ZPMC

HBBJ1500-400 Hydraulic Band Brake

Operator’s Manual

ZPMC(GROUP) FENGCHENG BRAKE Co., LTD.

Version No.：3.0 Copyright reserved Date：May 20, 2007

1. General
HBBJ1500-400 hydraulic band brake (hereafter shortened form brake) is mainly used
for deceleration and stop/braking of anchor and ream mechanisms in large-scale and medium
floating cranes.
HBBJ1500-400 hydraulic band brake is released by hydraulic drive, and applied by
screw compression spring. The construction of the brake is shown as Fig.1, which operation
principle is: when pressure oil in the hydraulic power unit enter cylinder through magnet valve,
hydraulic oil push up piston rod, then the brake spring is compressed further to make steel belt
rotate around built-in end, so that the brake shoes is free of the brake drum, the braking torque
remove; When magnet valve is de-energized, hydraulic oil reflux oil tank, and spring force
through set square pass through rod to the belt and friction lining, exerting on the wheel, then
brake torque is established.

Fig 1
1，Free end rod 2、fixed end rod 3，set square 4，switch touch board 5，proximity switch
6、cylinder 7，brake spring 8、brake rod 9、spring seat 10、manual wheel locking
mechanism 11、steel belt 12, clearance adjustment device 13，frame

Technical parameter for HBBJ1500-400 is shown as the following table

Release
Release
Type pressure Rated torque clearance
oil volume
（rated /max.）
HBBJ1500-400 10-12Mpa 1570mL 400KN.m 2mm

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2. Installation and adjustment
2.1lifting and transportation
The brake should be lifted appropriately to prevent damage. HBBJ1500-400 brake has larger
weights, so you should use crane or jacks to handle it. Prevent steel belt from distorting
2.2 Preparations before installation
In order to ensure the brake operating properly, please install the brake in accordance with
the procedure stipulated in the manual correctly. If you need assistance of installation, please
contact with the company
2.2.1 Inspection of the brake and wheel
a. Check if the type of brake meets requirements;
b．Are the parts and components of the brake complete;
c．Check if various hinged points have rust or jamming.
d．If there is any oil (grease), paint or other contamination stuck on the brake lining that may
affect the friction force;
e．The surface of the brake drum shall not have defects such as corrosion, oil (grease)
contamination, unevenness and etc. The brake drum which has cracks or any other defects is
strictly prohibited from using;
If any of all above do not meet the requirement, please resolve the trouble firstly before
installation.
2.3 Installation
a. The position of bearing pull rod refers to bearing site welding in fig 1.
b. In order to insure assembly technical requirements, install the brake according to assembly
drawing.
c. Adjust spring compression allowance to insure enough torque when braking.
d. Connect the cable (signal indicating) of limit switch, and the connecting must be firm.
e. Connect the brake with hydraulic pipeline (the installation and adjustment of hydraulic power
unit refer to operator’s manual), and check whether it is leakage.
2.4 Adjustment
The brake shall be adjusted before first installation (operation) or after replacement of the
brake lining. In first installation, please strictly follow the following orders:
a. The adjustment of spring torque：screw down the pull rod after assemble spring subassembly,
fix spring holder, then pass over the pressure oil to the cylinder, continue compressing the spring,
revolve the handwheel locking device, then release pressure oil, spring reset, after that, the
length is to adjust about 540mm. When braking, the spring compresses to 580 mm, the rated
torque can be achieved.
b. The adjustment of steel belt clearance balancing：Open the brake, observe if the clearance of
steel belt along the wheel circumference is consistent, if not, adjust the adjustment bolt of
bracket subassembly (piece 12, four groups) to be equal. The method to adjust is that screw the
adjustment bolt towards steel belt direction, then open and close the brake 3~5 times, observe if
the clearance is equal, if not, repeat the above step, adjust the different bolt until be equal, finally
tighten he lock nut in the bolts.
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c. The adjustment of limit switch：release indicating switch (B1) is installed in the brake, it is
limit switch, it can connect with control system according to main machinery’s requirements.
3. Operation and maintenance
3.1 Operation of brake
3.1.1 The following check shall be carried out before using brake.
a. Check if the installation of brake meets requirement;
b The adjustment and testing of brake meets requirement;
c. Check if there is oil (grease) contamination on the brake lining and brake disc.
Check everything is normal, run-in can be done.
3.1.2 Running-in
Please run-in according following step after all check are confirmed:
a. Run-in without load 10~20 times; (drive motor and wheel run-in), if abnormal, run-in till
normally.
b. Operate the brake 10~20 times with 50% load, observe if the braking state is steady (each
braking distance must be same), if so, the brake can run-in for 3~5 times with full load;
c. During run-in, check the following conditions regularly: 1. the joint condition of lining and
disc 2. disc temperature (not more than 100℃)；3. Fittings of screw thread loosen；4. the action
of limit switch is right；5. The braking and operating sound is normal；6. Hydraulic system is
leakage
The brake can be operated only after running-in is normal.
3.2 Maintenance of brake
3.2.1 Brake should be checked every 3~7 days as following:
a． Check if there is oil (grease) on the brake drum and brake shoe；
b．Surface wear should not be over 2mm, or replace the brake wheel.
c． Check the wear of brake lining. The brake lining shall be replaced if its thickness is worn
to <10mm only. After replacement of brake lining, running in shall be carried out;
d．Check whether fittings of screw thread loosen.
e． Check whether hydraulic system is leakage.
f． The operation of limit switch is exactly correct;
g．Check whether clearance has change.
If abnormal situation is found, please stop operating the brake and deal with the fault or
adjust brake again.
3.2.2 Replacement of brake lining
When friction material of lining thickness is less than 10mm, the lining must be changed
(total thickness of lining is 15mm,), the changing method is following:
a. Unscrew the springs on both sides, remove the torque;
b. Tighten the connecting bolt of belts, and dismantle all the bolts in the linings, then take out
brake lining.
c. Check if the surface of new brake lining is clean. If not, please clean firstly with dishcloth.
d. Set the brake lining key way engage to the linking key with bolt and lock washer.
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 e. Install steel belt in the brake over again.
After install new lining, adjust according to 2.4, then check and run-in according to 3.1 till
everything is normal.