ZPMC

YP11.YP21.YP31.YP32.YP41 Series Electro-hydraulic Disc Brake

Operator's Manual
ZPMC(Group) Fengcheng Brake Co.,Ltd.

Version:4.2 Date:May.1,2007
 Contents

1. Important Information…………………………………………… (1)

1.1 Safety Precautions …………………………………………………… (1)

1.2 Limited Warranty ……………………………………………………(1)

2. General ………………………………………………………………(2)

3. Installation and Adjustment………………………………………(3)

3.1 Inspection before installation …………………………………………(3)

3.2 Installation………………………………………………………………(5)

3.3 Adjustment……………………………………………………………(9)

4. Operation and Maintenance……………………………………(13)

4.1 Running-in……………………………………………………………(13)

4.2 Hand Release…………………………………………………………(14)

4.3Maintenance … ………………………………………………………(15)

5. Spare Parts List……………………………………………………(17)

1. Important Information
1.1 Safety Precautions
The Electro-hydraulic Disc Brake (short form: the brake) is used for deceleration
and stop/braking of rotating machinery by exerting pressure on friction linings on the
brake disc. At the same time, the mechanical energy of moving parts is absorbed and
transformed into heat energy at the frictional surfaces and then is emitted by heat
flow.
The necessary conditions for the brake normal operating are: 1. The mechanism of
exerting on the linings on the brake disc is normally actuated, 2. The contact pressure,
the frictional coefficient between linings and brake disc are within design values.
In order to confirm the brake function normally, avoid accident and ensure the
safety for life, the designers who will select the brake and operators must understand
following principles and requirements (not limited to these) and strictly adhere to:
a. The braking torque of new brake can be 50% rated value or less until the
friction lining and brake disc are ran-in;
b. The braking torque of the brake used in the hoist mechanism or similar must be
double more than actual load torque on the brake shaft;
c. Read and understand the manual thoroughly and obey it before installing,
operating and maintenance;
d. Prohibit optionally releasing the braking spring, ensure the torque must comply
with the value designed;
e. Prohibit sticking or spraying any oil, paint, grease and other contaminations on
the friction surface of the brake disc and brake lining;
f. Prohibit touching the brake disc, brake lining and adjoining parts so as to avoid
skins burnt by the heat of braking, even if the machinery stop; do not drop any object
on the rotating disc because centrifugal force of rotating disc will project the object
then damage somebody; equip cover for all disc and coupling or hub as possible;
g. Prohibit releasing the brake by hand release lever when the brake work
normally (see section 4.2);
h. Do not enter or near the area under the lifting cargo to avoid hurt for body or
death due to the load falling down resulting from the brake sudden malfunction;
i. Only use the spares and parts from our company or approbated by it;
j. Do not cover the nameplate and warning marks due to the painting and other
contaminations.

-1-
1.2 Limited Warranty
Our company warrants that the product will be free from defects in design,
produce, materials and workmanship for one year from the date on which the product
is delivered to the purchaser. Within the warranty period, our company's responsibility
is to replace or restore the brake that has been confirmed which is defective after test
in our company, but the original purchasers must keep the brake is intact and carry it
to our company or to our company's authorized service stations. Except as stated in
this limited warranty our company does not make and disclaims all express or implied
warranties,including (but not limited to) its fitness for a particular purpose, its design,
condition or workmanship.
Our company will not be liable for any special, indirect, incidental damages,
including without limitation: transportation costs, loss of profits, property
damage, lost production, loss of life or body injury. Our company's maximum
liability under any circumstances will be the purchase price of the product paid
by the original purchaser.
If the product is damaged due to installing and maintaining not complying with
the manual, misuse or incorrect operation and accident, our warranty will not be valid.
Only maintain or operate the brake after read and understand thoroughly the
manual and warning on the brake warning marks. However, such warning information
can't ensure to forecast all possible mishaps or accidents, so the user is obligated to try
to find out dangerous state under the brake work normally on the base of
understanding the chapter 1.1, and to maintain or care correctly.
2. General
The series brake is widely used for various heavy-duty mechanisms' deceleration
and stop/braking of various cranes, belt transport, port handling machinery and
metallurgical machinery.
The construction of the brake is shown as Fig.1, which is small outline, excellent
rigidly and stability. The brake is equipped advanced device such as automatic shoe
clearance balancing device, automatic lining wear compensation device and shoe
automatically aligning device. It is also equipped hand release lever to conveniently
open the brake under installation, maintenance and emergency. The brake can add
various limit switches or proximity switches to realize failure signal, lining wear limit
indication (interlocking) and other additional function by PLC control according to
different requirements. It is basically free of maintenance while operation.

-2-
 Its all fasten standard parts are made of stainless steel and the shafts' surface is
treated with special anticorrosive technics, other construction parts are coated
anticorrosive paint, which can fit the condition of the coastland and of the steelworks.
The brake adopts the company's Ed series thruster as corollary equipment. The
brake lining is made from half-metal material. When operating, the brake produces an
acoustic noise which value is Lw 58.3~63 dB (A) measured in accordance with
GB/T10069.1-1988.
3. Installation and adjustment
Please install the brake correctly according to the procedure stipulated in the
manual.
3.1 Inspection before installation
3.1.1 Inspection of brake
a. If the parts and components of the brake arecomplete;
b. If the action of the brake is maneuverable and all hinged points have corrosion;
c. If there is grease, paint or other contamination stuck on the lining, it may affect
the friction force;
d. Check if the type of brake (including electrical voltage, frequency and the type
of thruster) meets requirements;
If any of above does not meet the requirement, please resolve the trouble firstly
before installation.
3.1.2 Inspection of brake disc
a. The brake disc surface must have no defects such as corrosion, oil (grease)
contamination, damage due to welding, unevenness and etc. Strictly prohibit using any
brake disc with cracks or any other serious defects;
b. The braking surfaces of the disc have vertical error to the axis which rotates as
following: when the disc diameter is no more than 500mm,the error is limited within
0.15mm,when the disc diameter is beyond 500mm,the error is not more than 0.2mm;
c. Both sides of the surfaces roughness on the brake disc shall be 3.2, excessive
rough or smooth surfaces may be resulted in difference of braking performance;
3.1.3 Machining and inspection of the installation base
a. The installation base shall be firm and level with accurate installation
dimension;
b. If the brake installation base is installed together with the brake, we should fix
(welding or with bolts) base and brake after they have been positioned accurately;

-3-
 Lifting point Lifting point

1 12
8 13
2
3 ●
●

9 ●
14 ●

● ● ●
15
●
16
4
●

10 ●

11
5
●
●

6
A View
7
●

A View(balancing device)

12
●

YP11、YP21
Lifting point Lifting point
12
1
8 13
2 14
●

9
●

15
●

3 ●
●

16
●

10
● ●
●

4 ● 11
5 ●

● ●

6
7 ● Ａ向
●

12 A View(balancing device)
●

YP31、YP32、YP41
Fig.1
1.Torque adjusting nut 2.Angle lever 3. Brake rod£¨compensation device£© 4.Brake
arm 5.Thruster 6.Balancing device 7.Foundation base 8.Automatic wear compensation
device 9.Clearance adjusting nut 10.Brake spring (assembly) 11.Brake shoe 12. Hand
release lever 13.Tighten bolt 14.Compensation sleeve 15.pin 16. Adjusting screw
Note: The product purchased will possibly have dissimilarities due to
technique progress and customers' information in market.
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 盘式制动器
Disk Brake
型号Type:
Type of the brake
力矩Mbr: Nm
Rated braking torque
编号Serial　No.: 　　　重量Wt.: kg
Serial number and weight
上海振华港机（集团）丰城制动器有限公司
Name and address of manufacturer ZPMC(Group) FengCheng Brake Co.,Ltd.

c. If the installation bores on the brake installation base have not been drilled, they
shall be drilled after the brake has been positioned correctly, then tighten the brake.
The relative tolerance between the surface of installation base and brake disc must
not exceed the value listed in Table1 (refer to Fig.2).
Ｓ Ｓ
０．５~５
Brake disc

d3

Brake lining
ａ

ｈ１

Installation base
d2

ｋ１ ｋ２

Fig.2
Table 1
Center height Offset Parallelism
K1 K2
(h1) (S) (a)
Brake type
Rated Tolerance Rated Tolerance Rated Tolerance S a
YP11-22０～800 16０ ±１ 80 ±0.5 150 ±0.5 1 0.5
YP21-50０～800 230 ±1.5 145 ±１ 145 ±0.5 1.2 0.8
YP31-1250～3000 280 ±２ 180 ±１ 180 ±0.5 1.5 1.0
YP32-3000 280 ±２ 180 ±１ 180 ±0.5 1.5 1.0
YP41-4500 370 ±２ 180 ±１ 180 ±0.5 1.5 1.0

3.2 Installation
Caution: 1.The series brakes have weights between 91 and 410kg, you should
use crane or jacks to handle it. 2. During installation, the brake shall be handled
as shown in Fig.1. It must be noted that handling by brake rod is strictly
prohibited.

-5-
3.2.1 Before installation, adjust the braking torque (spring working length) to the
minimum value (refer to Fig.6), remove the tighten bolt (piece 13, refer toFig.1), take
off the compensation sleeve (piece 14), then counterclockwise rotate the clearance
adjusting nut (piece 9) to open the brake, and make the clearance between two linings
be bigger 2mm (for YP11) or 3mm (for YP21, YP31, YP32, YP41) than the disc
thickness.

Caution: At any time, counterclockwise rotating the clearance adjusting nut, the
compensation sleeve must first be removed.

Warning: Do not set the brake rod free from thread sleeve at opposite end of
automatic wear compensation device (refer to Fig.1).

3.2.2 Move the released brake to the installation position as Fig.3. Observe if
installation type is right.

Lifting Lifting

Direction of movement
●

Fig.3
3.2.3 Determine the theoretical diameter d3 according to the brake type and disc
diameter d2. When install, make the circle of the theoretical diameter d3 just pass
through the centerline of the brake lining (refer to Fig.3);

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 Table 2 mm
250 280 315 355 400 450 500 560 630 710 800 900 1000 1100 1250
YP11 200 230 260 300 345 395 445
YP21 275 320 370 420 480 550
d3 YP31 350 400 460 530 610 700 800 900 1000
YP32 460 530 610 700 800 900
YP41 500 580 670 770 870 1120
YP11 110 140 170 210 255 305 355
YP21 155 200 250 300 360 460
d4 YP31 170 240 300 370 450 540 640 740 840
YP32 300 370 450 540 640 740
YP41 310 390 480 580 680 930
Usually the distance between the out edge of brake lining and the diameter d2 is
0.5~5mm (refer to Fig.2).
3.2.4 After the brake is primarily set, loosen the lock nut of the adjusting bolt of shoe
clearance balancing device to set the balancing lever free (refer to Fig.1), and then put
on the foundation bolt (refer to Table 4) and fix nut lightly (Note: not tighten).
3.2.5 Clockwise rotate the clearance-adjusting nut to clamp the brake disc, and lift up
the push rod of the thruster about 5mm.
3.2.6 Assemble compensation sleeve and screw the tighten bolt tightly. Note: The pins
must inset the hole of the compensation sleeve, if the position of the pins is wrong,
please move anticlockwise the pins by hands to suitable position.
3.2.7 Cable connection of the thruster: Remove the cover of terminal box, connect the
thruster power supply (phase sequence isn't considered) and grounding line (refer to
Fig.4). After installing, cover the box and tighten the lock bolt.
Note: The protection class of the thruster is IP65. The cable must be entered through
stuffing tube. And the cable entry size is M27×1.5 (or NPT3/4") with 4×1.5mm2
conductor size, max conductor size 4×2.5mm2. Six M5 wiring terminals are in terminal
box, bridge connection can form Y or △ connection method (see to fig 4). The
customer can choose earthing screw inside and outside terminal box to use. Main lead
and earth wire are only connected when connecting (not consider the direction of motor
rotation). The connection of motor coil(Y/△) is finished before delivery. Do not
change the connection except it doesn't comply with the power supply.

Ｗ１ Ｗ１
Ｖ２ Ｌ３ Ｖ２ Ｌ３
Cable entry Ｖ１ Ｖ１
Ｕ２ Ｌ２ Ｕ２ Ｌ２

Ｕ１ Ｌ１ Ｕ１ Ｌ１
Ｗ２ Ｗ２

Fig.4
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 Warning: The connection must be firm and complied with rule, the nut of stuffing
tube must be fastened to fix cable; otherwise, the accident such as short-circuit,
phase lacked and even motor damaged will happen.

Power supply
C1 L1 L2 L3
FU2 S1
FU1
S2
C1

RJ RJ
Control Voltage １　　２　　３
C1

Motor of the thruster

Fig.5
Table 3
380V 50Hz 460V 60Hz

Thruster RJ
FU1 rated RJ adjustment FU1 rated
Rated Rated current adjustment
type value value value
current (A) value
(A) (A) (A) (A) (A)
Ed220-50 0.38 0.75 0.38 0.39 0.75 0.39
Ed300-50 0.78 1.85 0.78 0.80 1.85 0.80
Ed500-60 1.34 2.5 1.34 1.37 2.5 1.37
Ed800-60 1.52 3.75 1.52 1.55 3.75 1.55
Ed1250-60 1.52 3.75 1.52 1.55 3.75 1.55
Ed2000-60 1.98 4.5 1.98 2.02 4.5 2.02
Ed3000-60 2.21 4.5 2.21 2.25 4.5 2.25
Ed4500-80 2.56 5.5 2.56 2.61 5.5 2.61
3.2.8 The brake shall be energize intermittently for 20~30 times to realize self-
centering adjustment. Check if the installation position is right after the brake is de-
energized.

Warning: Anytime, the driving motor of the mechanism by the brake cannot be
activated when operating the brake separately. If the mechanism is hoist mechanism,
it should be no load and the lifting tool must be on the earth or be supported by
other devices.
3.2.9 Energize thruster to open the brake and observe the clearance between linings and
disc is equal. If not, move the position of the brake to left or right (relative to the center
of the disc) to make the clearance almost be same, and then close the brake, set the

-8-
balancing lever (refer to fig 1) to the horizontal state with the adjusting bolt of balancing
device, eventually fasten the lock nut.
3.2.10 Across tighten the 4-foundation bolts (tighten torque refers to Table 4), so the
installation is finished.
Table 4
Type Type of bolt and quantity Tighten torque (Nm)
YP11-220～300 4-M16 5.6 class 90
YP21-500～800 4-M20 5.6 class 170
YP31-1250～3000 4-M24 5.6 class 290
YP32-3000 4-M24 5.6 class 290
YP41-4500 4-M24 5.6 class 290

3.3 Adjustment
Warning: Ensure the mechanism cannot rotate accidentally before carrying out any
adjustment on the brake.
The adjustment of brake includes torque adjustment, shoe clearance adjustment (thruster
compensation stroke hb), equal clearance adjustment and limit switch adjustment. The brake
shall be adjusted before first operation or after replacement of the brake lining. During
operation, everything is normal, no need to adjust.
3.3.1 Adjustment of braking torque: the brake torque shall be adjusted to the rated value
(max) at factory before shipping. The customer can change the braking torque from 100% to
50% rated value according to the factual requirement. The length of spring is inverse ratio
with the braking torque. The method to adjust: Clockwise turn the torque adjusting nut with
spanner (refer to Fig.6 and Fig.1), the length of brake spring becomes shorter, the braking
torque increases, on the contrary the braking torque reduces.
Torque adiusting nut

The roted brake torque(max.) Indicating line

Ｍｂｒ．ｍａｘ ９１００

Ollowable adjusting ronge

9100

4550

５０％ｍａｘ ４５５０
50% brake torque

Fig.6

Warning: The braking torque shall not exceed the range listed on nameplate (refer to Fig6);
otherwise it will affect the brake application.

-9-
3.3.2 The adjustment of shoes clearance (the reserve stroke of thruster): the working stroke h
is direct ratio to the brake shoes clearance (C). The relation among the working stroke h, the
rated stroke H and the reserve stroke hb is shown as the following equation: h=H-hb and
Table 5. The thruster type Ed1250~Ed3000 have a ruler of stroke as Fig.7. The working
stroke must be limited in the range of green (include green). The brake is equipped with
the automatic wear compensation device and the clearance of the brake shoe has been
adjusted before delivery. Only it is necessary adjustment when first installing, replacing new
lining and abnormal in operating.

Danger: The reserve stroke must comply with the value listed in Table 5; otherwise
the braking torque will reduce or even to zero!

Danger: Prohibit the brake operating if the reserve stroke of thruster is less than the
hbmin listed in Table 5 or the cover bottom of the push-rod is in the range of red area
when brake closes. Otherwise, it is possible failure then occur serious accident!
hb

Stroke ruler

Green area
hb

Red area

Fig-7
Table5 mm
Rated Shoe Working Reserve Reserve stroke
Brake type stroke clearance stroke stroke (min.)
H C h hb hbmin
YP11-220~300 50 ０．８～１．０　 30~32 18~20 5
YP21-500~800 60 ０．８～１．２　 50 10 5
YP31-1250~3000 60 ０．８～１．２　 50 10 5
ＹＰ３２－３０００　 ６０　 ０．８～１．２　 ５０　 １０　 ５　
ＹＰ４１－４５００　 ８０　 ０．８～１．２　 ６０　 ２０　 ５　
The adjustment method is as follows: the thruster is energized separately to release the
brake (by hand release lever, refer to chapter 4.2), clockwise rotate the clearance adjusting
nut for 3~5 circles, observe and measure the reserve stroke of the thruster, if meets
requirement, stop adjusting; otherwise readjust in accordance with above sequence until the
reserve stroke is the same to the Table.5.
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3.3.3 Adjustment of the brake shoe clearance equalizing
The adjustment method is as follows (refer to Fig.8): Open brake (to energize or use
hand release lever), observe the clearance between lining and disc each side. If the clearance
of two sides is not equal, adjust it as follows: anti-clockwise rotate and loosen lock nut
(piece 2), if the clearance of brake arm B side is smaller, clockwise rotate adjustment
nut(piece 4) to make it fall down, and observe the clearance on both sides is equal, then stop
rotating, clockwise tighten lock nut; If the clearance of brake arm C side is smaller, anti-
clockwise rotate adjustment nut to make it move up, and observe the clearance on both sides
is equal, then stop rotating, clockwise tighten lock nut.
1
2 ●
6
●

3 ●

2 ●

5 ●

1.adjustment lever 2.lock nut 3.brake arm B conneotion board 4.adjustment nut 5.lever
6.brake arm C
Fig.8
3.3.4 Adjustment of two sides lining parallel to the disc
The adjustment method is as follows: Open brake (to energize or use hand release lever),
observe if brake lining and disc show inverse eight as fig A, if that, slap the upper shoe with
rubber hammer, to make upper lining near to brake disc (see to fig B). Open and close (to
energize or use hand release lever) the brake 2-3 times, brake lining is parallel to brake disc
in the function of self-aligning device (see to fig C).

Slap point Slap point

Self-aligning Self-aligning
device device

Fig A Fig B Fig C

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3.3.5 Limit switch
The brake can be equipped various limit switches or proximity switches. All switches
must be inspect and adjust (if it is in incorrect condition) before operation, and then connect
to PLC with flexible cable. Please adjust according to following (It is not to be adjusted that
the switch isn't described hereinafter):
3.3.5.1 Adjustment of mechanical limit switch
a. The adjustment of release limited switch: use inside hexangular spanner (M5) to loose
fasten screw in the switch rock arm (refer Fig.9), then adjust the arms to a suitable position
and lock the screw.
b. The adjustment of the hand-release limit switch: it is same to a.
c. The adjustment of lining wear limit: In normal closed state (brake lining is wear), the
distance A between limit switch touch head and touch board should accord with the
regulation listed in table 6. If not, adjust it by rotating touch board. After adjustment, tighten
lock nut.

6 7
1 Ａ
2 4
●

3 5
●

●
●

YP11、YP22 YP31、YP41
(With mechanical limit) (With mechanical limit)

1. Released limit switch 2. Closed limit switch 3.Lining wear limit switch 4. Hand release
limit touch board 5. Hand release limit switch 6. Released limit switch touch board
7. Lining wear limit switch touch board
Fig.9
table 6
Type YP11 YP21 YP31 YP32 YP41
A 38mm 54mm 58mm 58mm 58mm

3.3.5.2 Adjustment of inductive proximity switch

a. The adjustment of release proximity switch: measure the dimension C between the switch
head and the inductive device, if it isn't approx. 4mm, loosen the two screw (not remove) of
seat of switch, move the switch to a correct position to make C meets requirement (refer to
Fig.10) and fasten the screw.

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 1 1
2 2
●
4 ●

3 ●

3
5
●
●

●
●

YP11、YP22(With inductive limit) YP31、YP41(With inductive limit)

1. Released limit switch 2. Closed limit switch 3.Lining wear limit switch 4. Hand
release limit touch board 5. Hand release limit switch 6. Released limit switch touch
board 7. Lining wear limit switch touch board
Fig.10
The contactor of the limit switch and proximity switch is respectively shown in
Fig.11 and Fig.12. The cable connected shall be flexible cable. The area of the cable
wire section is not less than 2×0.75mm2, which must be flexible to ensure the
connection cannot be damage as the brake action.

4
NO
3

2
NC
1

Fig.11 Fig.12
4. Operation and maintenance
4.1 Running-in

Caution: Only running-in can be commenced after all adjustments have been made
and the instructions in the section have been read carefully.

Warning: Running-in must be done after replacing new lining and brake disc or first
installing, otherwise, the braking torque marked in the nameplate can't be guaranteed.

4.1.1 The following check shall be carried out before running-in:

a. Check if the brake installation meets requirement;
b. Check if the type, voltage, frequency (listed on nameplate), the wiring of thruster
shall accord with the requirement;
c. Check if the adjustment of brake meets requirement;
d. Check if the length of brake spring meets requirement;
e. Check if there is oil (grease) contamination on the brake lining and brake disc.
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4.1.2 Please run-in according following step after all check are confirmed:
a. Run-in without load (horizontal movement mechanism is not limited) 25~30
times, which mean that the driving motor of the braked mechanism start at low speed
and gradually increased to rated value, the brake apply 25~30 times;
b. Operate the brake 20~25 times with 50% load under the motor working in
accordance with a, observe if the braking state is steady (each braking distance must be
same), if so, the brake can run-in for 10~15 times with full load (the step for horizontal
movement mechanism is un-necessary);
c. The brake can be normally operated only after each braking distance of running-
in with full loading comply with design requirement, otherwise the brake must run-in
again according step a and b till up to the requirement.

Warning: The running-in must stop for not less than half minutes every braking 5 times,
so as to ensure the temperature of the brake disc and the lining are not too high (more
than 350℃）.

During running-in, following items should be paid attention: 1.Condition of lining

fit to the disc when braking 2. The temperature of the disc (less than 350℃); 3.
Whether the screw joint is released; 4. The switch signal is normal; 5. The sound of
braking and running is normal.
4.1.3 After running-in is normal the brake can be operated.
4.2 Hand release
The hand release device is used to release the brake in emergency, installing and
maintenance. It is shown in Fig.13. For YP11、YP21 series brake, you can only lift the
handle, if not comforting, you can use the strengthener (inset the safety pin to avoid
slipping). YP31、YP32、YP41 hand release device is actually a hand lifting jack, if
open the brake manually, first clockwise screw down aligning nut (7), then operate
handle from up to down till the brake is open. Counter-clockwise unscrew aligning nut
to close the brake.
The brake can't apply when the hand release device is actuated. So when brake
ordered without hand release limit switch, the user must be equip the switch (not
proximity switch but mechanical switch that can be forced cut) that is connected to
protect circuit, or set program that check if the brake is released by release limit switch
in PLC system before operating the mechanism braked by the brake.

Warning: 1.Do not use the hand release device to release brake under brake
normal operation conditions. 2. The lowering speed of the lifted cargo under hand
releasing brake must be controlled; otherwise the temperature generated by
braking may be high to hurt the lining!

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 5
ope up ope
1 Ｓ　Ｕ　Ｎ　Ｒ　Ｕ　Ｎ
●

●
●
●

6
●

2
●

closed ｄｏｗｍ 7 closed

3
●

4
●

YP11、YP21 YP31、YP32、YP41
1. Released handle 2. Handle Clip 3.Strengthener 4.Safety pin 5.Lifting jack 6.Lifting
jack strengthener 7. Aligning nut
Fig.13
4.3 Maintenance
4.3.1 Brake should be checked every 1~3 days as following:
a. Check whether the thruster working stroke (clearance of the shoe) is normal or not;
b. Check if the automatic wear compensation device is worn and the compensation
sleeve and tighten bolt is loosen;
c. Check if the length of brake spring changes;
d. Check if the touch board (plate) of limit switch is in correct position and firm;
e. Check if there is oil (grease) on the brake disc and brake lining;
f. Brake disc shall be replaced if any side of brake disc is worn in beyond 1mm;
g. Check the wear of brake lining. The brake lining shall be replaced if its thickness
is worn to <5mm. After replacement of brake lining, adjustment and running-in shall be
carried out;

Caution: When check the lining, please pay attention to that the worn dust will be
probably produced and emitted or smells developing under braking though the lining
substance is free harmful to you health.

h. After emergency braking, the disc may appear some colored spots .If serious
cracks occur, replace the brake disc.
4.3.2 Inspection during operation
During operation, the following matters shall be inspected timely.
a. Check if the braking time and braking distance abnormally increase during
operating;
b. Check if the brake disc over-speed appeared during operation;

-15-
 c. Check if the operation of limit switch is correct;
d. Check if the temperature of brake disc and brake lining are continually beyond
350℃ or brake disc and brake lining is smoking.
If this unusual phenomenon appears, you shall stop to check. After finding out
reason of troubles and getting rid of them, you can operate the brake again.
4.3.3 Repainting
Painting can be damaged during transportation, storage, installation and operation.
It is necessary to repaint in good time, otherwise the anticorrosive performance of brake
will be reduced. During repainting, following locations shall not be contaminated:
a. Various hinge points;
b. Brake disc and brake lining surface;
c. Automatic compensation device and piston rod surface of Electro-hydraulic
thruster;
d. Surface of shaft.
4.3.4 Lubrication: self-lubricated bearing is used in the brake and it is unnecessary to
grease during operation.
4.3.5 Replacement of brake lining
After a period of operation, the brake lining is worn and if it is worn to <5mm in
thickness, it shall be replaced. During replacement of brake lining, attention shall be
paid to safety due to their heavy weight.

Warning: 1. Ensure that the braked shaft is free from any load and cannot occur
accident rotation before replacing the lining. 2. Caution to avoid body burnt by hot
brake disc or lining that heated from previous operation.

The replacing method is following:

a. Firstly, thruster is energized separately to release the brake (by hand release
lever), release the brake to suitable position according to section 3.2.1;
b. Remove the connecting bolt (refer to Fig.14);
1
2
●

3
●
4 ●

5
●

1. Brake disc 2.Brake lining 3.Shoe 4. Connection key 5. Handle hole 6. Connection bolt
Fig.14
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 c. Hold the lining by the handle hole and pull lining toward the disc to disengage the
linking key;
d. Take out the worn brake lining;
e. Check if the surface of new brake lining is clean. If not, please clean firstly with emery
paper or alcohol;
f. Insert new lining to the installation position;
g. Set the brake lining key way engage to the linking key;
h. Tighten the connecting bolt;
After replacement, please check and running-in in accordance with section 4.1.
4.3.6 Maintenance of thruster
This series brake adopts the company's most advanced Ed thruster as corollary
equipment. The thruster operates for 5,000,000 times or 10,000 hours with S3, 60% circle-
duty, the thruster should be overhauled or replaced by a new one. The thruster is oiled before
delivery. If the thruster needs to add or replace hydraulic oil, please refer to the operator's
manual of Electro-hydraulic thruster.
5. Spare Parts List
1. The thruster (details refer to the nameplate of the products)
2. The braking lining (the outline and data refer to Fig.15 and Table 6)

Ⅰ b1
+0.1
0

3: 1
+0.1
b1 0
Ⅰ
3: 1
+0.2
h3+0.1

I I
h1

h2

h2
+0.2
h3+0.1

2-Md

H
H

h2
h2

b
2-Md

b B
YP11 YP2１．31.41

Fig.15

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 Table 6

Weight
Brake type B H Md b b1 h1 h2 h3 Order No. Quty.
(Kg)
YP11-220～300 52 120 8 17 2.3 31 20 8 ZW38.2 2 0. 47
YP21-500～800 70 230 8 20 2 48 12 ZW112.2 2 1.7
YP31-1250～3000 90 307 12 25 3 60 16 ZW210.2 2 3.2
YP32-3000 90 307 12 25 3 60 16 ZW210.2 2 3.2
YP41-4500 120 400 12 25 3 90 16 ZW350.P.2 2 5.3

Marketing and After-sale service Department:

Tel: 0086-795-6201884 6203474 6201939
Fax: 0086-795-6201896 E-mail: zpmc@hua-wu.com
Web site: www.hua-wu.com
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Tel: 0086-795-6203464 6201004

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