COREMO OCMEA ID 2500N Operating instructions

FAILSAFE HYDRAULIC BRAKE
ID 2500N
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 140701 REV. 0
ISO 9001 - Certificate N°0238

User and Maintenance Manual
Failsafe hydraulic brake ID 2500N
Model ID 2500N
Date: 2014/07/01
Revision: 0
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TABLE OF CONTENTS
1. Introduction ............................................................................................................................................ 3
2. Manufacturer .......................................................................................................................................... 3
3. General information................................................................................................................................ 3
4. Warnings ................................................................................................................................................. 5
5. Technical data ......................................................................................................................................... 6
5.1. Product performance .............................................................................................................................. 6
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 feed of the safety component ................................................................................................... 10
8.2. Improper use......................................................................................................................................... 10
9. Maintenance and cleaning.................................................................................................................... 11
9.1. Restoring the play ................................................................................................................................. 11
9.2. Replacement of the lining pads and cleaning the friction surfaces...................................................... 11
9.3. Changing the sealing rings..................................................................................................................... 12
9.4. Changing the cup springs ...................................................................................................................... 13
9.5. Periodic maintenance............................................................................................................................ 14
10. Spare parts list....................................................................................................................................... 15

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1. Introduction
The purpose of this manual is to provide the user with all the information necessary to use the
product properly, independently and as safely as possible.
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: in[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 perfect and safe use of the product are stated in this manual.
Design parameters: COREMO OCMEA brakes have been designed in compliance with the norm UNI EN
ISO 12100:2010 and to satisfy the performance requirements and conditions stated in the catalogue and
in Chapter 5 of this manual.
Model selection: Selection of the correct model for a given application is of basic importance. In the
case of failsafe brakes the service factor must not be less than 2. The technical department of COREMO

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OCMEA can provide you with information, suggestions and assistance regarding correct application and
use.
Use: Following the mounting and maintenance instructions prevents costly down time and accidents
due to incomplete knowledge of the product. Please note that the initial braking force may be from 30%
to 50% less than the rated value until the brake lining adjusts to the disc.
Rotating parts: The 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 hydraulic brakes: Use mineral oil SAE/ISO 46.
Spring loaded failsafe brakes: Spring loaded failsafe brakes must be handled with special care because
they contain mechanically preloaded springs. In order to avoid the risk of accidents during maintenance
work, it is necessary to follow the instructions in this manual.
Friction material: All COREMO OCMEA 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.
Cleaning of the product: Do not wash the product with water or any detergent.
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 linings 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.

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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 the 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
Dangers caused by a power failure: A power failure will cause the brake to be applied suddenly. 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 products are designed for the purposes
stated in this user and maintenance manual therefore the minimum power supply pressure is indicated
to ensure that the brake can be opened and the maximum pressure to ensure that braking is always safe
and reliable. The operating conditions also vary depending on the diameter of the brake disc used; an
equation for calculating the dynamic torque as a function of disc diameter is given in this manual. It
should be stressed that an error in calculation will result in a braking torque that is different from the
desired value and this may represent a risk to 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

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5. Technical data
5.1. Product performance
The “ID 2500N” failsafe hydraulic brake has a tangential force of 150000 N attributing a coefficient of
friction of 0.4
Warning: The value of the friction coefficient is purely theoretical as it depends on environmental
conditions and on how the product is used.
The hydraulic failsafe brake is intended exclusively for emergency stops or holding stops.
Use of the product for any purpose other than those indicated may represent a risk to
any aspect of safety.
Dynamic torque
The dynamic torque provided by the brake will be a function of the diameter of the disc used and can be
determined using the following equation:
Dynamic torque [Nm] = tangential force [N] x ( radius of the disc [m] - 0.101 )
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 14 mm. A maximum overall lining wear of 18
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.

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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
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, etc.) 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.
1. The ID 2500N brake must be installed on a bracket having the same thickness as the disc + 56
mm (Figure 1). The fixed part which is to support the brake must withstand a tangential force
of 165000 [N].
The brake must be anchored using three M36 class 12.9 screws.

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Figure 1
2. Connect the brake to the power line using a 1/4” gas fitting. The brake can be supplied on
request complete with Ø8 pipe fitting (H0045) already connected.
3. Pay attention to the control pressure; this must not exceed 220 bar, while the minimum
opening pressure must not be less than 180 bar.
The brake must be powered exclusively using mineral oil hydraulic fluid.
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.
4. With the brake powered up, disengage the safety hook (C62379) from the housing of the
piston which is protruding from the cover. To prevent the safety hook from getting lost while
the brake is in operation, attach it to the side part of the caliper block using the TCEI M5x18
screw (C61372) as shown in assembly drawing A4025/A4027 (use a CH BR 5).
5. The brake is supplied with a bleed vent (Z50315). To bleed air out of the circuit, loosen the
retaining nut of the fitting and pull the tubular cap outward. After bleeding off the air tighten
the fitting again (Figure 2).
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.

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Figure 2
6. Restoring the play
˗Power up the brake and bleed the air from the oil circuit through the bleeding device
(Z50315), as described in point 5.
˗With the brake powered up rotate the play adjuster (D71316) in the clockwise
direction using a CH BR 12, until a play of 1 mm is obtained between the disc and each
brake lining (Figure 3).
Pay particular attention during this regulation because rotating the gap regulator
(D71316) anticlockwise, this could tighten inside the thruster (D71315) and get
definitely stuck.
Figure 3 –Initial play adjustment
7. Safety lock of the wear adjuster: to prevent the wear adjuster from rotating or moving while
the brake is in operation due to machine vibration, each brake unit (K9........) has two safety
grub screws (C61584) to lock the adjuster (D71316), located in the part of the thruster which

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protrudes from the cover (seat of the safety hook); see also assembly drawings A4025/A4027
to find the positions of the grub screws. To lock and/or unlock the adjuster, tighten and/or
loosen the grub screws using a CH BR 4; when doing this, with the brake in operation or during
maintenance, the safety hook (C62379) must not be inserted in the seat of the thruster
(D71315) otherwise the operation cannot be carried out.
Warning: The brake is supplied with the wear adjuster NOT locked.
8. BEDDING-IN: The initial braking torque may vary from 30% to 50% less than the rated value
until the lining has bedded into the disc.
8. Operation
8.1. Power feed of the safety component
The control pressure of the hydraulic brake must not exceed 220 bar, while the minimum
opening pressure must not drop below 180 bar. The brake must also be powered exclusively
using mineral oil hydraulic fluid.
In case the minimum opening pressure of the brake results lower than the one
indicated, stop immediately the machine and change the cup springs. This check is
necessary to avoid compromising any safety aspect.
The technical department of COREMO OCMEA can provide information, suggestions and
assistance for correct application and use of the product.
To check the minimum opening pressure it is possible to use a hydraulic hand pump by
performing the following step:
1. Connect the brake to a manual hydraulic pump.
2. Power up the brake with the hand pump.
3. Check that the pressure indicated by the manometer of the pump at the opening of
the brake is the same as the one previously indicated.
4. In case the minimum opening pressure of the brake results lower than the one
indicated, stop immediately the machine and change the cup springs.
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 improper or unreasonable use of the product.

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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. Restoring the play
1. With the brake powered up, loosen two safety grub screws (C61584) placed in the external
part of the cover (seat of the safety hook) and rotate the play adjuster (D71316) in the
clockwise direction using a CH BR 12, until the optimal play of 1 mm between the disc and
each lining has been restored.
Pay particular attention during this regulation because rotating the gap regulator
(D71316) anticlockwise , this could tighten inside the thruster (D71315) and get definitely
stuck.
2. Using a feeler gauge, check that the play between the disc and each brake lining is 1 mm.
3. Following this operation, retighten the two safety grub screws (C61584) in order to prevent
possible rotations and movements of the wear adjuster during operation of the brake.
9.2. Replacement of the lining pads and cleaning the friction surfaces
1. Power up the brake and insert the safety hook (C62379) in its seat of the thruster which
protrudes from the cover. Once the hook has been inserted the pressure can be removed
from the brake. (Remove the brake from the machine only if necessary; in this case
proceed as described from point 1 to point 3 of section 9.3)

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2. Loosen the screws (C61399) which anchor the plates (C62242) to the brake and extract the
brake lining guide pins (C62377), without removing the other screws (C61397) which
connect the plates to the pins.
3. Remove the lining pads (Z50366/Z50367/Z50368) pulling the backing plate outward until it
is released from the magnet (C62333) incorporated in the play adjuster (D71316).
4. Remove any oil or grease from the surface of the disc using a non-pollutant detergent
product.
5. If the brake linings are contaminated only on the surface it is a good idea to clean them
using fine emery cloth. If they are contaminated in depth or worn to the limit replace them
with new linings.
6. Put back the lining pads attaching them to the magnet (C62333).
7. Align the holes of the brake body (E80887) and the backing plate in which the guide pins
will be inserted. Reinsert the guide pins (C62377) in their housings and anchor the plates
(C62242) to the brake body using the screws (C61399) previously removed. (If the brake
has been removed from the machine skip this point)
8. Power up the brake and remove the safety hook (C62379). (If the brake has been removed
from the machine proceed as described from point 19 to point 21 of section 9.3)
9.3. Changing the sealing rings
1. Power up the brake and insert the safety hook (C62379) in its seat of the thruster which
protrudes from the cover.
2. Cut off the control pressure and disconnect the power line.
3. Remove the brake from the machine.
4. Reconnect the power line and power up the brake.
5. Remove the safety hook (C62379).
6. Cut off the control pressure and disconnect the power line.
7. Remove the lining pads as described in point 3 of section 9.2.
8. Unscrew the anchoring screws (C61443) and remove the cover (D71314).
Take special care during these operations as the brake contains preloaded springs,
proceed therefore gradually with the utmost care and attention so that they are
completely released and do not jeopardize any aspects of safety.
9. Remove, in the following order: 1 shim C62378, 12 cup springs C62380 and 1 shim C62378.
10. Remove the play adjuster (D71316) from the thruster.
11. Carefully remove the thruster (D71315) from the brake body (E80887) carefully allowing
compressed air to enter from the feed hole until the thruster has come out completely.
12. Remove the damaged gaskets and guide rings and replace them. It is advisable to replace all
the gaskets, the wiper seals and all guide rings to avoid further down time. COREMO
OCMEA provides a complete kit with 4 gaskets, 2 guide rings, wiper seals and 2 o-ring.
13. Put back the thruster (D71315) and play adjuster (D71316).

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14. Put back the cup springs as described from point 4 to point 6 of section 9.4;
15. Put back the cover (D71314) on the brake body (E80887) using the screws (C61443) and
washers (C61322). Tighten the M12 class 12.9 (C61401) screws in a diagonal sequence with
a tightening torque of 136 Nm.
16. Connect the power line, power up the brake and insert the safety hook (C62379) in its seat
on the thruster which protrudes from the cover.
17. Cut off the control pressure and disconnect the power feed line.
18. Put back the lining pads re-attaching them to the magnet (C62333) incorporated in the play
adjuster (D71316).
19. Reinstall the brake on the machine.
20. Reconnect the power feed line and power up the brake.
21. Remove the safety hook (C62379 ) and bleed air from the circuit as described in point 5 of
section 7.
9.4. Changing the cup springs
1. Remove the brake from the machine proceeding as described from point 1 to point 6 of
section 9.3.
2. Carefully unscrew the anchor screws (C61443) in a diagonal sequence and remove the
cover (D71314).
Take special care during these operations as the brake contains preloaded springs,
proceed therefore gradually with the utmost care and attention so that they are
completely released and do not jeopardize any aspects of safety.
3. Remove, in the following order: N. 1 shim C6278, 12 cup springs C62380 and 1 shim C6278.
Replace all the cup springs, including those which might seem in good condition (replace
also the shim only if necessary).
4. Clean any excess grease from the bottom of the cover and the thruster.
5. Lubricate the cup springs and the part of the thruster where they are housed with Molycote
D321R spray grease (or similar), before proceeding with reassembly.
6. Insert one shim C62378, twelve cup springs C62380 and one shim C6278 into the piston
(D71315).
Position the cup springs correctly so that they do not affect the good operation of the
brake (Figure 4). Incorrect assembly will result in a tangential force different to what is
stated in this manual; the braking torque provided by the safety component will
consequently be different to what is desired and to the detriment of safety aspects.

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7. Put back the cover (D71314) on the brake body (E80887) using the M12 (C61443) class 12.9
screws with a tightening torque of 136 Nm, complete with washers (C61322), proceeding in
a diagonal sequence.
8. Connect the power line, power up the brake and insert the safety hook (C62379) in its seat
of the thruster which protrudes from the cover.
9. Cut off the control pressure and disconnect the power line.
10. Reinstall the brake on the machine.
11. Reconnect the power line and power up the brake.
12. Remove the safety hook (C62379) and bleed air from the circuit as described in point 5
of section 7.
Figure 4 –Position of the cup springs for the ID 1500N brake
9.5. 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 the disc and each brake lining is 1 mm. If the play encountered
is greater, reset the original play as described in section 9.1.
2. There is a wear line on the brake lining, however, it is advisable to check that the wear of each
lining does not exceed 9 mm in order not to compromise the correct operation and good
working condition of the brake. When the lining pads reach maximum wear replace them as
described in section 9.2.

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3. Check that the surfaces of the brake linings and the disc are not contaminated with grease,
oil or similar substances which prevent the brake from working efficiently.
4. Check that the cup springs are lubricated well.
5. Check that the anchor screws of the brake have been tightened correctly.
6. Check that the hoses are undamaged.
7. Apply the brake repeatedly to check that the gaskets are undamaged and the springs are
working correctly.
10. Spare parts list
In order to avoid costly down time we suggest keeping a stock of the spare parts listed below
adequate for the number of brakes in use (the quantities indicate are for each brake):
Lining pads: Qty. 2 [ST11.2] cod. Z50366
Qty. 2 [ST11.4] cod. Z50368
Qty. 2 [ST12.2] cod. Z50367
Cup springs: Qty. 24 cod. C62380
Shims: Qty. 4 cod. C62378
Sealing ring kit: Qty. 2 gaskets cod. C62386
Qty. 2 gaskets cod. C62382
Qty. 2 guide rings cod. C62381
Qty. 2 wiper seals cod. C62384
Qty. 2 o-ring cod. C62385
These spare parts must be kept if possible in a dark cool place and away from substances that could
damage their capacity to work properly.