use spare parts from KATEEL BRAKES

Unpacking the brake

7. If anything is missing from the delivery according to the ordered items, or if

Cleaning the brake disc

Handling the brake

The total weight of the caliper is approx.100 kilos.

Mounting the brake

3. The brake can be lifted using these eye bolts.

4. Ensure that the mounting flange is cleaned of dirt and oil.

6. Tip the brake backwards.

7. Unscrew the cover on the adjusting screw.

11. The hydraulic pressure can now be released.

13. Unscrew the adjusting screw approx.2turns (anti-clockwise)with the spanner

17. The hydraulic unit can now be mounted to the brake.

Inspecting the alignment of the brake

2. Check that the pads can move freely.

Connecting the hydraulics

Bedding in of the brake

Mounting the brake pads

1. Brake pads of composite material-for example BE pads-are delivered packed in

3. Always keep the pads in the packet for as long as possible.

Adjusting the brake

5. Mount the flange nut and release the oil pressure.

8. Apply release pressure to the caliper, ref name plate.

9. Remove the flange nut, and release the oil pressure

10. Re-mount the cover and O-ring.

Before using the brake

Please make sure you check:

3) That the electrical installations have been connected correctly

4) That the brake set for the correct air gap

6) That the indicators function correctly

Free the disc from the mechanical blocking.

Removing the brake

1. Apply hydraulic pressure, see test certificate or sign.

3. Relieve the pressure

Servicing the brake

Replacing the brake pads.

1. Unscrew the cover.

4. Release the oil pressure.

7. Otherwise disconnect the hydraulic lines from the brake.

8. Loosen the mounting bolts in the brake pad holders.

9. Remove the pad retraction springs (if fitted).

12. Re-connect the hydraulic unit to the brake.

Follow the section “Adjusting the brake”

14. Remember the bedding in of brake pads.

Operation & Maintenance Manual of Disc Brake

Operation & Maintenance Manual of Disc Brake