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Mondel Electric Shoe Brakes Installation & Maintenance Manual
DT Heavy Duty Disc Brakes


Mondel DT Heavy Duty Disc Brakes Instruction Manual





Part Number: 560005-R1
February 2006
© Copyright 2006 Magnetek Material Handling



SUPPLEMENTS FORMING PART OF THIS MANUAL:
































DATE OF MANUFACTURE:

APPLICABLE DIMENSION PRINT:

EXPLODED VIEW:

PARTS LIST:
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Installation and Maintenance
Instructions

DT Heavy Duty Disc Brakes

Table of Contents

Chapter 1.0: DT Heavy Duty Disc Brakes Warnings and Cautions .................................................... 4

Chapter 2.0: General Description........................................................................................................ 6

Chapter 3.0: Installation ...................................................................................................................... 8

Chapter 4.0: Adjustment.................................................................................................................... 10

Chapter 5.0: Actuator Delay Adjustment (Optional Feature) Refer to Fig. 5 .................................... 14

Chapter 6.0: Operational Test ........................................................................................................... 15

Chapter 7.0: Inspection and Maintenance ........................................................................................ 16

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Chapter 8.0: Brake Pad Replacement Refer to Fig. 6....................................................................... 17
Chapter 1.0: DT Heavy Duty Disc Brakes Warnings and Cautions

These instructions contain safety recommendations for users. Read and follow the information
contained in these instructions and any standards referred to.


If a brake is not installed immediately, it may require protection. For long-term storage, consult
factory for details.


Chapter 3: INSTALLATION Warnings and Cautions

Anyone involved in the installation or service of this brake must have:

Received specific training.

Had experience on similar equipment.

Knowledge of the equipment on which the brake is installed.

The ability to understand the terminology.

The ability to understand the diagrams.


Do not proceed unless technically qualified for the work involved.


Ensure that all suspended loads or systems, subject to the effects of gravity, wind or otherwise,
having the potential of causing the mechanism to move when the brake is released, removed, or
being worked on, are blocked or supported in a satisfactory manner, totally independent of the
brake.


Hazardous voltage can cause burns, injury, or death. Consult the diagrams to identify and switch
off, lock open, and tag the appropriate disconnecting devices. This includes all power to the
brake, drive, control, heating or other related circuits. Verify by testing for voltage and try the
operational controls to prove that all power sources are isolated.


The design of the support structure must be engineered to take the load and reaction when the
maximum torque of the brake is applied. The duty cycle and all special considerations must be
taken into account and an appropriate safety factor applied.


Do not alter the brake to achieve the required alignment, otherwise the integrity of the brake may
be compromised and a replacement brake may not fit.


Excessive run-out or High Spots on a brake disc can cause localized and unnecessary heating
and unequal expansion. This may result in severe and permanent damage to the brake disc.
Other factors can contribute to excessive run-out which cannot be detected at low speeds, typical
are bearing wear or the effect of critical shaft speed.


Aligning the calipers accurately to the disc in the plan view will maximize lining life and ensure
that rated performance can be achieved with a minimum of bedding.
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Chapter 4: ADJUSTMENT Warnings and Cautions

It is the users responsibility to determine the torque required from the brake and to ensure the
brake is set to provide the torque required for the application.


Chapter 6: OPERATIONAL TEST Warnings and Cautions

Unexpected movement, dropped loads or hazardous voltage can cause burns, injury or death.
Make sure the following have been tested prior to the Operational Test:

Torque set properly.

Time Delays set properly (if supplied).

Brake secure, and aligned properly.

Electrical controls installed and adjusted.


Chapter 7: INSPECTION AND MAINTENANCE Warnings and Cautions

To allow for expansion of the working fluid, do not over fill the Actuator. Thoroughly clean-up all
spills to aid in quickly detecting new leaks.







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Chapter 2.0: General Description

2.1:
The Mondel DT brake is a single caliper disc brake, consisting of spring applied, electro-hydraulic
actuator released brake mechanism. See Fig. 1A and 1B.

2.2:
The caliper unit is complete with lined pads, spring mechanism, Hy-thrust actuated release
mechanism, manual release, automatic wear compensation (AA), and automatic equalization of
running clearance (AE). When specifically ordered, the brake can be furnished with limit switches
to indicate specific functions.

2.3:
Operation of the brake may be enhanced to suit specific applications by the use of optional
adjustable time delay valves installed within the actuator. The (S) delay is used to delay the
return stroke of the actuator on de-energization and will result in a delay in the brake application.
This feature can also be used to delay subsequent brakes until the first of multiple brakes has
been applied. The (H) delay can be used to delay the release of the brake. A typical application
would be where the drive torque will build-up gradually and brake release must be delayed to
prevent run-back.

2.4:
The brake can be used in conjunction with a Mondel Braketronic controller or can be equipped
with hydraulic over-rides.

Figure 1A


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Figure 1B










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Chapter 3.0: Installation

3.1:
Care taken when installing the brake will ensure maximum operational life.

3.2:
After unpacking, visually inspect the brake to ensure that damage has not occurred during
shipment and that there are no damaged or missing parts.

3.3:
Prepare and align the brake support structure ready to receive the brake. Detailed dimensions
are shown on the certified dimension prints. The support structure must satisfy three
requirements as follows:


3.3.(a): Height or elevation the brake support structure must present a level, rigid mounting
surface (brake seat) at an elevation compatible with the base of the brake, with a reasonable
shimming allowance of not less than 0.030.


3.3.(b): Plan location The bolt holes for securing the brake to the base must be positioned
accurately to ensure brake alignment in both the axial and transverse directions.


3.3.(c): Base Skewing The bolt holes, for fixing the brake to the brake seat, must be positioned
to ensure the brake can be installed and secured with the brake pads in full contact with the disc.
Ensure there is adequate clearance between the mounting bolts and the base bolt holes, to allow
the alignment of the pads to the disc. A disc brake is particularly susceptible to this type of
misalignment.

3.4:
The basic installation procedure is as follows:


3.4.(a): Install the brake disc and hub assembly on the drive shaft.


3.4.(b): Using a dial gauge indicator, check that disc run-out is within acceptable tolerance over
the entire braking surface. We suggest a maximum run-out of 0.0005 per inch of disc diameter,
to a maximum of 0.010.


3.4.(c): Install the caliper assembly on the equipment base. Verify the securing bolts are
centered within the holes in the base and that the base is located correctly with respect to disc.
Temporarily fit two of the bolts to secure the base to the equipment seat.