Kobelt 5024-A Instruction Manual

KOBELT MANUFACTURING CO. LTD MNL-5024-A.docx (rev A) 1
5024-A DISK BRAKE
AIR APPLIED VERSION
Owner’s Operation, Installation &
Maintenance Manual

KOBELT MANUFACTURING CO. LTD MNL-5024-A.docx (rev A) 2
Table of Contents
1Introduction ..................................................................................................................4
1.1 Contact Information......................................................................................................4
1.2 Safety Information ........................................................................................................4
1.2.1 Safety Alerts..............................................................................................................4
1.2.2 Safety Instructions ....................................................................................................5
1.2.3 Hazards .....................................................................................................................5
1.3 Product Description.......................................................................................................6
1.3.1 Overview...................................................................................................................6
1.4 Technical Data...............................................................................................................6
1.5 Model Code Key ............................................................................................................7
2Installation ....................................................................................................................8
2.1 Preparation ...................................................................................................................8
2.2 Brake Discs ....................................................................................................................8
2.3 Caliper brakes..............................................................................................................10
2.3.1 Mechanical..............................................................................................................10
2.3.2 Piping ......................................................................................................................10
3Commissioning ............................................................................................................12
3.1 Air Gap ........................................................................................................................12
3.2 Function Test...............................................................................................................12
3.3 Burnishing ...................................................................................................................12
3.4 Torque Test .................................................................................................................13
4Operation....................................................................................................................14
4.1 Functional Requirements ............................................................................................14
4.1.1 Pressure Supply.......................................................................................................14
4.2 Service Limits ..............................................................................................................14
4.2.1 Disc Temperature....................................................................................................14
4.2.2 Ambient Temperature ............................................................................................14
4.2.3 Pressure ..................................................................................................................14
4.2.4 Disc speed...............................................................................................................15
5Maintenance ...............................................................................................................15
5.1 Preventative Maintenance..........................................................................................15
5.2 Inspection....................................................................................................................15
5.2.1 Pad Wear ................................................................................................................15
5.2.2 Seals........................................................................................................................16
5.2.3 Pin Wear .................................................................................................................16
5.2.4 Brake Disc ...............................................................................................................16
5.3 Service.........................................................................................................................17
5.3.1 Lubrication..............................................................................................................17

KOBELT MANUFACTURING CO. LTD MNL-5024-A.docx (rev A) 3
5.3.2 Stroke Adjustment ..................................................................................................17
5.3.3 Brake Linings...........................................................................................................17
5.4 Recommended Spares.................................................................................................18
6Warranty.....................................................................................................................20
7Appendix A: Technical Drawings...................................................................................21
8Appendix B: Parts List Drawings...................................................................................23

KOBELT MANUFACTURING CO. LTD MNL-5024-A.docx (rev A) 4
1INTRODUCTION
1.1 CONTACT INFORMATION
Kobelt Manufacturing Co. Ltd.
8238 129th Street
Surrey, British Columbia
Canada, V3W 0A6
Sales Tel:
Fax:
Email:
Website:
[phone]
[phone]
[email protected]
www.kobelt.com
For further instructions, please contact our distributors or visit our website.
1.2 SAFETY INFORMATION
1.2.1 Safety Alerts
Throughout this manual, the following symbols, and their accompanying explanation, are used
to alert the user to special instructions concerning a service or operation that may be hazardous
if performed incorrectly or carelessly. The associated risk levels are stated below.
This symbol indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
This symbol indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
This symbol indicates a hazardous situation, which if not avoided, could
result in minor or moderate injury.
This symbol informs the reader of events not related to personal injury but
which there is a risk of damage to property or equipment.
This symbol informs the reader of safety-related instructions or procedures.

KOBELT MANUFACTURING CO. LTD MNL-5024-A.docx (rev A) 5
1.2.2 Safety Instructions
Notice to Installer:
Disregarding the following safety measures can result in an accident causing severe injury to
personnel and damage to material assets:
•Only use the product as directed in this manual.
•Never put the product into service if there is evidence of visible damage.
•Never put the product into service before fully completing installation and
commissioning.
•Do not carry out any modifications to the product.
•Only use authentic Kobelt spare parts.
•Observe all local regulations, directives and laws during the installation of this product.
•All installation, commissioning and maintenance work must only be conducted by
qualified personnel. (For the purpose of this manual, qualified personnel are persons
who are familiar with the assembly, installation, commissioning, and operation of the
product and who have the qualifications necessary for their occupation.)
•Observe all specifications in this manual. If these guidelines are not followed and
damage occurs, the warranty will be voided.
1.2.3 Hazards
Equipment Starts Automatically:
Brake systems frequently are controlled remotely and may activate suddenly
causing bodily harm. Ensure all power sources are locked out prior to
performing work.
Brake Actuators Contain Compressed Springs:
The brake actuators contain springs that are under compression even when
the brakes are not pressurized. The springs will release suddenly if
disassembled incorrectly posing a risk of serious injury or death.
Pinch Points:
Brakes contain numerous pinch points which can cause serious injury.
Ensure all power sources are locked out prior to performing work.
High Pressure Fluids:
Kobelt lever brakes use pressurized air. Ensure all pressure is exhausted and
the pressure source locked out prior to performing work.
Hot Surfaces:
Disc brakes are capable of making the surfaces of the brake disc dangerously
hot when burnishing or during braking events. Ensure the disc is adequately
guarded to prevent inadvertent contact with the disc.