COREMO OCMEA D-M Operating instructions

DManual
Model D-M
DPneumatic positive
Model D05
Model D1
Model D2
Model D3
DHydraulic positive
Model D3-ID
COREMO OCMEA S.P.A.
Via Galilei, 12 - 20090 Assago (MI) - Italy
Tel. [phone] Fax [phone]
www.coremo.it [email protected]
User and Maintenance Manual
Translation of the original instructions
EN 130701 REV. 1
ISO 9001 - Certificate N°0238

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
www.coremo.it
Pag. 2di 14
TABLE OF CONTENTS
1. Introduction............................................................................................................................................... 3
2. Manufacturer............................................................................................................................................. 3
3. General information .................................................................................................................................. 3
4. Warnings.................................................................................................................................................... 4
5. Technical data............................................................................................................................................ 5
5.1. Product performance ................................................................................................................................ 5
5.2. Brake lining wear....................................................................................................................................... 6
5.3. Special note ............................................................................................................................................... 6
6. Transport and storage ............................................................................................................................... 7
7. Installation................................................................................................................................................. 7
8. Operation................................................................................................................................................. 10
8.1. Power supply of the product................................................................................................................... 10
8.2. Improper use ........................................................................................................................................... 11
9. Maintenance and cleaning ...................................................................................................................... 11
9.1. Readjusting the play ................................................................................................................................ 11
9.2. Changing the lining pads and cleaning the friction surfaces................................................................... 11
9.3. Changing the thruster spring (brakes D05 , D1 , D2 , D3 e D3-ID)........................................................... 12
9.4. Changing the thruster spring (brake D–M).............................................................................................. 12
9.5. Changing the diaphragm and the gaskets ............................................................................................... 12
9.6. Changing the brake shoe alignment springs ........................................................................................... 13
9.7. Periodic maintenance.............................................................................................................................. 13
10. Spare parts list......................................................................................................................................... 14

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 3di 14
1. Introduction
The purpose of this manual is to provide the user with all the information necessary to use the
product properly, independently and safely.
This manual constitutes an integral part of the safety features and must be read in its entirety
before installation and use of the product. It must therefore be kept in a safe place should future
reference be necessary before proceeding with any kind of work.
The user is strongly advised to read it carefully and to follow the rules and procedures contained
in it as these provide important information concerning safe use and maintenance.
If any doubt should arise concerning the correct interpretation of the instructions, contact our
technical department for the necessary clarification.
It is prohibited for anyone to disclose or modify the content of this manual or to use it for
personal purposes.
2. Manufacturer
COREMO OCMEA S.P.A.
Via Galilei, 12 - 20090 Assago (MI) - Italy
Tel.: [phone] Fax: [phone]
e-mail: i[email protected]
3. General information
Correct use of the product: In compliance with Italian Legislative Decree 17/2010 and DIRECTIVE
2006/42/EC the operating limits for ideal and safe use of the product are stated in this manual.
Design parameters: COREMO OCMEA caliper brakes have been designed for use in conformity with the
performance and conditions stated in the catalogue and Chapter 5.1 of this manual. It is advisable not to
exceed these limitations.
Model selection: Selection of the correct model for a given application is of basic importance. The
technical department of COREMO OCMEA can provide you with information, suggestions and assistance
regarding correct application and use.

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 4di 14
Use: Compliance with the assembly and maintenance instructions prevents not only costly down time
but also accidents due to incomplete knowledge of the product.
Rotating parts: The caliper brakes are coupled mainly with rotating parts. In this case the moving parts
must be protected in conformity with the requirements of DIRECTIVE 2006/42/EC and Italian Legislative
Decree 17/2010 or equivalent legislation in force in the countries in which they are used.
Power source for pneumatic brakes: Use air not contaminated with oil or water and a 25 micron filter
with automatic condensation discharge.
Power source for hydraulic brakes: Use mineral oil SAE/SO 46.
Friction material: All COREMO OCMEA caliper brakes are fitted with friction material which is absolutely
free of asbestos and is declared as NON toxic/harmful in full observance of health and environment
regulations and laws. In any case it is better not to inhale dust produced by them and to wash hands
thoroughly before eating or drinking.
Oils, greases, lubricating components: These are used in extremely limited quantities. Personnel
suffering from allergies to these substances are advised to wear gloves or use protective cream which
must be washed off thoroughly before eating or drinking.
Product markings: All the data on the plates must always be kept legible. Use the data shown on the
plates when contacting the manufacturer for spare parts, information or assistance for example.
Disposal: Worn brake lining pads and other materials of which brakes are made are classified as special
NON toxic/harmful products and therefore must be disposed of in accordance with the laws in force in
the countries in which they are used.
4. Warnings
Failure to follow the instructions in this manual and on any plates attached to the
product exposes persons to risks and may cause damage to other equipment and
machinery.
˗The product must not be used at an ambient temperature lower than -20 °C.
˗The disc must be made of iron alloy (cast iron or steel) having a hardness in the range 190 to 220
HB.
The technical department of COREMO OCMEA can provide additional information in order to ensure
correct application and use of the product.

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 5di 14
Dangers caused by a power failure: A power failure will cause the brakes to fail. It is therefore
necessary to provide an uninterrupted power supply or, if the case requires, use suitable power failure
warning systems as a brake failure may cause personal injury and damage to property.
Danger of breakage during operation: To reduce the risk of breakage during operation carry out the
periodic inspections shown in this manual.
Risks connected with changes in operating conditions: The product is designed for the purposes stated
in this user and maintenance manual therefore the power supply pressure required for the brake to
work safely and reliably is indicated. The operating conditions also vary depending on the diameter of
the brake disc used; this manual contains an equation to calculate the dynamic torque provided as a
function of the disc diameter. Please note that an erroneous calculation may result in a braking torque
different to the desired value which could compromise aspects of safety.
Residual risk: Residual risk can be attributed to the operator not following all the procedures stated in
the user and maintenance manual and not giving due consideration to the warnings.
5. Technical data
5.1. Product performance
The type “D” caliper brakes differ basically in manual (D-M), pneumatic (D05, D1, D2, D3) and hydraulic
(D3-ID) models. The manual brake is intended to be used for holding stops, operating stops or
tensioning unlike the pneumatic and hydraulic brakes designed exclusively for operating stops.
Use of the product for any purpose other than those indicated may represent a risk to
any aspect of safety.
Warning: The value of the friction coefficient is purely theoretical as it depends on environmental
conditions and on how the product is used.
Manual brake
Every rotation clockwise of 360° of the handle increases the tangential force by 222,5 N. The maximum
tangential force of 2670 N (considering a coefficient of friction of 0.4) is obtained with 12 rotations of
360°.

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 6di 14
Pneumatic brake
Pneumatic type “D” caliper brakes are different basically due to the dimension of the pneumatic
actuator (05, 1, 2 and 3); the table below shows the tangential force for each brake type if powered at 6
bar and considering a coefficient of friction of 0.4
TYPE
Tangential Force
D05
1600 N
D1
3800 N
D2
7500 N
D3
12700 N
Hydraulic brake
The hydraulic D3-ID caliper brake is able to apply a tangential force of 14868 N if powered at 100 bar
and considering a coefficient of friction of 0.4
Dynamic torque
The dynamic torque provided by the brake will be a function of the diameter of the disc used for each
single type of product and can be determined using the following equation:
Dynamic torque [Nm] = Tangential force [N] x ( radius of the disc [m] - 0.033 )
An error in calculation will result in a braking torque different to the desired value and a
risk to aspects of safety.
The technical department of COREMO OCMEA can provide information, suggestions and
assistance for correct application and use of the product.
5.2. Brake lining wear
The thickness of each single new lining is 11 mm. A maximum overall lining wear of 12
mm is allowed. Failure to remain within the above limit may represent a risk to aspects
of safety.
5.3. Special note
During braking kinetic energy is converted into heat caused by friction between the surfaces of
the brake linings and the brake disc. It is therefore fundamentally important to consider the
amount of heat that can be dissipated.

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 7di 14
Ignoring the heat produced during braking affects brake lining wear and may jeopardize
the safety of the operators and the reliability of the product. Since a brake can be used
for many applications, it is advisable to contact the technical department of COREMO
OCMEA for further explanation in this regard.
6. Transport and storage
Personnel assigned to this work must wear suitable PPE such as gloves, safety footwear
and take any other precautions necessary before proceeding with transport, handling
and storage of the this part.
1. Transport: When handling it is important to bear in mind the dimensions and weight of each
single type of product as shown in the product drawing enclosed with this manual and in the
catalogue of the brake type in question.
2. Storage: When storing brakes it is important to bear in mind that a considerable weight is
concentrated in a small space. Personnel assigned to this work must wear suitable PPE
(safety footwear, gloves, and take any other appropriate precautions) in order to avoid the
risk of injury.
7. Installation
THE BRAKE MUST BE INSTALLED WITH THE MACHINE OFF.
Personnel assigned to this work must wear suitable PPE such as gloves, safety footwear and
take any other appropriate precautions to ensure adequate protection and avoid the risk of
injury.
Before installation, remove the spacer between the pads. To remove this spacer, widen the
space between the pads, rotating the grub screw (Figure 1) using a n. 12 Allen key, after
loosening the nut (C61600) with a n. 36 key and the grub screw (C61728) using a 5 Allen key.
Once the spacer has been removed, proceed with the installation.
1. Mount the brake on a rigid flat surface of the machine or on a support capable of withstanding
a certain tangential force as shown in Table 1.

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 8di 14
Tangential force
Brake model
2937 N
D-M
1760 N
D05
4180 N
D1
8250 N
D2
13970 N
D3
16355 N
D3-ID
Table 1
The brake can be mounted in any position as it is provided with a balancing system for the
levers and alignment of the brake shoes. Anchor the brake to the supporting base using 3 class
8.8 M12 screws and a tightening torque of 85 Nm.
2. Adjust the play between the brake linings and the disc using the play adjuster and a n. 12 Allen
key, rotating in the appropriate direction (Figure 1); when a play of 1 mm has been obtained
between the disc and each brake lining, lock the adjuster in position screwing the nut (C61600)
all the way down using a n 36 spanner and locking the adjuster (C61728) using a n. 5 Allen key.
Adjust the screw located between the levers using a n. 10 spanner (Figure. 1), until the weight
of the thruster is balanced; when balanced lock the screw by tightening the nuts.
Figure 1
3. Adjust the brake shoes using the grub screw C61724 rotating it in the appropriate direction
with a n. 3 Allen key; the friction surface of the brake linings must be parallel to the surface of
the disc (Figure 2).

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 9di 14
Figure 2
4. PNEUMATIC AND HYDRAULIC THRUSTERS: Connect the thruster piston of the brake to the
power line using a 1/4” gas fitting for thrusters 05 and 1, 3/8” gas fitting for thrusters 2 and 3,
1/8” gas fitting for thruster 3-ID, and a flexible hose of sufficient length to allow the thruster a
broad range of movement.
5. PNEUMATIC THRUSTERS: The control pressure must not exceed 6 bar. The air must not be
contaminated with oil or water, therefore a 25 micron filter with automatic condensate
discharge should be used.
6. HYDRAULIC THRUSTERS: The control pressure must not exceed 100 bar. The thruster must be
powered exclusively with mineral oil hydraulic fluid.
7. MANUAL THRUSTER: To obtain the correct torque value rotate the handle D70985 in the
clockwise direction until the brake linings come into contact with the disc. Each rotation of
360° of the handle increases the tangential force by 222,5 N. The maximum tangential force of
2670 N is obtained with 12 rotations of 360°.
Do not apply the brake without the disc positioned between the brake linings; failure to
follow this rule could result in fingers being crushed and other dangers in addition to
damage to the brake itself.
8. HYDRAULIC BRAKES: Bleed air out of the oil circuit by loosening the grub screw C61961 with
a n. 4 Allen key until oil begins to come out. When all the air has been bled out tighten the
grub screw again (Figure 3).

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 10 di 14
Figure 3
Personnel assigned to these operations must take special care, working cautiously
when bleeding the circuit, wearing suitable PPE such as gloves, goggles and safety
footwear and taking any other precautions necessary before proceeding.
9. BEDDING-IN: The initial braking torque may be from 30% to 50% less than the rated value until
the brake lining adjusts to the disc.
8. Operation
8.1. Power supply of the product
Chapter 5.1 contains a table of the tangential force provided by each single type of product
and the relevant equation for calculating the braking torque of each brake as a function of the
diameter of the disc used.
The control pressure for pneumatic brakes (D05, D1, D2, D3) must not exceed 6 bar while for
hydraulic brakes the limit is 100 bar.
The technical department of COREMO OCMEA can provide information, suggestions and
assistance for correct application and use of the brake.
The wrong power supply pressure will result in a tangential force different to the value
indicated in this manual; the braking torque of the product will therefore be different to
the value desired and represent a risk to safety aspects.

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
www.coremo.it
Pag. 11 di 14
8.2. Improper use
The products considered here must be used exclusively as described in Chapter 5 of this
manual. Any other use is to be considered improper. The manufacturer declines all
responsibility for damage caused by erroneous or unreasonable use of the product.
Use of the product for purposes other than those stated in this manual may
compromise any aspect of safety.
9. Maintenance and cleaning
ALL TYPES OF WORK ON THE BRAKE MUST BE DONE WITH THE MACHINE OFF.
Staff assigned to this work must wear suitable PPE such as gloves and safety footwear and take
any further precautions necessary to ensure adequate protection and prevent injury. Failure to
follow the instructions given for maintenance and cleaning of the product may compromise
personal safety and cause damage to equipment and machinery.
High temperatures may be produced after braking on the surfaces of the disc brake and
the brake linings. Personnel must therefore wait for parts subject to overheating to cool
down and wear suitable protective gloves and PPE.
9.1. Readjusting the play
1. Cut off pressure to the thruster, loosen the nut C61600 and grub screw C61728 (Figure 1).
2. Rotate the play adjuster clockwise until the optimal play of 1 mm is obtained between the
disc and each brake lining (see Chapter 7 point 2).
3. Lock the nut C61600 and the grub screw C61728 (Figure 1).
4. Realign the brake shoes as described in point 3 of Chapter 7.
9.2. Changing the lining pads and cleaning the friction surfaces
1. Cut off pressure to the thruster.
2. Remove the seeger rings C61275, then pull out the pin C61110 and remove the shoe
Z50263.

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 12 di 14
3. Remove the worn linings levering the metal part to overcome the force of the magnet
which holds it in its seat. Check that the magnet is well housed in the shoe.
4. Remove any oil or grease from the surface of the disc using a non-pollutant detergent.
5. If the lining pads are contaminated only superficially it is better to clean them using fine
emery cloth. If the contamination of the linings is deep or at the maximum wear limit as
indicated in Chapter 5.2 and stated in the catalogue, replace them with new linings.
6. Reassemble the shoe following the sequence in point 2 in reverse order, positioning the
shoe alignment spring C61968 as indicated in Figure 2.
7. Readjust the play between the disc and lining as described in Chapter 9.1.
9.3. Changing the thruster spring (brakes D05 , D1 , D2 , D3 e D3-ID)
1. Cut off pressure to the thruster and disconnect the power line. Unscrew the ring nuts and
remove the thruster from the brake.
2. Remove the screws that anchor the thruster body to the cover.
3. Remove the cover and for thrusters 1, 2 and 3, remove the diaphragm also.
4. Pull out the internal thruster unit / plate and replace the spring. Grease the stem before
putting the internal thruster back.
5. Put back the cover following the procedure in points 3 and 2 in reverse order.
6. Put the thruster back on the brake anchoring it with the two ring nuts. Reconnect the
flexible hose.
7. Apply the brake a number of times to ensure that the internal thruster slides perfectly and
check for any air leaks (for pneumatic thrusters) or oil (for hydraulic thrusters).
9.4. Changing the thruster spring (brake D–M)
1. Remove the handle D70985 from the threaded tube C61020 rotating it anticlockwise.
2. Replace the spring C61018.
3. Screw the handle D70985 back onto the threaded tube C61020 until the desired torque is
obtained.
9.5. Changing the diaphragm and the gaskets
1. Cut off pressure to the thruster and disconnect the power line. Unscrew the ring nuts and
remove the thruster from the brake.
2. Remove the screws that anchor the thruster body to the cover.
3. Thrusters 1, 2 and 3: remove the cover and replace the diaphragm.
4. Thrusters 05 and 3-ID: remove the cover and pull out the internal thruster / plate unit.
Remove the damaged gaskets and replace them with new ones. It is advisable to replace all

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 13 di 14
the gaskets to avoid further down time of the machine. Before placing the new gaskets in
their seats, lubricate with lithium soap grease, mineral oil and solid lubricants. Grease the
thruster stem too before remounting the internal thruster / plate unit.
5. Put back the cover and secure the unit by tightening the anchor screws.
6. Put the thruster back on the brake anchoring it with the two ring nuts. Reconnect the
flexible hose.
7. Apply the brake a number of times to ensure that the internal thruster slides perfectly and
check for any air leaks (for pneumatic thrusters) or oil (for hydraulic thrusters).
9.6. Changing the brake shoe alignment springs
1. Cut off pressure to the thruster.
2. Remove the seeger C61275, then pull out the pin C61110 and remove the brake shoe
Z50263.
3. Remove the shoe alignment spring C61968 from its seat and replace it with a new one,
positioning it as shown in Figure 2.
4. Remount the brake shoe following the procedure in point 2 in reverse.
5. Readjust the play between the disc and the lining as described in Chapter 9.1.
9.7. Periodic maintenance
All inspections must be done with the machine switched off.
Although the intervals between these inspections depend on the frequency of use of the
brake, they should be done every 3 months in any case so as not to compromise all
aspects of safety.
1. Check that the play between each lining pad and the friction disc does not exceed 1
mm. If the play is too large adjust it to the initial value as described in Chapter 9.1.
When the wear of each lining reaches 6 mm replace it as described in Chapter 9.2.
2. Check that the surfaces of the linings and the disc are not contaminated with grease, oil
or similar substances as these prevent the brake from working effectively.
3. Check that the anchoring screws of the brake and the brake units are correctly
tightened.
4. Check the condition of the flexible hoses.
5. Apply the brake a number of times to check the condition of the gaskets, the operation
of the springs and correct sliding of the stem.

User and Maintenance Manual
“D” Caliper brake
Model D-M
Model D05
Model D1
Model D2
Model D3 and D3-ID
Date: 2013/07/01
Revision: 1
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Pag. 14 di 14
10. Spare parts list
To avoid costly down time we recommend keeping a stock of spare parts adequate for the number
of brakes as listed below:
Lining pads: Cod. N° Z50054 ST 10
Cod. N° Z50055 ST 11
Cod. N° Z50117 ST 10 with wear indicator
Cod. N° Z50118 ST 11 with wear indicator
Thruster springs: Cod. N° C60993 Thruster 05
Cod. N° C60908 Thruster 1
Cod. N° C60918 Thrusters 2 and 3
Cod. N° C62024 Thruster 3-ID
Cod. N° C61018 Manual thruster
Shoe alignment springs: Cod. N° C61968
Lever balance springs: Cod. N° C61951 with disc of thickness 12.7 mm
Cod. N° C61952 with disc of thickness 12.7 mm
Cod. N° C61953 with disc of thickness 12.7 mm
Diaphragms: Cod. N° C61518 Thruster 1
Cod. N° C60915 Thruster 2
Cod. N° C60920 Thruster 3
Gaskets: Cod. N° C61139 - C61140 Thruster 05
Cod. N° C61976 - C62022 Thruster 3-ID
Cod. N° C62021 - C62023 Thruster 3-ID
These spare parts must be kept in a place that is preferably dark, cool and far from substances that
could reduce their functionality.