Eaton Airflex DPA User manual

Airex DPA Caliper Brake
CA 10020 – Installation, operation and maintenance manual 204204

EATON Airex DPA Caliper Brake Installation, operation and maintenance Manual E-CLCL-II010-E October 20152
Warning
Forward this manual to the person responsible for Installation,
Operation and Maintenance of the product described herein.
Without access to this information, faulty Installation,
Operation or Maintenance may result in personal injury or
equipment damage.
Caution
Use Only Genuine Airex®Replacement Parts
The Airex Division of Eaton Corporation recommends the
use of genuine Airex replacement parts. The use of
non-genuine Airex replacement parts could result in
substandard product performance, and may void your Eaton
warranty. For optimum performance, contact
Airex:In the U.S.A. and Canada: [phone]
Outside the U.S.A. and Canada: [phone]
Internet: www.eaton.com/airex
!!
Airflex DPA Caliper Brake
General infor mation

EATON Airex DPA Caliper Brake Installation, operation and maintenance manual E-CLCL-II010-E October 2015 3
Table of contents
Section Description Page
1.0 Introduction 5
1.1 Description 5
1.2 How it works 5
2.0 Installation 6
2.1 Mounting 6
2.2 Allignment 6
2.3 Preparation 6
2.4 Actuating medium supply 6
3.0 Operation 7
3.1 Pressure limits 7
3.2 Discs 7
3.3 Initial operation 7
4.0 Maintenance 7
4.1 Periodic inspection 7
4.2 Periodic maintenance 7
4.3 Friction material replacement 7
4.4 Piston seal replacement 8
5.0 Ordering information / Technical assistance 9
5.1 Equipment reference 9
6.0 Parts standard 10
7.0 Rebuild kit 10
7.1 Seat kit 10
8.0 Revisions 11

EATON Airex DPA Caliper Brake Installation, operation and maintenance Manual E-CLCL-II010-E October 20154
Figure 1
10
4
11 12
1
6
12 13 3
9
10
8527
Airflex DPA Caliper Brake
Item Description
1 Cylinder
2 Caliper Piston
3 Caliper Guide Pin
4 Friction Sub Assembly Shoulder Screw
5 Caliper Friction Sub Assembly
6 Return Spring
7 U Seal
8 Rod Wiper
9 45DEG Elbow, 37DEG Flare X 1/8" NPT Male
10 Air Bleeder
11 M16X2.0 X 130 Hex Head Screw
12 Flat Washer
13 M16 X 2.0 Hexagon Nut
14 Name Plate
15 Warning Plate
Table 1
Parts description
Basic assembly

EATON Airex DPA Caliper Brake Installation, operation and maintenance manual E-CLCL-II010-E October 2015 5
1.0 Introduction
Throughout this manual there are a number of
HAZARD WARNINGS that must be read and
adhered to in order to prevent possible personal
injury and/or damage to the equipment. Three signal
words "DANGER", "WARNING", and "CAUTION" are
used to indicate the severity of the hazard, and are
preceded by the safety alert symbol .
Danger
Denotes the most serious injury hazard, and is used
when serious injury or death will result from misuse
or failure to follow specic instructions.
Warning
Used when serious injury or death may result from
misuse or failure to follow specic instructions.
Caution
Used when injury or product / equipment damage
may result from misuse or failure to follow
specic instructions.
It is the responsibility and the duty of all personnel
involved in the installation, operation and
maintenance of the equipment on which this device
is used to fully understand the
Danger, Warning, and, Caution
procedures by which hazards are to be avoided.
1.1 Description
Throughout this manual, explanations mentioning
specic components of the caliper brakes are often
followed by numbers in parentheses, which refer to
the item numbers on Figure 1 Friction shoe
assembly (5).
1.1.1 Eaton Airex 200DPA caliper brakes are ideally
suited for many high torque, high energy stopping
applications. By properly choosing actuating pressure,
number of calipers per disc,number of discs and disc
diameter, a braking system can be custom designed
for a wide variety of applications.
1.1.2 These models are opposed-piston, direct-acting,
disc-style brakes, activated by hydraulic or pneumatic
pressure. The braking torque is directly proportional
to the applied pressure.
1.1.3 The symmetrical split housing construction makes
it possible to accommodate brake discs of different
thicknesses. Friction shoes attach to the cylinders
and are replaceable without disturbing the caliper
mounting. Applying pressure to the cylinders
piston causes the friction shoes to clamp the disc,
developing the braking torque.
1.1.4 The brake design includes guide pins, which transmit
the tangential braking force from the brake pads to
the brake housings. Therefore the brake piston is not
subjected to radial force extending brake life.
1.1.5 Retracting springs, help retract the brake pads from
the disc, while brake pad wear is automatically
accommodated by an increase of the piston stroke.
1.1.6 These calipers can be air or hydraulic actuated.
Seals are compatible for either actuating media.If
hydraulic actuation is to be used, use mineral
base hydraulic uid.
1.1.7 All Airex 200DP caliper brakes are supplied with
long wearing, NON-ASBESTOS friction material.
1.1.8 This manual includes English measurement system
values with metric equivalents usually shown in
parentheses (XX). Please be sure to use the
correct value.
1.2 How it works
1.2.1 Air or hydraulic pressure is introduced into both
the cylinder blocks (1) via the input tting (9).Both
pistons (2) move simultaneously and squeeze the
piston-mounted friction shoe assemblies (FSA) (5)
against the disc, causing a braking action. When the
actuation pressure is released to '0' psi (bar), the
return springs (6) retract the friction shoes from
the disc.
Airflex DPA Caliper Brake

EATON Airex DPA Caliper Brake Installation, operation and maintenance Manual E-CLCL-II010-E October 20156
2.0 Installation
2.1 Mounting
2.1.1 There are four ½" - 13 X .75 tapped holes in the
base of the cylinder block. These are to be used for
mounting the brake to a rigid surface. The
brake-mounting bracket should be fabricated to butt
against the base of the cylinder block. This bracket
must also be of sturdy construction and rigidly
mounted to prevent deection during operation.
2.1.2 For hydraulic actuation installations, install the brake
with the bleeder (10) as high as possible.
2.1.3 First install the disc, and then clamp the caliper brake
to the disc with either air or hydraulic pressure.
Caution
Before locating the holes for drilling, make sure the
brake friction pads completely engage the disc so
they do not overhang the outer edge of the disc.
The outside diameter (O.D.) of the disc must not rub
against the cylinder block (1).
2.2 Alignment
2.2.1 Align the caliper so that the friction pads make full
contact with the discs. Partial engagement of the
disc will greatly decrease the braking effectiveness
of the caliper and cause malfunction.See Figure 2.
2.2.1 It is very important that the mounting bracket be
properly aligned with the mounting surface of
the brake. When proper alignment is achieved
the surface of the disc should be parallel with the
adjacent surface of the brake shoe. See Figure 3. For
proper operation and service life, alignment of the
mounting surface to the shaft of the disc gear should
be held within specied tolerance limits.
Angular alignment tolerance:
Angular misalignment between disk and the
caliper should not to exceed 0.0005 inches / per
inch diameter, at which the readings are taken.For
example, readings taken at a diameter of 10 inches,
multiplied by .0005" (the allowable offset per inch),
equals the total allowable offset .005".Example
10.00"(Diameter) X .0005" (Allowable offset per inch)
= .005" (Total allowable offset).
2.2.2 Before nal tightening of the mounting screws,apply
the brake, tighten the screws, release the brake and
check the alignment again.
2.3 Preparation
The friction discs should be protected from being
contaminated by oil, grease,dirt or
excessive moisture.
2.3.1 Friction shoe gap
The initial gap between the friction shoes and the
disc should approximately 0.053 inches (1.3mm). The
maximum gap between friction pads and disc during
operation should be 0.28 inches (7.3 mm), this will
be seen with fully warn friction shoes. Note that the
gap will become larger as the friction material is worn
away during operation.
2.4 Actuating medium supply
Actuation medium is supplied to the brake via
connections (9) on both cylinder blocks. Connection
details are: 37° are, 1/4" OD tube, 1/8-27 NPT
thread.Before assembly, actuation medium supply
tubes should be clean and free of any debris.
2.4.1 Hydraulic actuation system
Warning
Maximum allowable actuation pressure is 2000 psi
(138 bar). Exceeding the maximum pressure may
result in personal injury or damage to the brake
components. For hydraulically actuated systems,
remove any air from the system by following
instructions found in Section 4.2.1 later in
this manual.
Airflex DPA Caliper Brake
Incorrect Correct
Incorrect Correct
Figure 3
Figure 2

EATON Airex DPA Caliper Brake Installation, operation and maintenance manual E-CLCL-II010-E October 2015 7
Airflex DPA Caliper Brake
3.0 Operation
Warning
Do not overheat the brake pads. Maximum
recommended temperature on the brake disc surface
is 392° F (200° C).
3.1 Pressure limits
Warning
Maximum allowable operating pressure is 2000
psi (138 bar). Exceeding the maximum allowable
pressure may result in personal injury or damage
to the brake.Due to the spring force, a minimum
pressure of 8 psi (.6 bar) is required to engage new
friction shoes. Thirteen psi (.9 bar) is required with
worn friction material.
3.2 Discs
Minimum disc diameter is 12 inches (304.8 mm).
3.3 Initial operation
Before putting the brake into operation a short wear-
in period is required before generating full rated
torque. Use the brake to slow and stop the machine
a number of times. The brake shoes are ready for
operation when the entire surface of the friction shoe
shows signs of contact and discoloration.
4.0 Maintenance
4.1 Periodic inspection
The friction discs should be checked to make sure
that they are not contaminated by oil, grease, dirt or
excessive moisture. Brake pads should be replaced if
the friction material has absorbed oil or grease.
Warning
Contamination of the friction material will signicantly
reduce the torque capacity of the brake and/or result
in erratic torque. Observe the friction shoes with
the actuation pressure at zero Psig/ bar. If the brake
shoes do not release from the disc, it may indicate
the calipers are not releasing.
Caution
Damage to the guide pin (3) and shoulder screw (4)
will result if the lining is allowed to wear beyond this
point.
4.2 Periodic maintenance
The piston (2) should be inspected when pressure
is applied and the brake shoes do not move. If
inspection of the piston shows signs of wear or
damage it should be replaced.
4.2.1 Bleeding the hydraulic system
Warning
Use appropriate gloves and eye protection equipment.
Caution
Do not work on the brake while the system is
pressurized. Pinch points exist when pressurizing the
brake and injury may occur.
Caution
Re-tighten the bleeder valve before releasing the
applied pressure to avoid drawing air back into
the system.
Find the air bleeder connection (10) on each of the
cylinder blocks (1). Apply hydraulic pressure of 8PSI
standard operating pressure, to the actuation media
connection (9); gently loosen the bleed screw,
venting the air from the system. During this operation
uid will escape, the amount depends upon the
number of times needed to thoroughly vent the air
from the system. Retighten bleed screw once the
air has been removed from the system. Repeat this
procedure on both brake cylinders, and as many
times as necessary to remove all the air bubbles from
the system.
Caution
Prevent contamination of friction material.
Caution
During the bleeding operation, make sure that an
adequate supply of uid is available to prevent air
from entering the system.
4.3 Friction material replacement
Caution
Keep replacement friction material clean and free
from oil and grease during storage. Use only genuine
Airex friction material. Use of non-original Airex
material may result in unpredictable performance.
The brake does not need to be removed in order
to replace friction material. Doing so may require
realignment of the brake.
4.3.1 Friction material wear adjustments
There are no wear adjustments necessary with
this caliper.
4.3.2 Friction material wear limits
An inspection is required to determine when the
friction shoes should be replaced. New friction lining
thickness is 0.315 inches, (8 mm), not including the
backing material. See table 2 for wear limits

EATON Airex DPA Caliper Brake Installation, operation and maintenance Manual E-CLCL-II010-E October 20158
Table 2
4.3.3 Friction shoe removal
4.3.3.1 With the pressure off, remove the guide pins (3).Then
remove the shoulder screws (4) and returnspring (6).
Slide the friction shoe assembly (5) out.
4.3.4 Friction shoe replacement
4.3.4.1 Slide the new friction shoe assembly (5) in. Reinstall
the guide pins (3). Place the return spring (6) over the
shoulder screw (4) and apply Loctite #222. reinstall by
inserting the screw with the attached spring through
the bore in the caliper cylinder (1) and attach to the
Friction Shoe Assembly (5). Tighten the screws to the
values seen in Table 2.
4.4 Piston seal replacement
Warning
Only qualied maintenance personnel should install
piston replacement kits. Faulty workmanship may
result in possible personal injury, brake malfunction or
damage to the machinery.
Caution
Use only genuine Airex friction material.Use of
non-original Airex material may result in
unpredictable performance.
4.4.1 The caliper brake assembly must be removed from
the machinery in order to replace the piston (2), U
seal (7) and rod wiper (8). Remove the friction shoe
assemblies (5) as explained in section 4.3.3.1.
4.4.2 To remove the old piston (2), depressurize the
system. Split the brake by removing the 2 large
hex head bolts (11). Once the brake is split, a small
amount of line pressure may be needed to remove
the piston.
Caution
Do not use excessive pressure if the piston does not
slide out. Doing so may result in injury.
Once the piston (2) has been removed, remove and
discard the U seal (7) and rod wiper (8). Inspect the
cylinder for any corrosion or pitting. If the cylinder
is free of any galling, pitting, corrosion or abrasive
particles, clean the cylinder wall using a non-abrasive
oil free cleaning agent.
Caution
Keep the U seal and rod wiper grooves free of debris.
Coat the new U seal (7) and rod wiper (8) with a
compatible oil, and place them carefully into their
respective grooves. Also, coat the piston (2) wall with
compatible oil. Make sure the seal and rod wiper are
installed with the proper orientation.See Figure 4.
Caution
Do not damage the U seal or rod wiper.Damage to
these components may cause leaks.
4.4.5 Carefully place the piston (2) into the cylinder block
(1) making sure not to damage the U seal (7) or rod
wiper (8). Press the piston into the cylinder block until
fully inserted. It may be necessary to loosen the bleed
screws (10) on the cylinder block to bleed off the
pressure to fully insert the piston.
4.4.6 Slide the new Friction Shoe Assembly in. Reinstall the
guide pins and return the compression spring screws
as described in section 4.3.4.1. Then tighten the
screws to the values in Table 3.
Airflex DPA Caliper Brake
Figure 4
Lining 146505 (Standard)
145605A
146505B
in mm in mm
New 0.315 8.00 0.315 8.00
Needs Replaced 0.080 2.00 0.205 5.20
Fully Worn 0.010 0.25 0.010 0.25
Lining condition

EATON Airex DPA Caliper Brake Installation, operation and maintenance manual E-CLCL-II010-E October 2015 9
Airflex DPA Caliper Brake
Table 3
Fastener assembly torques
Fastener Description Torque (ft/lbs) Torque(nm)
3 Caliper 308453 **44 59.4
Guide Pin
4 Shoulder 308521 **88 9.94
Screw
13 Hex Head (M16 X 2.0) 140 Dry 189
ScrewX 130 Hex
**Assemble with Loctite #222
5.0 Ordering information /Technical assistance
5.1 Equipment reference
5.1.1 In any correspondence regarding Airex
equipment,refer to the information on the product
nameplate and call or write:
Eaton
Airex Division
9919 Clinton Rd.
Cleveland, Ohio 44144
Tel: [phone]
Fax: [phone]
Internet: www.airex.com
Loctite is a registered trademark of Henkel KgaA.

EATON Airex DPA Caliper Brake Installation, operation and maintenance Manual E-CLCL-II010-E October 201510
6.0 Parts (Standard)
Basic assembly
Standard 200DPA
146505 (Standard)
Item Description Part number Qty
1 Cylinder 515093 2
2 Caliper Piston 308452 2
3 Caliper Guide Pin 308453 4
4 Friction Sub Assembly Shoulder Screw 308521 4
5 Caliper Friction Sub Assembly 417043 2
6 Return Spring 308520 4
7 U Seal 000153X1277 2
8 Rod Wiper 000153X1272 2
9 45DEG Elbow, 37DEG Flare X 1/8" NPT Male 000153X1276 2
10 Air Bleeder 000153X1274 2
11 M16X2.0 X 130 Hex Head Screw 000391X1608 2
12 Flat Washer 000067X0059 4
13 M16 X 2.0 Hexagon Nut 000414X0011 2
14 Name Plate 308483 1
15 Warning Plate 308484 1
7.0 Rebuild Kit 146505 Only (Contact Eaton for kits related to other assemblies)
Kit P/N Description Pin (3) Friction shoe assembly Friction shoe Return spring (6)
shoulder screw (4) assembly (5)
146505Y Part No. 308453 308521 417043 308520
Quantity 4 4 2 4
7.1 Seat Kit
Model Kit P/N Description U-Seal Piston wiper ring (8)
200DPA 146505X Part No. 000153X1277 000153X1272
Quantity 2 2
Airflex DPA Caliper Brake

EATON Airex DPA Caliper Brake Installation, operation and maintenance manual E-CLCL-II010-E October 2015 11
8.0 Revisions
Original Publication Date: 2007
Revision Date Description Page
Airflex DPA Caliper Brake

© 2015 Eaton
All Rights Reserved
Printed in USA
Document No. E-CLCL-II010-E
October 2015
Eaton
Hydraulics Group USA
Airex Division
9919 Clinton Road
Cleveland, OH 44144-1077
Tel: [phone]
Fax: [phone]
Eaton
Hydraulics Group Asia Pacic
Airex Division
281 Fa Sai Road
Waigaoqiao Free Trade Zone
Shanghai 200131
China
Tel: [phone]
Fax: [phone]
Eaton product warranty
Subject to the conditions stated here in, Eaton
Corporation warrants to the Purchaser that each
new Airex Product manufactured by Eaton will be
free from failures caused by defects in material and
workmanship, and will deliver its rated capacity,
for a period of twelve (12) months from the date of
shipment to Purchaser, provided such Product is
properly installed, properly maintained, operated under
normal conditions and with competent supervision.
Warranty claims shall, be made in writing and the
part or parts shall, if requested by Airex Division, be
returned repaid to the Airex Division for inspection.
Upon a determination that a defect exists, Eaton shall
thereupon correct any defect, at its option either by
repairing any defective part or parts or by making
available at Eaton’s plant a repaired or replacement
part. This warranty does not extend to normal wear
parts or components of the Product, such as friction
material and friction surfaces.
Limitation of warranty
The foregoing warranty is exclusive and in lieu of all
other warranties whether written, oral or implied.
Any implied warranty of merchantability or tness for
a particular purpose are specically excluded. In no
event shall eaton be liable for
In no event shall Eaton be liable for special,incidental
or consequential damages. Eaton’s liability arising out
of the supplying of such Product, or its use, whether
in warranty, contract or otherwise, shall in no case
exceed the cost of correcting defects in the Products
as herein provided. Upon expiration of the twelve (12)
month period, all such liability shall terminate.
The foregoing shall constitute the sole remedy of
purchaser and the sole liability of eaton.