COREMO OCMEA E4N-ID Operating instructions

E Hydraulic failsafe
Model E4N-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
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
www.coremo.it
Page 2of 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............................................................................................................................. 6
7. Installation............................................................................................................................................... 7
8. Operation .............................................................................................................................................. 10
8.1. Power supply of the safety component ................................................................................................ 10
8.2. Improper use......................................................................................................................................... 10
9. Maintenance and cleaning.................................................................................................................... 10
9.1. Readjusting the play.............................................................................................................................. 11
9.2. Changing the lining pads ....................................................................................................................... 11
9.3. Cleaning the friction surfaces................................................................................................................ 11
9.4. Changing the thruster springs............................................................................................................... 11
9.5. Changing the brake shoe alignment springs ......................................................................................... 12
9.6. Changing the gaskets............................................................................................................................. 13
9.7. Periodic maintenance............................................................................................................................ 14
10. Spare parts list....................................................................................................................................... 14

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
www.coremo.it
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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 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: 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 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
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
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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 hydraulic brakes: Use mineral oil SAE/SO 46.
Failsafe spring brakes: Failsafe spring brakes must be handled with special care as they contain
mechanically preloaded springs. To avoid the risk of accidents during maintenance it is necessary to
follow the instructions in this manual and those highlighted in red on the label attached to the brake.
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
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
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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 product is designed for the purposes stated
in this user and maintenance manual therefore the minimum power supply pressure necessary to allow
the brake to open and the maximum pressure required for the brake to work safely and reliably are
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 failsafe brake is to be used 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.
Warning: The value of the friction coefficient is purely theoretical as it depends on environmental
conditions and on how the product is used.
The type “E” failsafe caliper brakes applies a tangential force of 42000 N attributing a coefficient of
friction of 0.4 . The tangential force is obtained with 16 springs, proportionately lower values can be
obtained with 14, 12 or 10 springs
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] - 0,065 )

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
www.coremo.it
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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 13 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.
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, etc.) in order to avoid the risk of injury.

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
www.coremo.it
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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. Mount the brake on a rigid flat surface of the machine or on a support capable of withstanding
a tangential force of 46200 N.
2. 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.
3. Anchor the brake to the supporting base using 3 class 8.8 M16 screws and a tightening torque
of 200 Nm.
4. Adjust the screws C61562 located between the levers using a n. 6 spanner (Figure 1), until the
weight of the thruster is balanced; when balanced lock the screw by tightening the nuts
C61608.
Figure 1
5. Adjust the play between the brake linings and the disc using the play adjuster D71022
(D71076 if with ON/OFF), and a n. 30 Allen key, rotating in the appropriate direction (Figure
2); when a play of 1 mm (with disc of thickness 25.4 mm) or 1.5 mm (with disc of thickness 40
mm) has been obtained between the disc and each brake lining, lock the adjuster in position
screwing the ring nuts (C61711).

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
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Figure 2
6. Adjust the brake shoes using the grub screw C61559 rotating it in the appropriate direction
with a n. 4 Allen key; the friction surface of the brake linings must be parallel to the surface
of the disc (Figure 3).
Figure 3
7. Connect the thruster piston of the brake to the power line using a 1/4” gas fitting and a flexible
hose of sufficient length to allow the thruster a wide range of movement.
8. The control pressure must not exceed 100 bar while the minimum opening pressure must not
be less than 60 bar.
9. Power up the thruster and substitute the safety screw TE M14 with the silencer C61846 (Figure
4).

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
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Figure 4
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.
10. 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 5).
Figure 5

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
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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.
11. 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 safety component
For the correct operation of the brake the control pressure must not exceed 100 bar while the
minimum opening pressure must not be less than 60 bar. Use mineral oil SAE/SO 46.
The technical department of COREMO OCMEA can provide information, suggestions and
assistance for correct application and use of the brake.
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
TUTTI I TIPI DI INTERVENTO SUL FRENO DEVONO ESSERE EFFETTUATI A MACCHINA
FERMA.
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.

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
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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. Power up the thruster (minimum supply pressure of 60 bar and maximum of 100 bar).
2. Loosen the ring nuts C61711.
3. Rotate the play adjuster clockwise until the optimal play of 1 mm (with disc of thickness
25.4 mm) or 1.5 mm (with disc of thickness 40 mm) is obtained between the disc and each
brake lining (Figure 2).
4. Lock the ring nuts C61711.
5. Realign the brake shoes as described in point 6 of Chapter 7 (Figure 3).
9.2. Changing the lining pads
1. Power up the thruster (minimum supply pressure of 60 bar and maximum of 100 bar) and
replace the silencer with the safety screw.
2. Pull out the pin K90073 and remove the shoe D71026 for brakes with disc of thickness 25.4
mm or the shoe D71023 for brakes with disc of thickness 40 mm.
3. Unscrew the 4 screws C61171, remove the brake lining and replace it with a new one. Put a
few drops of threadlock on the screws C61171 and tighten them to a torque of 12 Nm.
4. Reassemble the shoe following the sequence in point 2 in reverse order, positioning the
shoe alignment spring C61958 as indicated in Figure 3.
5. Readjust the play between the disc and lining as described in Chapter 9.1.
6. Replace the safety screw with the silencer.
9.3. Cleaning the friction surfaces
1. Dismantle the brake linings as explained in Chapter 9.2.
2. Remove any oil or grease from the surface of the disc using a non-pollutant detergent.
3. If the discs 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.
9.4. Changing the thruster springs
1. Power up the thruster (minimum supply pressure of 60 bar and maximum of 100 bar).
2. Replace the silencer C61846 with the safety screw TE M14.
3. Unscrew the ring nuts and remove the thruster from the brake.

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
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4. Remove the safety screw TE M14.
5. Cut off the pressure to the thruster and disconnect the power line.
6. Remove the threaded bars and their nuts which anchor the thruster body E80823, the bell
and the cover (Figure 6); unscrew slowly and carefully so that the preloaded springs are
released gradually.
Figure 6
Take the utmost care in these operations as the thrusters contain preloaded springs.
Therefore proceed gradually with the utmost care and attention until they are
completely released and no longer represent a threat to safety
7. Remove the cover Z50313 and replace all the springs including those which seem to be in
good condition.
8. Rest the cover on the springs, align the anchoring holes and insert the threaded rods
complete with nuts and flat washers in their seats. Tighten following a diagonal sequence
locking the unit in position with the self-locking nuts.
9. Reconnect the flexible hose and power up the thruster (minimum supply pressure of 60 bar
and maximum of 100 bar).
10. Insert the safety screw TE M14.
11. Remount the thruster on the brake locking it in position with the ring nuts.
12. Replace the safety screw TE M14 with the silencer C61846.
13. Apply the brake a number of times to ensure that the internal thruster slides perfectly and
check for any oil leaks.
9.5. Changing the brake shoe alignment springs
1. Power up the thruster (minimum supply pressure of 60 bar and maximum of 100 bar) and
replace the silencer with the safety screw TE M14.
2. Pull out the pin K90073 and remove the brake shoe D71026 (for brakes with disc of
thickness 25.4 mm) or D71023 (for brakes with disc of thickness 40 mm).

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
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3. Remove the shoe alignment spring C61958 from its seat and replace it with a new one
positioning it as shown in Figure 3.
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.
6. Substitute the safety screw with the silencer.
9.6. Changing the gaskets
1. Proceed as explained in Chapter 9.4 from point 1 to point 6.
2. Remove the cover Z50313.
3. Remove the bell E80822 and springs.
4. Remove the plate unit Z50314 and pull out the internal thruster piston D71224 complete
with rod D71225.
5. Using a n. 2.5 Allen key unscrew the screws C61162 and remove the gasket locking flange
C62219.
6. Remove the damaged gaskets (C62216 - C62218 - C61841) and the o-ring (C61820) and
replace them with new ones. Before placing the new gaskets in their seats, lubricate with
mineral oil. Grease the stem (D71225) and the internal thruster (D71224) too before
remounting the thruster unit.
7. Remount following the instructions from point 5 to point 3 of Chapter 9.6 in reverse order.
8. Remount following the instructions in Chapter 4 from point 8 to point 13 in reverse order.

User and Maintenance Manual
“E” Failsafe caliper brake
Model E4N-ID
Date: 2013/07/01
Revision: 1
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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 because 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.
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° D71000 ST 10
Cod. N° D70997 ST 11
Cod. N° D70998 ST 12
Thruster springs: Cod. N° cod. N° C61844 - C61845
Shoe alignment springs: Cod. N° C61958
Lever balance springs: Cod. N° C61959
Gaskets: Cod. N° C62216 - C62218 - C61841
O-Ring: Cod. N° C61820
These spare parts must be kept in a place that is preferably dark, cool and far from substances that
could reduce their functionality.