vksd - Altra Industrial Motion Literature Portal
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1.2. 5 ITEMS 57 AND 62 FITTED FOR TRANSPORT PURPOSES THESE ARE BE REMOVED AND ITEMS 17 20 57 AND 61 FITTED ON INSTALLATION SCHEDULE 212797 15 Tas SPRING MODULE ASSEMBLY ae 297 750119462 BASE MODEL u SA MATERIAL FINISH PART 57107 11 DATE 25 06 04 DRG AO01519 SHT 1 oF 2 A SCALE ba 0 14 FORM 00 56 4 XXXXX 10 06 11 CONVERTED NX ASSOCIATIVE DRAWING DIMENSIONS IN mm OPEN TOLERANCES 0 25 ITEM 15 46 51 AND 52 DELETED MECHANICAL RETRACTION 2 13325 5 04 05 7001 KIT PART No 7903437 4 SCHEDULE No 2157 22 oe H CERT D GENERAL M C FINISH 1 6 B p ________ SURFACE FINISH IN MICRONS TWIFLE ED eg 2 MICRONS 0 002mm CLA ISSUE ALT No DATE DESCRIPTION GRI EDF O RD 80 MICRO INCHES CLA RE 1 2 3 4 5 6 7 X 8 9 10 11 12 13 14 THIS DRAWING IS THE PROPERTY OF TWIFLEX LTD IT MUST NOT BE LENT REMOVE SHARP EDCES COPIED OR DISCLOSED WHOLLY OR IN PART TO ANY PERSON WITHOUT WRITTEN THIRD ANGLE PROJECTION METRIC 0 10 50 100 mm DO NOT SCALE AUTHORITY FROM TWIFLEX LTD DESIGN RIGHT SUBSISTS IN THE DESIGN OF USED ON ARTICLES MANUFACTURED WHOLLY OR IN PART IN ACCORDANCE WITH THIS DRAWING fd 180 0
3. 5 FOR PART IDENTIFICA 4 D SCREW AND ION SEE SCHEDULE 2157 PUT PORTS ARE PLUGGED FOR TRANSPORT PURPOSES IHE SE 5 FOR THE GREEN TWICKENHAM BE REMOVED AND NSTALLATION OP ERATION AND MAINTENANCE SE E MANUAL M1438 DIMENSIO S IN mm OPEN TOLERANCES 0 25 WIFLE X TWIFLEX AT oS SURFACE FINISH IN MICRONS eg 2 MICRONS 0 002mm CLA 80 MICRO INCHES CLA LIMITED MIDDLESEX ENGLAND TW2 SAQ FED SCREW AND COUPLING FITTED ON INSTALLATION B SEE NOTE 2 SEE NOTE 4 HOLES FOR 24 TIE RODS 2 SEE NOTE 1 LO CN xl HYDRAULIC INPUT FOR 12mm TUBE BLEED SCREW HYDRAULIC INPUT AND BLEED SCREW CAN BE INTERCHANGED D B B G1 8 1 8 BSP DRAIN PORTS KC m 345 SPACE REQUIRED FOR PAD REMOVAL EITHER SIDE MECHANICAL RETRACTION DETAIL TOOL KIT PART No 7903437 TO BE PURCHASED SEPARATELY THIS SCHEDULE 7157 22 os BRAKE CALIPER ASS
4. 9 115501 UIHMS 54 10 25012 125 MSd 9 055919 usii E JO ON 10 o Su MSd yams asnssasd ul yapms Buds 1438 28 of 31 Issue 02 April 2005 Performance curves for VKSD 119 62 Pressure at full retraction bar Shim thickness mm ue EE 385 0 in publication 011547 Braking force values are based on 21 1 106 mm 6 coefficient of friction of 04 i is Disc springs 5 series x 2 parallel nominal size 50mm x Timm x 8mm group 3 aeee Back pressure control of braking 16 3 Pee HT force is 104 bar kN 067 psi lbf 3 HIE tte Brake release pressure is 101 x ing force on vertical ordinate 14 2 98 4 10 5 92 6 X a amp 60 ro c App braking force 6 Air Gap Setting mm each side of catiper issue amp M1438 Page 29 of 31 Issue 02 April 2005 SES FORMANCE CURVES VKSD 64 28 it 2117 118 e
5. TIMITA III jud jk TE E ns HH HER Hin laa i E RNERAREIBHAH f it ii 211171 ji s E secte see pes 2 mu liri 1 3X T m 2 a IDE RUE 111 1 11 111 THICK NESS mm sence sores bowen POSITION Gmm STEP Lio SHIMN 0 INWARD N 6 i GHAL 19 id BRAKING FORCE AIRGAP SETTING mm Side G1458 Issue 3 M1438 Page 30 of 31 Issue 02 April 2005 STE 8 2 2 7 Shims MM Postion STEP OH LID _ 0 DEN 1 B 5400 i i 2 1 m 7 ER 1 1 ja thes ducum ANIC
6. Cougs S N NND N ANY 5 49 AN SS 2 A AN WZ if 2 ILIA T 2 yuh Fi IN AIR SV gt 22777 m PART SECTION SHOWING SHIMS END COVER POSITION END COVER POSITION BY 72 SEE NOTE 4 tax L 2 34 51 6 2 7 M 2 R ITEM NAME 2 NN Le ROUSING Cer 2 1 PRESSURE PLATE 412 5 1 ADJUSTING SCREW 9 40 2 SPRING GUIDE 20 SONm 36 ft 25 1 PISTON 8 ile ms 5 1 CYLINDER 61 4 7 1 END COVER 1795200 2 fix ie 57 I 8 1 PISTON COLLET G3 8 3 8 BSP PORT FOR BLEED AE RT EU RE E P 1 COLLET RETAINER SCREW HYDRAULIC INLET AND EE SCREW HYDRAULIC INLET AND 5721 27 LLZLLEL d La 5 T 2 21 1 SPINDLE BEARING 7902224 58 74 Z ie 2 2 2 2 12 1 SPINDLE LOCKING PLATE 7902225 SRAIN PORTS A 3 2 PAD RETRACTION HOOK C 1 14 2 PAD RETRACTION PLUNGER Sq ee n RA X 2 THRUST WASHER 2 WASHERIVKSD x is 3 washes N 2 E aN IS TE ET En 17 1 JBLEEDSCREW 1 8 5 SIN 2 N 20 3 87 5 1 1 787 5 N EIAS NN 2 54 Vi e T a gia Se 2 24 2
7. 95 SEE NOTE 1 4 HOLES FOR M24 TIE RODS SEE NOTE 1 344 HYDRAULIC INPUT FOR 12mm TUBE B 61 8 1 8 BSP DRAIN PORTS 104 345 SPACE REQUIRED FOR PAD REMOVAL KX KX OI EDGE X OX BRAKE DISC POX X lt x lt x Xo X CX lt x Dod ME RO XK T KX BRAKE DISC RRI 8 CX THIOKNESS X4 X 20 4 lt x Dod 22 Y 50 RA 2 i RL CX DO X CX XI DX bo lt lt gt lt x lt x H Xo X 956 1 RY X X CX lt x DO gt lt x eX 4 1 R lt lt x Ke E E sex X LA 54 wee 115 BRAKE DISC E MOMS 310 MN FOR NORMAL WORKING 2 2 L 330 MIN CLEARANCE FOR INSTALLATION TOTAL OIL DISPLACEMENT 28 FOR 1mm RETRACTION FOR BOTH PADS PERFORMANCE DATA TYPICAL VALUES OF BRAKING FORCES ARE GIVEN FOR 2mm AND 4mm GAP SETTINGS THESE CAN ONLY BE ACHIEVED WITH FULLY BEDDED AND CONDITIONED BRAKE PADS OPERATING ON BRAKE DISCS OF CORRECT MATERIAL HARDNESS AND FINISH FOR OTHER CONDITIONS APPLY SERVICE FACTORS FOR BRAKING FORCE AT OTHER GAP SETTINGS SEE CURVE GRAPH G1457 PRESSURE NOTES GRRE RELEASE RETRACTION 1 HOLES IN MOUNTING PLATE ARE 26 FOR M24 ROD
8. Re fit brake pads and adjust for correct air gap The disc spring bearing on the spring guide abutment must do so with its smallest diameter as shown on the drawing M1438 Page 17 of 31 Issue 02 April 2005 3 10 4 3 11 1 3 11 2 4 1 5 1 TESTING Carry out functional testing and operational testing as may be required Check settings of monitoring units if used after refitting the caliper Adjust if necessary OPERATION AS SHIP SHAFTS HOLDING BRAKE It is assumed that the brakes are in the Parked Off Position 1 2 1g HYDRAULIC PRESSURE AVAILABLE Apply hydraulic pressure and turn adjusting spindle 10 on both sides until the pads are firmly against the disc Releasing the hydraulic pressure will apply the brake and Braking Force will be as for zero gap setting as indicated for the shim height as fitted NO HYDRAULIC PRESSURE AVAILABLE Remove end cover and fit mechanical retraction tools see section 3 6 b Continue tightening the nuts until piston is fully retracted i e when spring guide 4 is within 8 mm of retraction tool face Turn adjusting spindles until the pads are firmly against the disc Releasing the nuts on retraction bolts will apply the brake Braking Force will be as for caliper at zero gap setting at no shim height Braking force will however be affected by the factors as under 1 2 2 ROTABOLTS Special Tie bolts are available optionally with a Rotabolt tell tale at
9. TN E lt al FEE a eee EN Ni e 6810016 2 505 RAIAR IRIX RO 55 5054 510 1 2510 40 2 20 m ETT EZ SRS 612005 ON Id TZAR 09 X ZIW D o je 8158 1006561 ON A JONVI 0112 8134 IN MINOW M1438 Page 27 of 31 Issue 02 April 2005 5 5 4 7 7SELO 297 094 6 0 H 67 791 gen 104 9 401 6 0 x fes sa 4 P 9109 1483 g 761 d 691 U 610291282 584 0103 6 7 4 309 EZL 4104 26 e SES SHA SHA 39 m H S eJnsseJd 114 4 pps 5 d jsa ainssaid aym 3 52454204049 6 0 2 54 Dunes MSd Bullies uado MSd 2 MSd uado MSd pasojo Ajaypsadas 5 x pun Kojar a 4DJq UIHMSUOW u2 i S uoi oy abun ur DSM AXDIA uado Suds yoan HO DIJNDIPAH 55 aspaja
10. 22777272 2 5 TIGHTENING TORQUE 40 47 2 SN lt MECHANICAL RETRACTION DETAII 17 0 1 227 lt TOOL KIT PART No 7903437 N SONM 5615 1 PURCHASED SEPARA
11. VKSD Performance Curves Explanatory Notes 1025 V Type Monitor Unit 1 amp M Manual M1438 Page 1 of 31 Issue 02 April 2005 1 1 SPECIFICATION GENERAL DESCRIPTION THE OPERATIONAL SEQUENCE is illustrated in Appendix 2 Numbers in brackets refer to item nos No 01519 for VKSD 119 62 and 01520 for VKSD 64 28 The VKSD disc brake caliper is a spring applied hydraulically retracted unit which may be used on any disc having a diameter of at least 1 0m and a thickness of 20mm or greater There is no upper limit on diameter or thickness Braking torque may be controlled by any combination of air gap setting varying shim thickness or by the use of hydraulic backpressure during braking The caliper consists of two halves which are mounted each side of a mounting plate or pedestal by means of 4 M24 tie rods and 3 M16 bolts No special bleeding arrangements are required for mounting at any angle as the fluid is almost entirely evacuated when the hydraulic pressure is fully released with the pads fully wound back The braking force is applied by the disc spring packs 25 through spring guides 4 and thrust screws 3 to the pressure plates 2 and hence to the friction pads The calliper is available in two models the VKSD 119 62 with 5 pairs of disc springs per module and the VKSD 64 28 with 7 single disc springs per module Conversion of model VKSD 119 62 into VKSD 64 28 is possible and is described in Section 5 T
12. 5 GAL 55 55052 2 BRAKE THICKN DISC ESS NNN 2222 NLL END COVER POSITION PART SECTION SHOWING B 910 MIN FOR NORMAL WORKING 330 MIN CL EARANC E FOR INSTALLATION TOLAL OIL DISPLACE ENT 28101 FOR 1mm ERFORMANC DA 1 FULLY PICA VALU END POSITION FOR 0 COV ES 0 BRAKING FORCES GIVE EDDED AND CONTIONED BRAKE PADS OPERATING ON BRAKE D ER CONDITIONS APPLY SERVIC FOR 2mm AND 4mm GAP SE SCS OF E FACTORS FOR BRAKING FORC ETTING E OI HYDRAULIC PRESSURE FULL RETRACTION Q FTI UJ 20 I PN AJ T m CIE JO p S l bar INGS THESE CAN 0 MATERIAL HARDNESS AND FINISH ETRACTION FOR BOTH PADS LY ACHIEVED WITH GAP SETTINGS SE GRAPH 01456 MAX PERMISSIBLE eI ce Ozi 4 4 4 1 21 1 SHIMS CO NO AN
13. IN 1 E 11177 ll 1 5 d cu idi oa RO li M 11 MS INIM IN 7 11 AIR GAP SETTING mm cee sine INWARD MC x 20 BRAKING FORCE kN 21459 155062 1438 Page 31 of 31 Issue 02 April 2005 20 1 89 USED ON ISSUE No 1 2 4 tar ana PROJECTON THIS DRAWING IS THE PROPERTY OF TWIFLEX LTD IT MUST NOT BE LENT COPIED OR DISCLOSED WHOLLY OR IN PART TO ANY PERSON WITHOUT WRITTEN AUTHORITY FROM TWIFLEX LTD DESIGN RIGHT SUBSISTS IN THE DESIGN OF ARTICLES MANUFACTURED WHOLLY OR IN PART IN ACCORDANCE WITH THIS DRAWING METRIC 0 10 100 mm 1 1 1 1 1 1 1 DO NOT SCALE T 12 MOUNTING PLATE THICKNESS 163 OPTIONAL TIE BOLT KIT TO SUIT DISC THICKNESS TIGHTENING TORQUES M16 BOLTS 200Nm 148 M24 RODS 675Nm 498 OPTIONAL 3 FUNCTION V TYPE MONITOR UNIT EDGE OF MOUNTING PLATE SEE NOTE 2 BLEED SCREW HYDRAULIC INPUT AND BLEED SCREW CAN BE INTERCHANGED 7 3 HOLES 17 FOR M16 BOLTS SEE NOTE 1 TIGHTING TORQUE 200Nm 148 151
14. Note and report any unusual observations Check condition of the brake paths They should remain smooth and free from contaminants for example rope lubricant Remove any deposits At the end of the running in period check the security of all bolted connections and pipe connections The caliper mounting bolts should be paint marked to provide a visual security check M1438 Page 9 of 31 Issue 02 April 2005 3 2 MAINTENANCE INSPECTION PROGRAMME After the running in period the following schedule should be followed in addition to any statutory requirements MAINTENANCE SCHEDULE ITEM WEEKLY MONTHLY PERIODIC Check for hydraulic fluid leakage fe Observe brake operation ois il c Clean calipers of accumulated deposits d Clean brake paths on disc e Observe bolt security Note and record brake pad thickness Note and record brake pad movement stroke Adjust if required Check availability and condition of spares and tools j Remove and inspect brake pads see 3 4 i See note a under Running in period 3 1 Any appreciable flow from the drain pipes indicates that one or more of the hydraulic seals needs replacing This may be conveniently done by replacing the complete half as in Section 3 8 However if servicing on site is essential consult Section 3 9 ree vi ii See note b under Running in period iii Under adverse conditions this may be required more frequently iv Check that
15. b to f The pressure plate 2 thrust screw 3 and spring guide 4 with springs 25 can now be removed from the housing d Alternativelv the pressure plate 2 and thrust screw 3 can be removed first bv rotating the latter clockwise bv means of the adjusting spindle 10 The spring guide 4 with springs 25 can then be removed for inspection Take great care not to damage the rubbing surface for the rod seals 29 Keep springs in their order as assembled if possible M1438 Page 16 of 31 Issue 02 April 2005 3 10 2 NON DESTRUCTIVE TESTING 3 10 3 NOTE If the springs are visually sound an N D T method may be employed It is essential that the surface finish of the disc springs is not damaged by electrical contacts sparking or otherwise so an N D T should be adopted which does not give rise to any such danger Inspect other parts as may be required RE ASSEMBLY Follow generally the reverse of the dismantling procedure but note vi Exercise great care not to damage seals and bearing surfaces Re assemble spring in the reverse order to that in which they were originally assembled to extend their fatigue life Observe assembly notes under 3 9 Clean wearing surfaces of cylinder 6 thrust screw 3 and spring guide 4 before re assembly Retighten set screws 55 to 6 Nm 4 5 Ibf ft It is essential when reinstalling caliper half to preload M24 tie rods and M16 bolts as under 3 8 j
16. with a wear life of 25 000 MJ For pad replacement see Section 3 4 MATERIALS AND QUALITY ASSURANCE The housings pressure plates and cylinders on the VKSD are castings of SG iron to BS 2789 grade 420 12 Other metal components are steel Calipers can be supplied with non destructive test NDT certificates for all critical components if required The main hydraulic seals are PTFE O rings are nit rile rubber Some cylinders may be steel Each caliper is fully tested after assembly and a test certificate issued MONITORING UNITS Monitoring units are supplied as an option a typical 3 function model part number 7700660 drg no A22444 is described below The unit is fitted to the cylinder end cover Each unit contains three micro switches which may be used to operate warning lamps or other indicating devices One switch SWC is operated by a collar on the adjusting spindle the other two are operated by a spring loaded actuator which bears directly on the back of the hydraulic piston SWA SWB A 20mm conduit entry is provided All switches are sealed to IP67 and suitable for temperature down to 50 C The Box itself is also sealed to be splash proof The functions and connections of the switches are as follows SWA Terminals 2 NC 3 NO Switch operates when brake is fully retracted indicating correct functioning of the hydraulic system and providing brake off warning SWB Terminals 5 NC 6 NO Switch closes with
17. 10111500 0 81 LEG as SN FETA 2 lt lt 55 lt gt 25 4 HY N 94 se 5500 y b 2 m M1438 Page 23 of 31 Issue 02 April 2005 A NE 2 KLL 9292594 525250506 72 EL 21 55 93 222 pk 2 222 55505 20 S 22 Ny lt gt E e e Page 24 of 31 Issue April 2005 2 506 222 CX ox Y N CN 8 A AN LR IX 22 NJ 5 5 WW 26245925609 94 25250 RSS dec lt gt 24 5 lt gt 4 2 22 2 i Qx 52521 jasia nva 4 lt G IVI 14 Page 25 of 31 Issue 55 02 April 2005 Buas deg 4 BIH ZZJAN 7 ESS KAAN dVD 7 oS SX KA 99 QAL 5 SS 510 D ER 4 KA 0005 LEXXI pin TTS ETA ep Xs 25 52 5 2900 E 17 7 1438 Page 26 of 31 Issue 02 April 2005 TALI
18. 73501025 A IL NS 42 2 SEAL BONDED 3 8 BSP TRANSPORT PURPOSES ONLY 7300148 mane E N WO TIGHTENING TORQUE Y 1 L 2 NY NI G 27 4 516 ft 7 gt 22 1 FOR PART IDENTIFICATION SEE SCHEDULE 7157 15 N AN N EN 1 2 SPRING MODULE BASIC PARTS PART 6701539 A 5 2 a USE LITHIUM COMPLEX GREASE HTEP _ INDUSTRIAL TS LID 45 16 MECHANICAL RETRACTION DETAIL 0 GREASE INNER AND OUTER ABUTMENT FACES OF ALL DISC SPRINGS TOO PARI 7905457 IO PURCHASED SEPARATELY 5 ITEM 47 AND 62 FITTED FO TRANSPORT PURPOSES THESE ARE BE REMOVED AND ITEMS SCHEDULE 21587222 9 20 59 AND 61 FITTED ON INSTALLATION SECTION B B 4 SEE TH PERFORMANCE DATA CHART ON DRAWING No 01518 SHOWING END COVER POSITIONS AN REQUIREMENTS SCHEDULE 2157 14 cr SECTION D D Li DESCRIPTION INERTIA WEIGHT rene DIMENSIONS IN CERT D 10 06 11 TO NX ASSOCIATIVE DRAWING L Ti SPRING MODULE ASSEMBLY ur 13325 13204 05 15 46 51 AND 52 DELETED MECHANICAL RETRACTION NI VY ANGLES 05 CHECKED ma VKSD64 28 BASE MODEL g H 03 H O kg TOOL KIT PART No 7903437 amp SCHEDULE 7157 22 ADDED GENERAL M C FINISH 1 6 um PART SURFACE FINISH IN MICRONS DRAWN REG MATERIAL FINISH 4701538 2 aa TWIFLE ED eg 2 MICRONS AMP
19. H CA OD ED coles ala CS CO cc NO FRO Cw OEO LO EOD CN Ci co NO C OO NO Cn O Rho N Co 34 FATIGUE LIFE ERATING A ED GAP CYS 15 55205 4101 EON 06 gt 5 yx 105 571108 5710s 57x10 52x10 5x1 0 6 REMOVE SHARP EDGES DIMENSIONS AND TOLERANCES TO BS 308 3 HOLES 017 FOR M16 BOLTS SEE NOTE TORQUE 200Nm 148 lb ft NOTES 1 HOL 017 FOR M16 BOLTS ES IN MOUNTING PLATE ARE 926 FOR M24 TIE RODS AND PERS SUBJECT TO US REVERSING BRAKING LOADS OVER 7OkN BE PROVIDED WI ONE M24 FITTED TIE ROD AT D ER A OR OF REQ 2 UIRING HOLE A OR B TO BE MACHINED MUM BRAKE DISC DIAMETER 1000mm ROW OF FOUR TIE RODS 625 025 25 000
20. RETRACTION SPRING SCREWLOCK 222 ARRAY REMOVED WHEN FITTING WA TA 26 1 SPACER SEE 7157 3 2 NOS sa 48 ALX LX LACK ZS 7 28 5 2mm SEE 25773 29 1 CYLINDER SEAL 150 0 0 TIG 50 1 ROD SEAL 70 10 IGHTENING TORQUE 6 4 516 ft 31 1 BEARING RING 150 32 1 BEARING RING 70 1 0 25 37 38 30 36 52 22 25 e 4 59 33 2 33 1 BEARING RING 172 1 0 34 1 JO RING 150 14553 8000399 35 1 O RING 74x70x2 4 36 1 JO RING 190 185 3 1 1 1 1 6000167 E 27 O RING 6 x Dx3 6000445 SECTION LET 6000445 58 1 BACK UP RING 75 10 25 G3 8 3 8 BSP PORT 41 3 6 DIA FEED 42 3 TENSION 5 5800183 CAN B INDEXED TO XS ANY POSITION az IN POSITION SHOWN a lt 4 WITH GROOVE IN LINE RILQ H H TEM 3 AS SHOWN H aa 1 TIN 4 48 4 SCREW HEX HEAD 5 12 Zn NINA ic A N Dvr 90 LLL 7 A 82 o 22722222 2 JSETSCREW HEX SOCKET CENTRE LINE OF 1 8 BSP o 18 24 DRAIN PORTS IN HOUSING 2 9 5 47 wi 7 CU U 5a 4 JPLUG 1 8 BSP 5 NE NN 2 59 1 COUPLING MALE STUD 3 8 BSPx12TUBE SECTION 77 WZ __ lt 1 SEAL BONDED 378 BSP
21. b Need for adjustment for pad wear Need for pad replacement M1438 Page 2 of 31 Issue 02 April 2005 1 2 1 2 1 DETAIL SPECIFICATION The VKSD series has a special operational feature called Parked Off position This is made possible by having a piston stoke long enough to permit the disc springs to fully expand Hence no internal spring loads exist in this condition Yet the brake pads can be retracted to be within the mounting face and 11 5mm 0 45 clear of the disc This brings the following advantages The unit can be shipped without a retraction tool and with the cylinder end cover and monitoring unit in position The unit can be installed without the need for hydraulic pressure The pads can be safely exchanged without a retraction tool and with the hydraulics at zero pressure Hydraulics can be operated and tested and air gap set without placing unbalanced axial load on the brake disc and shaft The module including spring pack can be safely assembled and disassembled In the case of hydraulic failure the retraction tool is only required to release the brake Full retraction is not necessary as upon release the pad can be wound back in the parked off position and the retraction tool removed For ship shafts maintenance use the brake when placed in the parked off position cannot be applied accidentallv or due to inadvertent operation or hvdraulic failure see also 3 11 The parked off feature co
22. b c and e Remove end cover 7 complete with bolts 47 and shims 27 28 Slacken off set screws 55 Remove retaining ring 40 from piston Retract and remove collet retainer 9 by inserting M4 x 40 screws in the tapped holes in this retainer Remove split piston collet 8 It may be necessary to free the segments by tapping them towards the pad end of the caliper Note that collet segments are marked with a batch number e g B 20 Remove cylinder 6 and piston 5 together by means of bar bolted to M12 retraction holes in piston O ring 36 may be reused unless severely damaged Take assembly to work bench and carefully remove piston 5 Inspect wear surfaces seals wear rings and O rings for damage and refurbish or replace as necessary Re assembly is generally as dismantling procedure but in reverse order note the following i Exercise great care not to damage seals and wearing surfaces ii Clean wearing surfaces on spring guide 4 and cylinder 6 iii First assemble piston into cylinder iv Note that cylinder seal 29 has to be sized by means of the cylinder and rod seal 30 by means of a tool with a diameter of 69 970 69 940 70f7 with a chamfer of 8mm 0 3 in long 15 blended into this diameter surface finish to be 0 4 microns 16 micro ins Slide cylinder piston assembly onto spring guide ensuring that cylinder spigot is fully home into housing Move piston into cylinder so that
23. brake on when stroke has increased due to pad wear sufficiently to required adjustment Normally set to indicate 1mm wear M1438 Page 5 of 31 Issue 02 April 2005 SWC Terminals 8 NC 9 NO Switch closes when the pad requires replacement Normally set to indicate 10mm 3 8 in pad wear The switch settings may be adjusted to some extent to suit particular applications These units are supplied loose and correctly set but should be checked for correct adjustments after re fitting to the caliper The switch ratings in amperes are as follows VOLTAGE RESISTIVE TUNGSTEN LAMP LOAD INDUCTIVE LOAD LOAD m s vs upto 18 os For a full description see Publication M1105 M1438 Page 6 of 31 Issue 02 April 2005 2 1 NOTE 2 2 INSTALLATIONS AND ADJUSTMENT INSTALLATION Refer to Drawing A01517 for VKSD 119 62 and Drawing A01518 for VKSD 64 28 Ideally two calipers should be used on each disc mounted diametrically opposite each other in order to neutralise the braking torque reaction forces on the shaft bearings Any other position can also be catered for as the bleed screw on the cylinder can be indexed to any position after releasing the two set screws 55 the set screws should be retightened to 6Nm 4 5 Ibf ft Brake mounting plates or pedestals should be of adequate strength and rigidity and must be flat and parallel to the disc surface Each calipe
24. no movement has occurred at paint marked bolts and test security of other fasteners v Note brake pad wear by measuring proximity of pad backing plate edges to disc with M1438 Page 10 of 31 Issue 02 April 2005 vi 3 3 brakes on A dimension of 2mm at any position indicates that the pad needs to be replaced Replacement thickness is 12mm 0 470 in measured over backing plate New thickness is 22 mm 0 866in over backing plate Air gap is nominally as shown on the drawing or on the curves but is affected by disc axial float and run out and will vary by that amount Actual stroke measured at the pad will be greater due to deflections of the caliper and movement of the adjusting spindle is the most convenient measurement See Publication 1025 Where no monitoring units are fitted and when pad wear is very low as is generally the case comparative checks of pad movement may be made monthly with accurate measurements at less frequent intervals ADJUSTMENT FOR FRICTION PAD WEAR The adjustment is made by turning the adjusting spindle 10 clockwise using a suitable spanner Adjustment can be made in 0 5mm 0 020 in increments 1 6th of a turn by leaving the locking plate in the same position or in 0 25mm 0 010 in by inverting the locking plate Determine adjustment required to bring piston stroke into line with original gap setting see note vi section 3 2 above Remove the M5 screws from spindle locking plate 12
25. one end This tell tale can be rotated by hand when the pre load is below specification and cannot be rotated when the pre load is correct CONVERSION OF VKSD 119 62 INTO VKSD 64 28 OR VICE VERSA To convert VKSD 119 62 into VKSD 64 28 See Section 3 10 1 and remove the ten disc springs 25 Discard three disc springs and re assemble springs facing alternate directions and with the disc spring bearing on the spring guide abutment with its smallest diameter as shown on drawing 01518 Add spacer part no 7952008 at the other end of the spring stack M1438 Page 18 of 31 Issue 02 April 2005 5 2 5 3 5 4 NOTE 5 5 Follow further re assembly instructions as under 3 9 and 3 10 3 fit shims as required up to maximum of 4mm with the end cover 7 step outward or 6mm with the cover step inward To convert VKSD 64 28 into VKSD 119 62 See section 3 10 1 and remove 7 disc springs and discard spacer Add 3 disc springs part no 2500154 and re assemble springs into 5 pairs facing alternate directions and with the disc spring bearing on the spring guide abutment with its smallest diameter as shown on drawing A01517 Follow further re assembly instructions as under 3 9 and 3 10 3 and add or discard shims as required up to a maximum of 7mm Position of end cover 7 on VKSD 119 62 the flat side is on outside on VKSD 64 28 the stepped side is on the outside for the higher capacity settings and to the insider for the low
26. split collet segments 8 can be entered into groove in spring sleeve Refit O ring 35 to hold segments in place Insert collet retainer 9 and apply some air pressure to the cylinder port to blow piston into place Collet segments should be M1438 Page 15 of 31 Issue 02 April 2005 Note 1 Note 2 3 10 3 10 1 Note vi vii viii replaced in their original positions referring to batch number and identifying marks Refit retaining ring 40 Turn cylinder so that bleed screw 19 is uppermost Note that thread at hydraulic feed port and at bleed screw port are the same size hence adaptor 20 and bonded seal 61 can be removed to port which is nearest top and thus save turning cylinder an unnecessary amount Retighten two set screws 55 to 6 Nm 4 5 Ib ft Refit end cover 7 note correct position see note 1 with monitoring unit if fitted taking care to enter the 3 tension pins 42 into the holes in the spring guide Tighten set screws 47 evenly in turn to a torque of 50 Nm 36 Ibf ft Refit external O Ring 36 Finally reconnect hydraulic pipes bleed and readjust brakes as under 2 1 and 2 2 Note position of end cover 9 and refit as shown on drawing i e flat side is always on outside Tension pins 39 have to be tapped into inside of lid REPLACEMENT OF SPRINGS DISMANTLING a Proceed as under 3 8 a to h and transfer caliper half to workshop b Proceed as under 3 9 steps
27. 0399 35 JO RING 74 70 24 60003598 EY 17 G3 8 3 8 BSP PORT 36 1 O RING 190x185x3 ASSEMBLE ITEM 14 4 2 37 1 O RING 67x75x3 WITH GROOVE IN LINE ANY POSITION 38 1 BACK UP RING 75 10 WITH FACE OF HOUSING S 39 1 QUAD RING SEAL 171 05 LDx3 53 ITEM 3 AS SHOWN TIGHTENING TORQUE ETAINING RI 2 NOTE PRESSURE PLATE 4 4Nm 04 516 ft V NS um ITEM 14 ADJUSTED 4 l 7 L Ng 300173 FULLY BACK 7 2 17 i 2 YA eX mo ATE 7 NI 4 7112 27 4 22 26 20 28 2 Z 77777 5 7 SCREWHEXHEADMIOXSO _ 5300192 Z We 2 4 a E 178 INI LAN a a 20 LZ ARS 7 0 0 Pt PJP 2 24 LLLLL gt e 1 4 53 2 SETSCREW 5400469 e E 2 2 22 PART SECTION SHOWING SHIMS Wt ML S G 5 22 2 7 2 5 05787855 TRANSPORT PURPOSES ONLY 22172 9 PLUG 178 BEE RN NOTES 59 1 MALE STUD 3 8 BSPx12TUBE A 7 NN 1 FOR PART IDENTIFICATION SEE SCHEDULE 7157 15 an SPRING MODULE BASIC PARTS PART 6701539 p amp 1 JSEAL BONDED 3 8 BSP _ ee 2 a USE LITHIUM COMPLEX GREASE HTEP 1402353 45 16 INDUSTRIAL PRODUCTS LTD 53 1 COLLAR EVEBOLT Bee SECTION B B b GREASE INNER AND OUTER ABUTMENT FACES OF ALL DISC SPRINGS
28. 2 MICRONS 80 MICRO INCHES CLA AO1 520 SHT 2 OF 2 A 2 3 4 5 amp 7 A 8 9 10 t FORM No 00 36 4
29. D 119 62 up to 712 turns on the VKSD 64 28 thus closing the gap at A Fig 3 The number of turns depends on the number of shims fitted The brake is now operational with about 11 5 mm retraction To Set Correct Air Gap Maintaining full retraction pressure continue turning spindle clockwise until brake pad is firmly up against disc Fig 4 Slacken off brake by turning spindle anti clockwise to obtain required air gap Thread pitch on thrust screw is 3 mm e g 1 6 turn for 0 5mm Air Gap 1 3 turn for 1mm Air Gap 1 2 turn for 1 5mm Air Gap 1 turn for 3mm Air Gap etc 1 12 turn for 0 25mm Air Gap can be obtained by inverting locking plate Releasing hydraulic pressure will now apply the brake M1438 Page 21 of 31 Issue 02 April 2005 APPENDIX 2 CONT D Replacing Brake Pads Return brake to Parked Off position as follows Apply just sufficient hydraulic pressure to release brake Turn spindle fully anticlockwise Release hydraulic pressure Sufficient space is now available to remove old pad and insert new pad Hydraulic Supply Failure Release brake by means of hand pump connected direct to feed port Turn spindle anti clockwise to obtain Parked Off position Mechanical Retraction Fit retraction tool Fig 5 Release brake by turning nuts the same amount in turn Turn spindle anti clockwise to obtain Parked off position M1438 Page 22 of 31 Issue 02 April 2005
30. EMBLY INERTIA WEIGHT m 2 MODULES 146 VKSD64 28 BASE MODEL RE 29 06 04 m 1 ERIAL 67A1542 FORM No 00 36 3 Component Drawing Part Number Quantity Number 01519 FLANGE 2661 7952007 1 STEEL PLATE BS4360 GRADE 43A 1520 SCREW HEX HEAD M12 x 60 530029 6 8 8 ZINC amp YELLOW PASSIVATE NUT M12 TWIFLEX Drawn Checked Date Alt No Issue 5100189 m mel ees Sheet 1 of 1 Form No DO 52 3 Any loose fittings to be placed in a plastic bag and tied to unit 1 2 3 4 5 6 7 X 8 9 10 1 THIS DRAWING IS THE PROPERTY OF TWIFLEX LTD IT MUST NOT BE LENT i COPIED OR DISCLOSED WHOLLY OR IN PART TO ANY PERSON WITHOUT WRITTEN THIRD ANGLE PROJECTION METRIC 0 10 50 100 mm DO NOT SCALE REMOVE SHARP EDGES AUTHORITY FROM TWIFLEX LTD DESIGN RIGHT SUBSISTS IN THE DESIGN OF USED ON ARTICLES MANUFACTURED WHOLLY OR IN PART IN ACCORDANCE WITH THIS DRAWING 27 67 1541 22 01517 GF A 1 C7 l a gt 49 EE 7 a 777 kk
31. S AND psi GAP CYS 17 FOR M16 BOLTS Pree 2 105 _ 2 105 CALIPERS SUBJECT TO REVERSING BRAKING LOADS OVER 70kN MUST BE PROVIDED WITH ONE M24 FITTED TIE ROD EITHER OR B OF THE ROW OF FOUR TIE RODS REQUIRING HOLE A OR B TO BE MACHINED TO 925 025 25 000 MINIMUM BRAKE DISC DIAMETER 1000mm FOR PART IDENTIFICATION SEE SCHEDULE 7157 16 BLEED SCREW AND INPUT PORTS ARE PLUGGED FOR TRANSPORT PURPOSES THESE ARE TO BE REMOVED AND BLEED SCREW AND COUPLING FITTED ON INSTALLATION SHOWN SHOWN AS SHOWN 0 20115 16 1682 21652 1450 2262 2160 2045 1928 124 21652 1450 l 80 L 125 FOR INSTALLATION OPERATION AND MAINTENANCE SEE MANUAL M1438 117 109 REACTION TOO KT PART Ka 790457 3 04 05 L sese ALTERATION GRID REF TWFLEX LIMITED THE GREEN TWICKENHAM MIDDLESEX ENGLAND TW2 5AQ EITHER SIDE MECHANICAL RETRACTION DETAIL TOOL KIT PART No 7903437 TO BE PURCHASED SEPARATELY SCHEDULE 7157 22 WEIGHT NEM DIMENSIONS IN OPEN TOLERANCES 0 25 ANGLES 0 57 SURFACE FINISH IN MICRONS eg 2 MICRONS 0 002mm CLA 80 MICRO INCHES CLA cerro Jpesonipron BRAKE CAUPER ASSEMBL wee WSD119 62 74 DRAWN MATERIAL FINISH DRG ka
32. T 0 002mm CLA Da 29 06 04 i ISSUE ALT DATE DESCRIPTION GRID EDF O RD 80 MICRO INCHES CLA 401520 sut i or 2 fil 1 1 No 0 ALTERATION SCALE 13 14 FORM 00 56 4 0 0 5 2 1 0 10 11 12 2 3 4 5 6 7 X 8 9 10 11 12 13 14 THIS DRAWING IS THE PROPERTY OF TWIFLEX LTD IT MUST NOT BE LENT REMOVE SHARP EDCES COPIED OR DISCLOSED WHOLLY OR IN PART TO ANY PERSON WITHOUT WRITTEN THIRD ANGLE PROJECTION METRIC 0 10 50 100 mm DO NOT SCALE AUTHORITY FROM TWIFLEX LTD DESIGN RIGHT SUBSISTS IN THE DESIGN OF USED ON ARTICLES MANUFACTURED WHOLLY OR IN PART IN ACCORDANCE WITH THIS DRAWING fd 258 6 180 0 60 0 60 0 60 0 91 0 57 0 57 0 a p B ON ox Y A 4 in Lf ON C Y 1 A o 2 D O lt Y Y 1 E O Y 91 0 5 0 134 0 F 184 4 216 0 b 9755 re 282 3 G THIS ISSUE ps 4 DIMENSIONS IN mm CERT D DESCRIPTION INERTIA WEIGHT Twiflex mm SPRING MODULE ASSEMBLY nt uem VKSD64 28 BASE MODEL GENERAL M C FINISH 1 6 um SURFACE FINISH IN MICRONS DRAWN pu wi MATERIA 1 67 01558 eg
33. TELY 20 NN SCHEDULE Z157 22 A KS 227 Nifs ep gt 175 E G3 8 3 8 BSPI PORT FOR BLEED 42 62077 UE 11111111 _ 1 HOUSING SCREW HYDRAULIC INLET AND 4 4h YZ NINNNNNN 2 11 PRESSURE PLAT A a ES BLEED CAN BE INTER CHANGEDJ 2 bc Sa 5 1 ADJUSTING SCREW A 5178 i al 22 4 6 1 CYLINDER 11222 CRI 8 1 PISTON COLLET je 7752003 5 7952003 NN 277 77 2 i enc ese 21 8 pen 2 11 120 EF 0 Lockin PLATE RETRACTION HOOK RETRACTION PLUNGER N W __ 5 __ _ E 22 72 USE LOCTITE D einn ANS SEREWLOCK 222 1 LX fi ON 55 ITEM REMOVED WHEN FITTING 72 U 277 2 5 2 n 1 1 E MONITORING UNIT MA OR 3 8 BSP MIx1 8 BSP F gt 8 4 21 907483 L g JIGHTENING TORQUE 23 RETRACTION SPRING 25 10 DISC SPRING OOOO 9 27 1 SHIM mm 7157 3 28 1 SHIM 2mm SEE 2157 29 1 CYLINDER SEAL 150 SECTION 30 1 ROD SEAL 70 1 0 51 1 BEARING RING 150 32 1 BEARING RING 70 12 a 33 1 BEARING RING 172 10 53 34 1 JO RING 150x145x3 800
34. The Air Gap should be set as follows Remove the M5 screws in the spindle locking plate 12 and disengage its slot from the hexagon spindle 10 Using a 19mm AF spanner turn one of the hexagonal adjusting spindles 10 clockwise until the pad is in firm contact with the disc then back off by 2 3rds of a turn for 2mm 0 080 in air gap 1 turn for 3mm 0 120 in air gap or 1 1 3 turns for 4mm 0 160 in air gap The pitch of the thrust screw 3 is 3mm 0 12 in The actual retraction dimensions will be slightly greater when the caliper deflects under load Repeat the setting procedure on the other side of the caliper Operate the caliper and check that the air gap or stroke is correct Adjust if required The minimum adjustment which can be made is 1 6th of a turn 0 5mm 0 020 in by leaving the locking plate in the same position or 1 12th of a turn 0 25mm 0 010 in by removing the M5 screws and inverting the locking plate 12 Please note that the correct shim stack height will have been fitted commensurate with the brake performance required The braking force can however be reduced by adding shims or increased by removing shims i Maximum shim stack height is 7mm for VKSD 119 62 and 6mm for VKSD 64 28 both with the step on the end cover 7 inwards Exceeding these amounts will under stress the disc springs and shorten their life WARNING The position of the step on the end cover 7 of the VKSD 119 62 MUST ALWAYS BE INWARD NE
35. Twiflex Limited TWIFLEX DISC BRAKE CALIPER TVPE VKSD BASE MODEL INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS M1438 AMENDMENT AND REVISION RECORD M1438 AMENDMENT NUMBER SIGNATURE AND DATE ISSUE AND DATE WHEN AMENDMENT ISSUED August 2004 April 2005 CONTENTS Page 1 Specification 1 1 General description 2 1 2 Detail specification 3 1 3 Monitoring units 5 2 Installation amp Adjustment 2 1 Installation 7 2 2 Initial Adjustment 7 3 Maintenance 3 1 Running in period 9 3 2 Maintenance inspection programme 10 3 3 Adjustment for friction pad wear 11 3 4 Friction pad replacement 12 3 5 Hydraulic supply failure 12 3 6 Mechanical retraction 13 3 7 Loss of braking force 13 3 8 Removal and replacement of caliper half 14 3 9 Replacement of seals in situ 15 3 10 Replacement of springs 16 3 11 Ships shaft brake operation 18 4 Rotabolts 18 5 Conversion of VKSD 119 62 into VKSD 64 28 or vice verse 18 Appendix 1 Spares 20 Appendix 2 Operational sequence including figs 1 5 21 G1354 Data Sheet weak spring detection 28 G1457 Performance curves of VKSD 119 62 29 G1458 Performance curves of VKSD 64 28 30 G1459 Combined performance curves of VKSD 119 62 and VKSD 64 28 31 List of drawings VKSD 119 62 Caliper General Arrangement and Installation A01517 VKSD 64 28 Caliper General Arrangement and Installation A01518 VKSD 119 62 Spring module assembly A01519 VKSD 64 28 Spring module assembly A01520 References
36. VER OUTWARD as this would severely overstress the disc springs il Always remove or add the same amount of shims on each side of the caliper iii Always after refitting end cover 7 retighten set screws 47 evenly in turn to a torque of 50Nm 36 Ibf ft The drain connections two each side of the caliper can now be piped away to waste It may be convenient to use flexible tubing and if transparent tubing is used any leakage will be immediately apparent M1438 Page 8 of 31 Issue 02 April 2005 3 1 MAINTENANCE RUNNING IN PERIOD For the first full week of operation make a DAILY CHECK of the following items a Note Hydraulic Fluid Leakage Note and report any evidence of fluid leakage If the leakage occurs at the pipe connections or at the bleed screws tighten as appropriate carefully wipe away spilled fluid and check for further leaks with brakes off The air gap is measured between pad and disc at full retraction The stroke is the air gap plus caliper deflection and is the movement of the adjusting spindle from brake to full retraction measured with respect to the end cover item 7 If friction pads become fouled with fluid they must be replaced after curing the leak and the disc s wiped clean A very slight seepage of oil past seals 29 30 is normal but should not be such as to cause a flow in the drain pipes Observe brake operation including smooth retraction and application of brake pads
37. and slide it back to disengage spindle Turn spindle clockwise by one 60 for 0 5mm 0 020 in adjustment two flats 120 for 1mm 0 040 in etc Should adjustment required be 0 25mm 0 002in then the locking plate must be inverted for 1 12 turn Replace locking plate and tighten M5 screws to 6Nm 4 5lbf ft so locking the adjusting spindle Repeat for opposite pad pads should always be adjusted in pairs M1438 Page 11 of 31 Issue 02 April 2005 3 4 3 5 FRICTION PAD REPLACEMENT Brake pad replacement is indicated when The monitor switch where fitted has signalled that pad is fully worn Top of the plunger 14 is level with housing face The backing plate edges are 2mm or less from disc If the pad thickness has more than 2mm 0 08 in taper as measured at the four corners it should be replaced even if not fully worn Minimum pad thickness is 12mm 0 47in Before removing brake pads secure the disc against rotation Retract brakes fully hydraulically and as a SAFETY measure place the brake in the parked off position by turning the adjusting spindle fully anti clockwise The hydraulic pressure may now be released Unhook the pad retraction hook 13 by inserting a large screwdriver in the pad retraction plunger 14 depressing spring 24 and turning the hook through 180 The pad can now be removed first by pushing it away from the pressure plate through the holes provided then by sliding it a
38. d in section 3 9 and replacement springs is described in section 3 10 REMOVALS AND REPLACEMENT OF CALIPER HALF Balance load and secure the installation from rotation Remove monitoring units if fitted Release the brakes hydraulically or mechanically and place the brake in the Parked Off position by turning the adjusting spindle fully anti clockwise hydraulic pressure may then be released If the brake pads are re usable remove them and put them in a dry clean place otherwise ensure that spares are available Disconnect the hydraulic unions controlling the fluid loss Support the weight of the caliper half to be removed Unscrew and remove the four M24 tie rod nuts and remove the three M16 mounting bolts Carefully slide the caliper half from the tie rods Replacement of the caliper half is the reverse of removal It is essential to preload the M24 bolts to 188 kN 42300 Ibf by torquing to 775 575 Ib ft The M16 bolts should be torqued to 200Nm 148lb ft See Note under 2 1 on calipers subject to reversing loads M1438 Page 14 of 31 Issue 02 April 2005 3 9 REPLACEMENT OF SEALS IN SITU Leakage of large cylinder seal 29 is indicated by oil seeping from the cylinder cover drain Leakage of rod seal 30 is indicated by oil seeping from the 1 8 BSP holes at the sides of the housing fitted with plugs 58 on delivery At least one plug normally the lower one must be removed Follow instructions as under 3 8 a
39. er capacity settings Follow installation and adjustment instructions as under 2 1 and 2 2 M1438 Page 19 of 31 Issue 02 April 2005 APPENDIX 1 TO PUBLICATION M1438 RECOMMENDED SPARES FOR VKSD SERIES For each brake in use at remote sites or in marine installation the following spares should be carried ONE SET OF BRAKE PADS These are to be stored in a dry place away from contact with oil or grease Please order correct grade of friction material Compnet Pano ty 75103 non asbestos 7080153 Z P 22 Ferodo 3904F non asbestos STANDARD 70A0153 9 2 2 from Dynamex Ferodo 02013 High 70A0153 AR Temperature non asbestos Bearing ring rod 70 I D Back up ring 70 I D 6000490 2 Quad ring seal 171 05 I D 6000450 M1438 Page 20 of 31 Issue 02 April 2005 APPENDIX 2 TO PUBLICATION M1438 OPERATIONAL SEQUENCE REF FIGS 1 TO 5 Brake Parked Fig 1 The brake is supplied in the Parked Off position so that it can be mounted with disc springs fully relaxed and yet with brake pads 11 5 mm clear of disc Brake cannot come on accidentally and can be dismantled safely Connect hydraulic feed and bleed brake in this position To Operate Brake Apply hydraulic pressure as for full retraction This compresses disc springs Thrust screw and pressure plate will separate at A Fig 2 Check for oil leaks Turn adjusting spindle clockwise up to 5 turns max On the VKS
40. ew on drawings A01519 and A01520 Release brake by tightening the nuts evenly in turn Turn the adjusting spindle fully anti clockwise thus placing the brake in the Parked Off position The retractor flange may now be removed by loosening the nuts evenly in turn Always remove retractor flange before resuming normal operation LOSS OF BRAKING FORCE Possible causes are Contaminants on surface of pads or disc especially lubricants Higher than normal hydraulic back pressure when brakes are applied Increased stroke due to pad wear necessitating adjustment or incorrect adjustment M1438 Page 13 of 31 Issue 02 April 2005 Damaged or broken disc spring or springs Where the monitoring switch assembly is fitted any significant reduction in the force developed by a spring can be detected by the addition of a pressure switch to the hydraulic fluid supply as shown in data sheet G1354 If the above system is not used spring force can be checked by use of a calibrated oil pressure gauge suitable for the maximum back pressure employed Pressures required for full retraction are given on the drawing or can be taken from the curves Springs should be changed if the reduction in pressure is 12 5 or more Normally the easiest procedure would be to remove the complete caliper half as in 3 8 below and return it to Twiflex for service or replacement However for cases where this is not possible the procedure for seal replacement is describe
41. gt 258 6 gt 163 0 gt 60 0 60 0 60 0 91 0 gt WO ia 220 ON A d ON C ja ON D fe D E ii 2 S 5 imm E E O O Y Y 91 0 5 0 134 0 p 184 4 216 0 2788 282 3 G THIS ISSUE ps DESCRIPTION INERTIA WEIGHT Twiflex vs mees os SPRING MODULE ASSEMBLY ANGLES Las VKSDIT9 62 BASE MODEL GENERAL M C FINISH 1 6 um SURFACE FINISH IN MICRONS DRAWN sess MATERIAL i o 11 09 7 eg 2 MICRONS 80 MICRO INCHES CLA AO1 51 9 2 OF 2 A 1 1 8 9 10 11 14 FORM 00 36 4 1 2 4 5 6 7 X 8 9 10 11 12 13 14 5 THIS DRAWING IS THE PROPERTY OF TWIFLEX LTD IT MUST NOT LENT COPIED OR DISCLOSED WHOLLY OR IN PART TO ANY PERSON WITHOUT WRITTEN THIRD ANGLE PROJECTION METRIC 0 10 50 100 mm DO NOT SCALE REMOVE SHARP EDGES AUTHORITY FROM TWIFLEX LTD DESIGN RIGHT SUBSISTS IN THE DESIGN OF 5 USED 0 ARTICLES MANUFACTURED WHOLLY OR IN PART IN ACCORDANCE WITH THIS DRAWING 6741542 6 A1545 A015536 A
42. he pads are kept in position by pad retraction hooks 13 on to the pressure plates 2 which transmit the braking force to the main housing 1 The housing contains the spring chamber The hydraulic retraction cylinder 6 is spigoted to the housing and the bleed screw and inlet port can be positioned by releasing two set screws 55 and rotating the cylinder The hydraulic retraction piston 5 is held onto the spring guide by means of a piston collet 8 with its retainer 9 Brake rating can be varied by removing or adding shims 27 28 between piston 5 and end cover 7 Gap adjustment is manual and is effected by turning the hexagonal adjusting spindle 10 Nominal gaps are as given on the drawing Maintaining the correct gap ensures that the braking torque is effectively constant and minimises the stress range for the springs leading to an extended fatigue life Reduction in torque due to a 1mm stroke increase is about 6 to 8 for the VKSD 119 62 and 4 to 15 for the 64 28 Failure of an individual spring would result in a substantial loss of braking torque in the affected caliper see 3 7d Connections are provided for piping away any oil leakage Optional monitoring units are available which indicate a Full retraction of the brake i e correct functioning of the hydraulic system In conjunction with a suitable hydraulic pressure switch this facility can be used to give an indication of spring breakage see section 3 7 d
43. long the disc rubbing surface Remove dirt using a clean dry cloth and note condition of pad friction surface which should be polished uniformly marked and free of serious pitting Replacement of the pad is carried out by reversing the removal procedure but first clean the pressure plate Ensure that pad is properly seated by turning adjusting spindle such that pad is forced firmly against disc Refit pad retraction hooks After fitting the pads the piston stroke must be reset as in Section 2 2 Initial Adjustment paragraph b HYDRAULIC SUPPLY FAILURE The brake may be released by means of a hand pump connected direct to the feed port After the brake has been released the parked off position can be obtained by turning the adjusting spindle fully anti clockwise The hand pump can then be removed M1438 Page 12 of 31 Issue 02 April 2005 3 6 MECHANICAL RETRACTION The retraction tool kit an optional can be purchased separately The retraction tool should only be required to release the brake when a hand pump is not available or there is a hydraulic failure such as when the seals leak to such an extent that the brake cannot be released by hand pump The retraction tool should then be used as follows Remove end covers 7 complete with monitoring units if fitted Take care not to lose any shims With nuts M12 already threaded onto the retraction screws attach the retractor flange to the hydraulic piston 5 See scrap vi
44. mbined with a separate cvlinder allows Cvlinder to be rotated to position the bleed at anv time even after installation Cylinder can be dismantled permitting replacement of seals and cylinder wearing surface in situ M1438 Page 3 of 31 Issue 02 April 2005 1 2 2 1 2 3 1 2 4 BRAKING FORCE amp TORQUE SEE DRG A01517 and 01518 AND CURVES G1457 and G1458 The braking force F kN acting tangentially on the disc is given by F 2x ux S where u is the friction coefficient of the brake pad and is the spring pack thrust 1bf Nominal values for braking force are given on the drawings together with the appropriate air gap settings please note that these values are based on a coefficient of friction 0 4 This value can only be achieved under ideal conditions Factors which influence u are material and surface finish of disc amount of surface contact after bedding in cleanliness of pad and disc humidity temperature and grade of pad material and finally rubbing speed In a near static application for example can be as low as 0 15 Braking torque T kNm is given by T R 0 095m where is the outside radius of the disc in metres T Ibf ft F Ibf 0 312 ft The braking force obtained is also dependent on the gap setting and the amount of shims fitted as is shown on performance curve G1457 and G1458 Please note that these curves are also based on y 0 4 and that a service fac
45. r Toes FORM 00 36 3 USE D ON THIS D RAWING IS THE PROPERTY OF TWIFLEX LTD IT MUST NOT BE LENT COPIED OR DISCLOSED WHOLLY OR IN PART TO ANY PERSON WITHOUT WRITTEN AUTHO ARTICL RITY FROM TWIFLEX LTD DESIGN RIGHT SUBSISTS IN THE DESIGN OF ES MANUFACTURED WHOLLY OR IN PART IN ACCORDANCE WITH THIS DRAWING 4 METRIC THIRD ANGLE PROJECTION E 0 10 50 100 MOUNTING PLATE THICKNESS 55 EDGE OF MOUNTING PLATE EDGE OF BRAKE DISC OOS 5555 28 BRAKE DISC THICKNESS 25 LLI 52 Z LX DO NOT SCALE OPTIONAL TI BOL 0 SUIT DISC THIC IGHI ENING TORQUE N M16 BOLTS 200Nm M24 2 ESS 48 E RODS 675Nm 498 OPTIONAL 5 FUNCTION TYPE MONITOR UNIT 13325 13 04 05 ISSUE EU 20 AN PART SECTION SHOWING END COVER POSITION MECHANICAL RETRACTION TOOL KIT PART No 7903437 amp SCHEDULE 7157 22 ADDED DESCRIPTION RID ALTERATION REF Q 2 SRK KKK
46. r is secured by four M24 tie bolts and three M16 bolts can be supplied by Twiflex which should be tightened to a minimum torque of 775Nm 575 Ibf ft and 200 Nm 148 respectively VKSD 119 62 calipers subject to REVERSING BRAKING LOADS over 70kN must be provided with one M24 fitted tie rod at either end of the row of 4 tie rods One end hole in the mounting plate must also be machined to 25 0 025 0 000 The mounting plate should be positioned with respect to the disc as shown on the drawing with the mounting surfaces lined up with but 6 mm proud of disc rubbing surface Sufficient space should be allowed for access to the calipers for routine inspection and maintenance and for pad renewal as indicated on drawings 01517 and 01518 Calipers are supplied in the parked off position in which the springs are fully relaxed and the pad is retracted within the mounting face When the caliper halves have been bolted into position the hydraulic supply should be connected and all air bled from the system using the bleed screws 19 INITIAL ADJUSTMENT With the bleed screws closed the cylinders may be pressurised to a maximum of 25 bar 360 psi above the retraction pressure as given on the drawing In the fully pressurised condition the back of the spring guide 4 should be 2 0 mm 0 079 in from the inner face of the cylinder end cover 7 or shims 27 28 where fitted M1438 Page 7 of 31 Issue 02 April 2005 Notes
47. tor has to be applied fora particular application Also shown on these curves is the fatigue life for 99 of the springs for a particular gap setting See Publication S1025 for an explanation of how to read the curves RETRACTION CYLINDERS STANDARD Diameter 150mm 5 9 ins Spring guide diameter 70mm 2 756 ins Effective area 13823mm 21 425 in Hydraulic pressures for brake release and full retraction are given on the drawing for the nominal gap setting For other gap settings or shim settings these pressures can be read from the curves See Publication 1025 Performance Curves Explanation In order to avoid overstressing the 8 M10 set screws on the end cover it is recommended that the maximum hydraulic pressure shall not exceed the retraction pressure by more than 25 bar 363 psi Recommended hydraulic fluid is a good quality mineral oil such as Shell Tellus 37 an approved fire resistant type Fluid inlet connections are 3 8 BSP G3 8 and fittings are normally provided to connect the cylinders by means of 12mm o d x 1 5mm seamless steel tubing to DIN 2391 C FRICTION PADS Friction pads in non asbestos material are supplied some types may have a lower coefficient of friction Initial thickness of the pads including back plate 22mm 0 866in M1438 Page 4 of 31 Issue 02 April 2005 1 2 5 Total pad area two pads 694 107 5 The permissible wear on these brakes is 10 mm 0 39 ins
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