COREMO OCMEA G-M Operating instructions

G Manual
Model G-M
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
“G” Caliper brake
Model G-M
Date: 2013/07/01
Revision: 1
www.coremo.it
Pag. 2di 11
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....................................................................................................................................... 5
5.3. Special note ............................................................................................................................................... 6
6. Transport and storage ............................................................................................................................... 6
7. Installation................................................................................................................................................. 6
8. Operation................................................................................................................................................... 8
8.1. Performance of the product...................................................................................................................... 8
8.2. Improper use ............................................................................................................................................. 9
9. Maintenance and cleaning ........................................................................................................................ 9
9.1. Readjusting the play .................................................................................................................................. 9
9.2. Changing the lining pads ......................................................................................................................... 10
9.3. Cleaning the friction surfaces.................................................................................................................. 10
9.4. Changing the thruster springs ................................................................................................................. 10
9.5. Changing the brake shoe alignment springs ........................................................................................... 11
9.6. Periodic maintenance.............................................................................................................................. 11
10. Spare parts list......................................................................................................................................... 11

User and Maintenance Manual
“G” Caliper brake
Model G-M
Date: 2013/07/01
Revision: 1
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Pag. 3di 11
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
“G” Caliper brake
Model G-M
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.
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.
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 tangential force obtained with 10 rotations of the
handle to work safely and reliably is indicated. The operating conditions also vary depending on the

User and Maintenance Manual
“G” Caliper brake
Model G-M
Date: 2013/07/01
Revision: 1
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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 “G-M”manual caliper brake is intended to be used for holding stops, operating stops or
tensioning. Every rotation clockwise of 360° of the handle increases the tangential force by 2100 N. The
maximum tangential force of 21000 N (considering a coefficient of friction of 0.4) is obtained with 10
rotations of 360°.
Warning: The value of the friction coefficient is purely theoretical as it depends on environmental
conditions and on how the product is used.
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 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] - 0,062 )
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 8 mm. A maximum overall lining wear of 10
mm is allowed. Failure to remain within the above limit may represent a risk to aspects
of safety.

User and Maintenance Manual
“G” Caliper brake
Model G-M
Date: 2013/07/01
Revision: 1
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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, 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

User and Maintenance Manual
“G” Caliper brake
Model G-M
Date: 2013/07/01
Revision: 1
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Pag. 7di 11
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 of 23100 N. 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.
2. Anchor the brake to the supporting base using 3 class 8.8 M12 screws and a tightening torque
of 85 Nm.
3. 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
4. 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 2); 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.
Figure 2

User and Maintenance Manual
“G” Caliper brake
Model G-M
Date: 2013/07/01
Revision: 1
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Pag. 8di 11
5. Adjust the brake shoes using the grub screw C61559 rotating it in the appropriate direction
with a n. 54 Allen key; the friction surface of the brake linings must be parallel to the surface
of the disc (Figure 3).
Figure 3
6. To obtain the correct torque value rotate the handle E80816 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 2100 N. The maximum tangential force of 21000 N is obtained with 10
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.
7. 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. Performance of the product
Chapter 5.1 reports the tangential force provided by product and the relevant equation for
calculating the braking torque as a function of the diameter of the disc used.
The technical department of COREMO OCMEA can provide information, suggestions and
assistance for correct application and use of the brake.

User and Maintenance Manual
“G” Caliper brake
Model G-M
Date: 2013/07/01
Revision: 1
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Pag. 9di 11
The wrong number of turns of the handle produces a tangential force different to the
value indicated in this manual; the braking torque of the product will therefore be
different from the desired value and pose a risk to safety aspects.
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. Rotate the handle E80816 counterclockwise to open the brake.
2. Loosen the ring nuts C61600 and the grub screw C61728.
3. Rotate the play adjuster clockwise until the optimal play of 1 mm is obtained between the
disc and each brake lining (Figure 1 and Figure 2).
4. Lock the nut C61600 and the grub screw C61728.
5. Realign the brake shoes as described in point 5 of Chapter 7 (Figure 3).

User and Maintenance Manual
“G” Caliper brake
Model G-M
Date: 2013/07/01
Revision: 1
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9.2. Changing the lining pads
1. Rotate the handle E80816 counterclockwise to open the brake.
2. Remove the seeger rings C61275, then pull out the pin C62056 and remove the shoe
Z50217.
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. Insert the new lining pads.
5. Reassemble the shoe following the sequence in point 2 in reverse order, positioning the
shoe alignment spring C62058 as indicated in Figure 3.
6. Readjust the play between the disc and lining as described in Chapter 9.1.
9.3. Cleaning the friction surfaces
1. Remove the lining pads as described in Chapter 9.2.
2. Remove any oil or grease from the surface of the disc using a non-pollutant detergent.
3. 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.
9.4. Changing the thruster springs
1. Rotate the handle E80816 counterclockwise to open the brake.
2. Unscrew the locknuts C61133 and remove the thruster from the brake.
3. Unscrew and remove the bolts C61349 / C61422 that anchor the thruster body to the
cover.
4. Remove the cover D71212 with the handle.
5. Remove the push-spring disc C62155.
6. Remove and replace all the springs C62154 including those which seem to be in good
condition.
7. Lubricate the new cup springs and the part of the thruster E80815 where they are housed
with Molycote D321R spray grease (or similar), before proceeding with reassembly.
Position the cup springs correctly so that they do not affect the good operation of the
brake.
8. Put back the push-spring disc C62155 and the cover D71212 complete with hand wheel
using the anchoring screws C61349 / C61422.
9. Put the thruster back on the brake anchoring it with the two ring nuts.
10. To restore the braking torque follow the procedure in point 6 of Chapter 7.

User and Maintenance Manual
“G” Caliper brake
Model G-M
Date: 2013/07/01
Revision: 1
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9.5. Changing the brake shoe alignment springs
1. Rotate the handle E80816 counterclockwise to open the brake.
2. Remove the seeger rings C61275, then pull out the pin C62056 and remove the shoe
Z50217.
3. Remove the shoe alignment spring C62058 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 10.1.
9.6. 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 5 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.
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° Z50218 ST 10
Cod. N° Z50219 ST 11
Thruster springs: Cod. N° C62154
Shoe alignment springs: Cod. N° C62058
Lever balance springs: Cod. N° C61952 with disc of thickness 25.4 mm
cod. N° C61953 with disc of thickness 40 mm
These spare parts must be kept in a place that is preferably dark, cool and far from substances that
could reduce their functionality.