COREMO OCMEA ID 2000N-116 Operating instructions

FAILSAFE HYDRAULIC BRAKE
ID 2000N-116
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 140627 REV. 1.2
ISO 9001 - Certificate N°0238

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 2of 25
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............................................................................................................................................... 8
8. Operation .............................................................................................................................................. 12
8.1. Power feed of the safety component ................................................................................................... 12
8.2. Improper use......................................................................................................................................... 13
9. Maintenance and cleaning.................................................................................................................... 14
9.1. Restoring the play ................................................................................................................................. 14
9.2. Replacement of the lining pads and cleaning the friction surfaces...................................................... 15
9.3. Changing the sealing rings..................................................................................................................... 17
9.4. Changing the cup springs ...................................................................................................................... 21
9.5. Periodic maintenance............................................................................................................................ 24
10. Spare parts list....................................................................................................................................... 25

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 3of 25
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

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 4of 25
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.

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 5of 25
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.

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 6of 25
5. Technical data
5.1. Product performance
The type “ID 2000N-116” failsafe hydraulic brake has a tangential force of 116000 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] - 0.071 )
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 15 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.

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 7of 25
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.

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 8of 25
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 2000N-116 brake must be installed on a bracket having the same thickness as the disc
minus 2 mm (Figure 1).
The brake must be anchored using three M30 class 12.9 screws and tightening torque of 2300
Nm.
Figure 1
The fixed part which is to support the brake must withstand a tangential force of 126700 N
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; the pressure not exceed 220 or drop below 200 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 (Photo 1);
failure to follow this rule could result in fingers being crushed and other dangers in
addition to damage to the brake itself.

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 9of 25
Photo 1
4. Supply the brake and remove the safety hook (C62257) from the seat of the thruster which
protrudes from the cover (Photo 2). To prevent the safety hook from getting lost while the
brake is in operation, attach it to the side part of the caliper block (Photo 3) using the TCEI
M5x18 screw (C61372) as shown in assembly drawing A........ (use a CH BR 4).
Photo 2 Photo 3
5. The brake is supplied with a bleed vent cod. Z50315 (Figure 2) as in Photo 4. To bleed air out of
the circuit, loosen the retaining nut of the fitting (Photo 5) and pull the tubular cap outward.
After bleeding off the air tighten the fitting again.
Photo 4 Photo 5
(Z50315)

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 10 of 25
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.
6. Rotate the play adjuster (D71244) in the clockwise direction using a CH BR 12 (Photo 6) until
the play between the disc and each lining is 1 mm (Photo 7).
Check the gap between the disc and each lining using a feeler gauge.
Pay particular attention during this regulation because rotating the gap regulator (D71244)
anticlockwise , this could tighten inside the thruster (D71243) and get definitely stuck.
Photo 6 Photo 7
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 (C61579) to lock the adjuster (D71244), located in the part of the thruster which
protrudes from the cover (seat of the safety hook); see also the assembly drawing (A........) to
1 mm

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 11 of 25
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 3 (Photo 8); when doing this, with the brake in operation or
during maintenance, the safety hook (C62257) must not be inserted in the seat of the thruster
(D71243) otherwise the operation cannot be carried out.
Warning: The brake is supplied with the wear adjuster NOT locked.
Photo 8
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.
a. Before starting the bedding-in, ensure that the lining and disc surfaces are dry and clean.
b. Slide the linings on the disc until the disc surface corresponds 100% to that of the
linings.
c. The disc temperature during bedding -in must not be higher than 100°C.
d. Clean the disc and lining surfaces so that there is no trace of dust or dirt.
e. After bedding-in check that the disc has no trace of burns.

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 12 of 25
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 200 bar as already explained in the preceding section.
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 (Photo 9)
2. Power up the brake with the hand pump (Photo 10)
Photo 9 Photo 10
3. Check that the pressure indicated by the manometer of the pump (photo 11) at the
opening of the brake is the same as the one previously indicated

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 13 of 25
Photo 11
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.
Use of the product for purposes other than those stated in this manual may
compromise any aspect of safety.

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 14 of 25
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 (C61579) to unlock the wear
adjuster (D71244) (Photo 12). Rotate the play adjuster (D71244) in the clockwise direction
using a CH BR 12 (Photo 12) until the optimally play of 1 mm between the disc and each
lining has been restored.
Photo 12
Pay particular attention during this regulation because rotating the gap regulator
(D71244) anticlockwise , this could tighten inside the thruster (D71243) and get definitely
stuck.
2. Using a feeler gauge, check that the play between the disc and each brake lining is 1 mm
(Photo 13).

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 15 of 25
Photo 13
3. Following this operation, retighten the two safety grub screws (C61579) in order to prevent
possible rotations and movements of the wear adjuster (D71244) during operation of the
brake (Photo 14).
Photo 14
Pay particular attention during this regulation because rotating the gap regulator (D71244)
anticlockwise , this could tighten inside the thruster (D71243) and get definitely stuck.
9.2. Replacement of the lining pads and cleaning the friction surfaces
1. Power up the brake and insert the safety hook (C62257) in its seat of the thruster which
protrudes from the cover (Photo 15). 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)
1 mm

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 16 of 25
Photo 15
2. Loosen the screws (C61397) which anchor the plates (C62242) to the brake (Photo 16) and
extract the brake lining guide pins (C62255), without removing the other screws (C61397)
which connect the plates to the pins (Photo 17).
Photo 16 Photo 17
3. Pull out the lining pads sideways (Z50330, Z50380 o Z50352) as in Photo 18 until they
detach from the magnets (C62344) incorporated in the play adjuster (D71244) (Photo19).
Photo 18 Photo 19

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 17 of 25
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 the brake linings back following the reverse sequence as described in points 3 and 2.
7. Power up the brake and remove the safety hook (C62257). (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 (C62257) in its seat of the thruster which
protrudes from the cover (Photo 20).
Photo 20
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 (C62257) (Photo 21).
Foto 21

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 18 of 25
6. Cut off the control pressure and disconnect the power line.
7. Remove the lining pads as described in points 2 and 3 of section 9.2.
8. Unscrew the anchoring screws (C61421) (Photo 22), remove the cover (D71242) (Photo 23)
and the cup springs (C62410) (Photo 24).
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.
Photo 22 Photo 23 Photo 24
9. Remove also one shim C62256 for the ID 2000N-58 brake and two shims C62256 + one shim
C62295 for the ID 2000N-116 brake (Photo 25).
10. Remove the play adjuster (D71244) from the thruster (Photo 26).
Photo 25 Photo 26
11. Carefully remove the thruster (D71243) from the brake body (E80834) carefully allowing
compressed air to enter from the feed hole (Photo 27) until the thruster has come out
completely (Photo 28).

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 19 of 25
Photo 27 Photo 28
12. Remove the damaged gaskets (Photos 29 and 30) and guide rings (Photo 31) and replace
them. It is advisable to replace all the gaskets and all guide rings to avoid further down
time. COREMO OCMEA provides a complete kit with 4 gaskets and 2 guide rings.
Photo 29 Photo 30 Photo 31
13. Put the play adjuster (D71244) in the thruster (D71243) (Photo 32) then insert this
assembly back in the brake body (E80834) (Photo 33).
Photo 32 Photo 33

User and Maintenance Manual
Failsafe hydraulic brake ID 2000N
Model ID 2000N-116
Date: 2014/06/27
Revision: 1.1
www.coremo.it
Page 20 of 25
14. Put back the cup springs (Photo 34).
Photo 34
15. Put back the cover (D71242) on the brake body (E80834) using the screws (C61421) and
washers (C61321) (Photo 35). Tighten the M10 class 12.9 (C61452) screws in a diagonal
sequence with a tightening torque of 79 Nm (Photo 36).
Photo 35 Photo 36
16. Put back the lining pads following the reverse sequence of the procedure described in
points 3 and 2 of section 9.2.
17. Connect the power line, power up the brake and insert the safety hook (C62257) in its seat
on the thruster which protrudes from the cover.
18. Cut off the control pressure and disconnect the power feed line.
19. Reinstall the brake on the machine.
20. Reconnect the power feed line and power up the brake.
21. Remove the safety hook (C62257) and bleed air from the circuit as described in point 5 of
section 7.