Antec NHCD-1400 Assembly instructions
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
Technical data sheet number:
BC.TDS.00025I
Author:
Unitzer Bilbao / Oscar Lucio
Revised by:
Sales Department
Date:
September 2012
Date Rev.01.
-
Aplicación Nuevas Tecnologías, ANTEC S.A.
Ramón y Cajal, 74 – 48.920 Portugalete (Bizkaia) - Spain.
Tel.: 0034 94 496 50 11 Fax: 0034 94 496 53 37
After Sales Service: sales@antecsa.com
www.antecsa.com
Page 1-42
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.00: September - 2012
www.antecsa.com Page 2-42
1. INTRODUCTION. Page 3
1.1. WHO IS THE TARGET AUDIENCE? Page 3
1.2. SAFETY INSTRUCTIONS. Page 3
1.3. GENERAL ASPECTS. Page 5
2. BRAKE DELIVERY AND ASSEMBLY. Page 12
2.1. BRAKE DELIVERY. Page 12
2.2. DISC AND SURFACE FOR ASSEMBLY. Page 13
2.3. ASSEMBLY PROCEDURE. Page 13
3. BRAKE MAINTENANCE. Page 16
4. ADJUSTING THE BRAKE. Page 16
4.1. ADJUSTING THE CALLIPER OPENING. Page 16
4.2. ADJUSTMENT OF SENSORS. Page 19
5. CHANGING THE LININGS. Page 24
6. CHANGING THE SPRINGS. Page 28
7. CHANGING THE SEALS. Page 32
8. SPARE PARTS. Page 39
9. ONGOING IMPROVEMENT PLAN. Page 39
10. APPENDIX I. ASSEMBLY DRAWING. Page 40
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 3-42
1. INTRODUCTION.
1.1. WHO IS THE TARGET AUDIENCE OF THIS MANUAL?
This manual has been written to aid with the installation, start-up, operation and
maintenance of the brake. It is designed to help workers who are going to handle the
brake, and technicians. It should therefore be made available to everyone who is going
to work with these brakes and it must be ensured that the instructions given are
followed.
This manual is intended to clarify any constructive doubts and the basic functions
of the brake. We are sure that it will be an extremely useful information and a reference
tool for operators and technicians.
1.2. SAFETY INSTRUCTIONS.
Various symbols appear throughout this manual, which highlight the importance
of the subject section. They are usually related to safety matters and it is therefore
recommended to pay special attention to these points.
Warning: This symbol will be included at points
or in paragraphs that need special attention. It
usually refers to an operation in which special
care must be taken.
In the event of any problems or if you have any
questions regarding the brake, please do not hesitate to
contact the ANTEC After-Sales Service, specifying the
brake (Brake) model and the ANTEC order number,
data that can be found on the label that each unit has.
NOTE
Due to ongoing improvements to our brake designs,
your brake may differ slightly from the one described in
this manual. ANTEC reserves the right to make any
changes deemed necessary.
NOTE
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 4-42
A number of general safety rules must be taken into account when handling ANTEC
brakes:
1-. All workers and technicians must wear appropriate gear when handling the brake
(safety clothes, boots, helmet, goggles, etc.).
2-. Always keep warning signs (if any) on the brake in good condition and adhere to
them. During repairs or maintenance, place a warning sign to inform other workers that
an ANTEC brake is being repaired in that machine, and that the power supply has been
disconnected, if applicable.
3-. Find out the exact specifications of the liquids used to prevent health problems and
ensure safety.
4-. Make sure all electrical apparatus (if any) is properly grounded to prevent electric
shocks.
5-. Rigorously adhere to the limits set for each brake component and for the brake itself.
6-. Before switching on any machine fitted with ANTEC brakes, ensure that the brake is
fully applied and tightened with the required torque.
7-. ANTEC does not accept any liability for the use and maintenance of the tools that
the customer uses to assemble and handle the brakes.
Danger of death: This symbol will be included at
points or in paragraphs that need special
attention. It usually refers to an operation that
might involve a death hazard.
High temperatures: This symbol will be included
at points or in paragraphs that need special
attention. It usually refers to an operation that
might involve danger of high temperatures.
This symbol will be used to highlight an
important comment or piece of information.
NOTE
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 5-42
1.3. GENERAL ASPECTS.
The NHCD-1400 brakes, are failsafe emergency brakes, in other words they brake
using springs when there is no hydraulic pressure.
These brakes consist of two half-callipers mounted symmetrically to the plane of
the disc on which they act. The symmetry of both half-callipers may become unaligned
in some cases.
The calliper force of the brake directly depends on the force applied by the
springs.
The opening force of the brake directly depends on the force applied by the
hydraulic feed. The maximum feed pressure to open the brake is 21 Mpa, whereas the
minimum varies depending on the spring strength. The minimum pressure for opening
the brake as well as other data of interest are described in the following attached table.
CALLIPER
NHCD-1407
NHCD-1410
NHCD-1413
NHCD-1415
Clamping force
N
75000
100000
130000
150000
Releasing pressure
Mpa
11
14
20
21
Maximum pressure
Mpa
21
Release stroke
mm
1 each side
Oil volume
cm³
113 each side
Pad surface
cm²
500 each side
Friction coefficient (µ)
-
0.4
Braking force (µ=0.4) (Bf)
N
60000
80000
104000
120000
Approximate total weight
Kg
185
The use of Antec brakes for unplanned operations
or the negligent use thereof could seriously damage
them or severely injure people standing nearby.
Failure to comply with these rules may cause
irreversible damage to both the Antec brakes and
harm to the workers handling them.
These damages may result in the worker's death.
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 6-42
The braking torque of a NHCD-1400 brake, depends directly on the braking force
described in the previous table (for each brake) and the outside diameter of the disc on
which the brake acts.
CALCULATION OF THE BRAKE TORQUE
2000
)200)(()(
)( )...().()..(
).(
mmNBfn
NmTDISCTHEOFDIAMETERFORCEBRAKINGBRAKESOFNUMBER
TORQUEBRAKE
0
10000
20000
30000
40000
50000
60000
70000
80000
500 600 700 800 1000 1200 1500
ø Disc (mm)
Braking Torque (Nm)
NHCD 1415
NHCD 1413
NHCD 1410
NHCD 1407
Each half-calliper has 2 connections with a 3/8”G thread for the hydraulic feed. It
is recommended to use the lower 3/8”G connection, leaving the upper one free to fit an
air purge device or for the event that the oil must flow through the semi-calliper.
IMPORTANT: Never apply a greater pressure through
the hydraulic pressure connection than the one specified
on the technical specifications plate.
(Maximum pressure for NHCD-1400 = 21 Mpa).
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 8-42
The NHCD-1400 brakes are comprised of the parts listed below:
BRAKE PARTS SET
Number
Name
Quantity
1
MAIN BODY
2
2
PISTON
2
3
COVER
2
4
SPACER
2
5
ADJUSTMENT SCREW
2
6
LOCKING BACKSTOP
2
8
ACTUATOR
2
9
SENSOR BRACKET
2
10
LINING PLATE
2
11
SPRING
2
12
SUPPLEMENT (Optional)
2
13
SCRAPER
2
14
SCRAPER
2
15
GUIDE RING
2
16
GUIDE RING
2
18
BOLT
2
19
NUT
2
20
M12x50 8.8 SCREW
20
21
WASHER
20
22
M20x70 10.9 SCREW
8
23
BACKSTOP
4
28
WASHER
8
29
WASHER
2
30
WASHER
4
31
M6x12 8.8 SCREW
4
32
PLUG
4
33
SEAL
2
34
SEAL
2
35
TECHNICAL SPECIFICATIONS PLATE
2
36
SENSOR (CSA)
2
37
RIVET
8
38
M8x30 8.8 SCREW
2
39
M12 TRANSPORT EYE BOLT
1
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 12-42
ANTEC, has different options that can be included with NHCD-1400 brakes.
These options are the following:
-Lining wear indicator (D.D.).
-Hydraulic group.
-Connection tubing of the hydraulic group with the brake.
-Brake anchoring screws.
-Brake anchoring bracket.
2. BRAKE DELIVERY AND ASSEMBLY METHOD.
2.1. BRAKE DELIVERY.
When the brakes leave the factory, they are always packaged to ensure maximum
safety during transportation.
The NHCD-1400 callipers are supplied separately, to be anchored to a bracket
prepared by the user. In the event that it is supplied with a bracket or hydraulic
assembly, it will be supplied in another packaging.
The NHCD-1400 callipers are supplied without pressure, with fully distended
springs.
Antec certifies that the NHCD-1400 brakes have been tested on the company's test
benches at its facilities using the proper operating oil.
The inside brake parts are lubricated so that the brake will not suffer corrosion
while being transported to the customer's facilities and during the subsequent assembly
process.
All of the brake's drainage and hydraulic power outlets are plugged during
transportation.
NOTE
This film of oil that prevents the inside brake parts from
corroding during transportation and the subsequent assembly
only lasts for a limited amount of time.
NOTE
Any other option that may not be mentioned can be studied
by ANTEC's technical department and thus provide a
solution for any of the customer's requirements.
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 13-42
2.2. DISC AND SURFACE FOR ASSEMBLY.
Before starting the assembly process, check that the disc is clean and dry. Any
residue, whether grease, oil or particles due to disc corrosion could prevent the brake
and linings from working properly.
During transportation and storage, residue may build up in the brakes on surfaces
in contact with brackets in the future and on the areas between the linings and the disc.
We therefore recommend cleaning them thoroughly.
2.3. ASSEMBLY PROCEDURE.
To assemble the brakes, proceed as follows:
2.3.1.Clean the disc in which you are going to install the NHCD-1400 brake. Any
particles could damage the brake and prevent it from working properly. See the
first NOTE on disc cleaning in point 2.2.
2.3.2.Remove brake from packaging (do not remove plugs marked 32).
2.3.3.Clean the contact surface between the brake and its bracket and the contact
surfaces between the linings with the disc. Once the brakes have been unpacked
and transported to the installation point they could become dirty, which is why
both surfaces need to be cleaned.
NOTE
The brakes have been designed in accordance with the
customer's specifications. Therefore, possible disc and
bracket machining defects will not have been taken into
account. ANTEC thinks it is worth mentioning that
possible flaws regarding parallelism and flatness in the
brake's disc and securing bracket may reduce the contact
surface area between the lining and disc. Contact between
both surfaces will be restored fully after several braking
actions.
NOTE
When you clean the disc, you can use petroleum or diesel
fuel the first time, but after that (and this is very
important) the disc must be carefully cleaned using a
solvent. Take care when using solvents. Dry the disc
afterwards.
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 14-42
2.3.4. If the brake is supplied with the related bracket, anchor the brake bracket
using the corresponding anchoring bolts for each case.
2.3.5. Fit the fastening screws, washers and nuts. Fasten the NHCD-1400 brake to
the bracket using the anchoring screws and nuts with the proper torque.
ANTEC recommends using 10.9 screws lubricated with MoS2.
RECOMMENDED TIGHTENING
TORQUE
FOR M24 SCREWS Quality 10.9 (Nm)
Lubricated
with MoS2
Not lubricated
734
980
Contact surface with
the bracket.
Contact surface between
the linings and the disc.
NOTE
The anchoring screws, washers and nuts are optional
accessories and are not supplied with the brakes unless
the customer orders them.
NOTE
IMPORTANT: Do not use any liquid to clean these two
surfaces. Clean them using a dry paper towel or cloth.
The backstops (marked 23) are fitted
with an M12 threaded hole for
mounting eyebolts, which can be of
great use for handling the semi-
callipers.
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 15-42
2.3.6. Make the hydraulic feed connections of the brake. Each semi-calliper has 2
connections with a 3/8”G thread for the hydraulic feed. Remove the plugs from
the 3/8”G holes to which the hydraulic feed tubing is to be connected. It is
recommended to use the lower connection, leaving the upper one free to fit a
purging device, and if there is not one, leave the steel plug mounted.
2.3.7.After fitting the hydraulic connections, apply 2 Mpa of pressure to the brake to
bleed the air out of it. The purging of air out of the 3/8”G hole is done without
hydraulic feed. In the event of not having the option of fitting a minimex outlet,
the brake air can be bled out through the upper feed connection, by unscrewing
the steel plug until oil comes out. At that time we will know that there is no longer
any air in the brake, so we can screw the plug back on.
2.3.8.After bleeding the air out of the brake, proceed to adjust the brake, according to
point 4 of the instructions.
Important: Never apply more than 2 Mpa of pressure to
the brake during the brake bleeding procedure as this
could dangerous for the worker performing the operation.
Lower 3/8”G feed
connection.
Connection opposite
to the one shown in
the photo.
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 16-42
3. BRAKE MAINTENANCE.
NHCD-1400 brake maintenance will consist of regularly checking the following
points:
3.1 –Lining wear. When the lining thickness drops below 2 mm at the thinnest point, it
needs to be replaced. If the brake comes with a wear sensor (optional), replace the
linings when the sensor warning comes on. See point 4.2 (adjustment of detectors) and
point 5 (linings change).
3.2 –Adjust the brake whenever it displays a loss of force. If the brake comes with a
wear sensor (optional), adjust the brake when the sensor warning comes on. See point
4.1. (adjustment of the calliper opening).
3.3. - Check the torque of the stopper screws and the fastening screws of the brake to
any of the brackets. See the blueprint of the brake supplied with the documentation sent
by Antec.
3.4. - Check that there is no leakage in the hydraulic connections.
4. ADJUSTING THE BRAKE.
The brake has two unique adjustment points:
4.1. - Adjustment of the calliper opening.
The explanation of the adjustment of the calliper opening will be given for one of the
two semi-callipers. and is the same for the other.
4.1.1 Feed the semi-calliper with the related hydraulic pressure for each brake, as
shown in the attached table in point 1.3. of the instructions. At this pressure the
brake will be opened to the utmost.
4.1.2 Dismantle the bracket of the sensors (marked 9) with their bolts and washers
(marked 30-31) and the sensor (36). Loosen the nut (marked 19) up until the end
of the bolt, enough to free up the adjustment screw (marked 5). Dismantle the
locking backstop (6).
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 17-42
4.1.3 Adjust the adjustment screw (marked 5), by tightening or loosening until the
distance between the lining and the disc is of 1 mm. We will refer to this distance
as the air gap. Important, measure this distance using gauges.
5
19
Airgap
9
30-31
NOTE
Important,
measure 1 mm
using gauges.
19
5
6
36
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 18-42
4.1.4 Once this opening has been adjusted lock the adjustment screw (marked 5) using
the nut (marked 19).
4.1.5 The brake must ALWAYS be adjusted when the brake is installed, there is wear
in the lining of 1 mm or the linings are replaced.
4.1.6 At that time the brake, after having cancelled the hydraulic feed, will by the action
of the springs brake with the force shown in the attached table in point 1.3.
4.1.7 Mount the locking backstop (marked 6) with the bolt (marked 38) in the position
shown in the following diagram (storage position of the locking backstop).
NOTE
The airgap must be the same on both sides of the disc.
Otherwise, there may be anomalous forces applied to the
disc and to the brake bracket.
The wider the opening (>1 mm), the less the braking
force and the lifespan of the springs.
6
38
Backstop position
with brake
unlocked. Storage
position.
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 19-42
4.2. - Adjustment of sensors
In the event that you have an ANTEC brake with brake opening signalling (C.S.A.)
and a lining wear sensor (D.D.) (Optional), these must be mounted on the cover as
shown in the following diagram. There is another assembly option of the wear sensor
(D.D) by means of cables embedded in the lining as explained in point 4.2.3.
The two detectors fitted to the brake fulfil the following functions:
4.2.1. Opening signalling contact indicator (C.S.A.): This sensor indicates when the
brake is open (pressurised). Then the sensor does not detect, the brake is closed
(unpressurised).
To properly understand how to adjust the lining wear sensor, its technical
specifications data are attached.
C.S.A.
D.D.
HYDRAULIC CALLIPER TYPE NHCD-1400
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00025I
Rev.0.: September - 2012
www.antecsa.com Page 20-42
How is the opening sensor adjusted?
The sensor (marked 36), continuously detects the strip (marked 8), which moves
together with the piston (marked 2) previously mention in the instructions, both with the
brake open as well as with the brake closed.
By applying the opening pressure for each brake, shown in the attached table in
point 1.3. of the instructions, adjust the opening sensor indicator (C.S.A.), to the
measurement shown in the following diagram (44 mm between the head of the sensor
and the strip (marked 8)).
CURVES
1 Number of operations
2 Resistive circuit
3 Inductive circuit
4 Current in amps
1-Black (common)
2- Brown (NC)
4- Grey (NO)
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