Tulip BrakeMate User manual

Operating Manual
WARNING
Do not operate BrakeMate® before carefully reading and understanding
the operating and safety instructions contained in this manual.
Brake maintenance should only be undertaken by properly trained
personnel.
Standard workshop personal protection equipment should be worn.
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TABLE OF CONTENTS
1. CORRECT APPLICATION...................................................................3
2. DESCRIPTION OF BRAKEMATE® SYSTEM........................................3
a. System overview.......................................................................3
b. Main technical data..................................................................3
3. WARNINGS AND SAFETY INSTRUCTIONS........................................5
4. DAILY INSPECTION..........................................................................5
5. OPERATING INSTRUCTIONS...........................................................6
a. Preparation of vehicle..............................................................6
b. Calliper removal......................................................................6
c. Hub/Rotor removal..................................................................7
d. Separating Hub and Rotor.......................................................9
e. Changing rotor......................................................................10
f. Re-fitting Hub/Rotor assembly...............................................10
g. Re-fitting of Calliper...............................................................10
7. MANUFACTURER AND WARRANTY DETAILS................................11-14
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1. CORRECT APPLICATION
BrakeMate® is to be used only as described in this Operating Manual.
The BrakeMate® Hub/Rotor Trolley and the BrakeMate® Service Trolley are
engineered specifically for this task and are not to be used for general lifting or any
other purpose. BrakeMate® is designed to be used in a workshop environment on a firm,
level surface.
2. DESCRIPTION OF BRAKEMATE® SYSTEM
a. SYSTEM OVERVIEW
BrakeMate® is designed to eliminate the need for manual lifting of heavy brake
components when servicing disc brakes and bearings on heavy vehicles. The system
also utilises hydraulics to remove the hub/rotor assembly from the vehicle and
separate these components. BrakeMate® is comprised of two trolleys, the Hub/Rotor
trolley and the Service Trolley.
BrakeMate® is designed to assist with the following tasks.
- Removing and refitting calliper.
- Removing and refitting hub and rotor.
- Separation of hub and rotor.
- Changeover of rotors.
-Controlled realignment of hub to axle.
b. MAIN TECHNICAL DATA
Hub/Rotor Trolley (Fig. 1)
The BrakeMate® Hub/Rotor Trolley is operated by an air over hydraulic system. The air
operated hydraulic pump is rated at 5000 PSI and controls the up/down motion of the
trolley via the main ram. A limit switch stops the unit at working height and also protects
the ram from over travel. An additional manually operated10 tonne hydraulic ram is
used to remove the hub from the axle and separate the hub/rotor assembly.
Service Trolley (Fig. 2)
The BrakeMate® Service Trolley contains a manual hydraulic ram controlled by a foot
pump and pressure release lever. The Service Trolley has a maximum lift height of
1300mm.
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Fig.1 - BrakeMate® Hub/Rotor Trolley
Fig.2 - BrakeMate® Service Trolley
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3. WARNINGS AND SAFETY INSTRUCTIONS
Do Not
Put hands or feet in scissor lifting mechanisms.
Operate on sloping or inclined surfaces.
Lift people or any items other than brake components indicated in these instructions.
Use any extension bars on hydraulic puller handle.
Use torque wrenches or breaker bars whilst components are mounted on trolleys.
Modify BrakeMate® in any way or adjust settings without prior written permission of
manufacturer.
DO NOT OPERATE LIFTING MECHANISIM WHEN ATTACHED TO VEHICLE
Caution
Compressed air can be dangerous. Exercise caution when connecting and disconnecting
BrakeMate® from air supply. Safety glasses and gloves should be worn.
BrakeMate® controls should only be operated by one person at a time. Before raising or
lowering BrakeMate® Hub/Rotor Trolley or BrakeMate® Service Trolley, ensure all
persons are well clear of the area.
4. DAILY INSPECTION
The following tasks must be carried out each day prior to operating BrakeMate®
Inspect all airlines and hydraulic hoses for leaks or signs of cracking. Replace any
damaged items only with items of an equal or greater pressure rating.
Ensure all bolts, fasteners and fittings are secure and there are no damaged parts
Ensure both trolleys are free from foreign objects.
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5. OPERATING INSTRUCTIONS
a. PREPARATION OF VEHICLE
The following steps must be undertaken to prepare the vehicle prior to using BrakeMate®.
Remove wheel
Remove Brake Booster
Remove Calliper bolts (Leave 2 bolts finger tight for security)
Remove Hub Nut and/or Drive Axle
Ensure vehicle is correctly supported and standard workshop practices are followed during this
process. Tidy floor of work area to allow clear access of BrakeMate® Trolleys
b. CALLIPER REMOVAL
Remove Calliper Clamp (Fig. 3) from Service Trolley bracket.
Attach Calliper Clamp to calliper by positioning directly above the rotor, between the
inner calliper surfaces and the outer edge of the rotor. Tighten Calliper Clamp using a
30mm socket or spanner until firmly attached by winding threaded shaft until the clamp
locks. A rocking motion may be required to ensure clamp settles between calliper and
rotor.
Fig 3. Calliper Clamp mounted on calliper
Fully extend linear shaft on Service Trolley and tighten knob to lock in position.
Manoeuvre Service Trolley and adjust height using foot pedal so that linear shaft aligns
with Calliper Clamp. Insert lineal shaft into Calliper Clamp until spring loaded clip locates
in groove.(Fig.4)
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Remove remaining calliper bolts and lift calliper clear of rotor by raising trolley using foot
pedal. Manoeuvre Service Trolley until calliper is clear of the vehicle. Loosen knob on
linear shaft and retract linear shaft until calliper is against Service Trolley. Tighten knob
again to secure.
Fig.4 Linear Shaft inserted into Calliper Clamp
At this stage the ServiceTrolley can be moved away from the immediate work space and
either transfer the calliper to a workbench if a service is needed, or lower table and park
it ready for the rotor change over process. (Service trolley should be at lowest height
prior to manoeuvring around workshop)
c. HUB/ROTOR REMOVAL
Check that Face Plate is correct for stud pattern of vehicle. Manoeuvre Hub/Rotor Trolley
so that Face Plate aligns with wheel studs. (Fig. 5). Use ↑(up) ↓(down) control buttons
to adjust height. The black safety buttonmust held down whenever operating the
up/down functions.Use Pitch Adjustment Knob (Fig.6)to square Face Plate to hub. This
ensures correct realignment of hub when returning to vehicle. Firmly secure face plate to
studs using two wheel nuts.
Fig. 5 Face Plate aligned with hub Fig.6 Pitch Adjustment Screw
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Lift Hydraulic Puller into position and insert threaded centre into puller. Insert RED Arms
into lugs on Face Plate. Wind threaded centre in to contact stub axle. (Fig. 7) For Drive
axles insert appropriate size Disc into slots in Puller Centre to push off hollow axle.(Fig. 8)
Fig. 7 Hydraulic Puller in position with Fig. 8 Disc fitted in Puller Centre
arms attached to Face Plate and Threaded
Centre in fitted.
Operate Hydraulic Puller to remove hub/rotor assembly from axle.
Once hub/rotor assembly is free from axle manoeuvre Hub/Rotor Trolley with assembly
attached away from vehicle to a clear area. (Fig. 9)
IMPORTANT - DO NOT use extension bars on handle of Hydraulic Puller.
BrakeMate® is not designed to remove hubs with seized or welded bearings.
If hub does not separate from axle using BrakeMate's10 tonne puller, use other means
to break bond prior to continuing to use BrakeMate®.
Fig. 9 Hub/Rotor assembly clear of vehicle.
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d. SEPARATING HUB AND ROTOR
Raise Hub/Rotor Trolley to the full height position. This is a set position governed by a
limit switch. Raise Service Trolley to match height of locating rod on Hub/Rotor Trolley.
Manoeuvre Hub/Rotor trolley to insert the locating rod into tube on Service Trolley, then
tighten knob to secure (Fig. 10) (Adjust sliding plate on trolley to suit hub if required)
Fig. 10 Hub/Rotor Trolley mated with Service Trolley
Release Red Arms from Face Plate and lower Hydraulic Puller.
Remove bolts securing rotor to hub and then lift Hydraulic Puller into position again and
reattach Red Arm to Face Plate. Fit BLUE Arms to Hydraulic Puller by inserting pin into
hole best suited to hub/rotor distance. (Fig. 11) Position clamp ends of Blue Arms onto
rotor and tighten knobs to secure. (Fig. 12) The hydraulic puller can now be used to push
the rotor/hub assembly apart.
Fig. 11 Fitting Blue Arms Fig. 12 Securing clamps to rotor
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e. ROTOR CHANGE OVER
Remove Blue Arms and return to storage position. Release Red Arms and lower Hydraulic
Puller. Slide old rotor forward onto Rotor Support Cradle, then roll rotor into bracket on
carousel of Support Trolley. (Fig. 13)Tighten knob to secure rotor.
Rotate carousel through 180° and roll new rotor onto Rotor Support Cradle.
Manoeuvre new rotor onto hub and reinstall bolts to secure. (Fig.14)
Fig. 13 Rolling rotor onto carousel Fig. 14 Securing new rotor to hub
f. RE-FITTING HUB/ROTOR ASSEMBLEY
Separate Hub/Rotor Trolley from Service Trolley.
Adjust height of Hub/Rotor trolley and manoeuvre to align with axle.
Secure hub/rotor using procedures applicable to vehicle.
g. RE-FITTING CALLIPER
Extend Linear Shaft with Calliper attached and manoeuvre Service Trolley and adjust
height to position calliper directly above rotor. Carefully lower calliper onto rotor,
allowing calliper to rotate into position around rotor. Use blue handle on Calliper Clamp
for fine adjustment of mount hole alignment. Insert two calliper bolts. Withdraw linear
shaft from Calliper Clamp, then remove Calliper Clamp from calliper. Return Calliper
Clamp to storage position on Service Trolley. Refit remaining calliper bolts following usual
procedure.
ENSURE ALL FASTNERS ARE TORQUED TO MANUFACTURERS SPECIFICATIONS AT APPROPRIATE
TIMES DURING SERVICE.
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