Name: MEB-0300-062

Date: 16.03.2016
Revision: H

Installation and Maintenance

Manual

HYDRAULIC ACTIVE
MONO SPRING
DISC BRAKE
BSAK 300-MS30S-200
Siemens 2.3 MW

RELEASED
by christian.stevenson
Installation and Maintenance Manual - BSAK 300-MS30S-200

Table of contents
TABLE OF CONTENTS........................................................................................................... 1
1. GENERAL .................................................................................................................... 3
1.1 Who to contact ............................................................................................................. 3
1.2 Safety ........................................................................................................................... 3
1.3 Safety terms/symbols used in this manual .................................................................... 4
1.4 Original language ......................................................................................................... 4
1.5 Disclaimer..................................................................................................................... 4
1.6 Conversion factors ....................................................................................................... 5
1.7 Nameplate/serial numbers ............................................................................................ 5
1.8 How the brake works .................................................................................................... 6
1.9 Function ....................................................................................................................... 6
1.10 Transport ...................................................................................................................... 7
1.11 Connections ................................................................................................................. 7
1.12 Lubrication .................................................................................................................... 8
1.13 Storage......................................................................................................................... 8
1.14 Disposal ....................................................................................................................... 9
1.15 How to order spare parts .............................................................................................. 9
2. INSTALLATION ........................................................................................................... 10
2.1 Lifting and handling ...................................................................................................... 10
2.2 Cleaning the brake disc ................................................................................................ 10
2.3 Cleaning of the mounting surfaces ............................................................................... 10
2.4 Handling / mounting the brake pads ............................................................................. 10
2.5 Mounting the brake ....................................................................................................... 12
2.6 Inspecting the alignment of the brake ........................................................................... 14
2.7 Back-stop set ............................................................................................................... 14
2.8 Positioning system........................................................................................................ 14
2.9 Adjusting the positioning system .................................................................................. 15
2.10 Bleeding the calliper ..................................................................................................... 15
2.11 Installing the Indicator................................................................................................... 15
2.12 Bedding in .................................................................................................................... 16
2.13 Removing the brake ..................................................................................................... 16
3. MAINTENANCE ........................................................................................................... 17
3.1 Pad worn signal ............................................................................................................ 17
3.2 Replacing the brake pads ............................................................................................. 17
3.3 Replacing other components ........................................................................................ 18
3.4 Dismantling the active calliper ...................................................................................... 18
3.5 Replacing the seals ...................................................................................................... 18
3.6 Lubrication of the brake ................................................................................................ 20
4. TROUBLE SHOOTING ................................................................................................ 21
APPENDIX A - DIMENSION DRAWING, BRAKE ................................................................... 23
APPENDIX B - ASSEMBLY DRAWING, BRAKE EXPLODED ............................................... 24
APPENDIX B - ASSEMBLY PARTS LIST, BRAKE ................................................................ 25
APPENDIX C - SPARE PARTS DRAWING, CALLIPER HALF EXPLODED........................... 27
APPENDIX C - SPARE PARTS DRAWING, CALLIPER HALF ............................................... 27
APPENDIX D - MOUNTING DRAWING .................................................................................. 30
APPENDIX E - SPARE PARTS DRAWING, PASSIVE CALIPER ........................................... 31
APPENDIX E - SPARE PARTS LIST, PASSIVE CALIPER ..................................................... 31
APPENDIX F - SPARE PARTS DRAWING, BASE PLATE ..................................................... 32
APPENDIX F - SPARE PARTS LIST, BASE PLATE ............................................................... 32

MEB-0300-062 Page 1
Installation and Maintenance Manual - BSAK 300-MS30S-200

APPENDIX G - POSITIONING SYSTEM ................................................................................. 33

APPENDIX H - BRAKE SWITCH / INDICATOR ...................................................................... 34
APPENDIX I - TECHNICAL DATA........................................................................................... 35
APPENDIX J - RECOMMENDED FLUID ................................................................................ 36
APPENDIX K - RECOMMENDED SPARE PARTS.................................................................. 37

MEB-0300-062 Page 2
Installation and Maintenance Manual - BSAK 300-MS30S-200
1. General
Thank you for buying a Svendborg Brakes
product.
Before using the product please read this
manual carefully.
This manual provides instructions of how to
install and maintain the brake type/option
BSAK 300-MS30S-200.
For information on how to operate the brake
refer the manual for the control system and /
or the manual for the hydraulic system / unit.
1.1 Who to contact
In case you have any questions to this
manual please contact your local
representative or nearest Svendborg Brakes
Office:
Svendborg Brakes offices:
Denmark:
Phone: +45 63 255 255
Fax: +45 62 281 058
E-mail: sb@svendborg-brakes.com
For current contact information, please
reference www.svendborg-brakes.com.
1.2 Safety
The Svendborg Brakes line of products are
designed to be mounted on a rotating brake
disc for use in conjunction with parking brake
applications, service brake applications or
emergency brake applications only.
Note:
 Always use original spare parts from
Svendborg Brakes, in order to maintain the
warranty.
 Consult Svendborg Brakes before using
tools or any other equipment not
recommended / specified in this manual.
 Always use a torque wrench when refitting
mounting bolts or valves in order to ensure
the torque obtained is the torque described
in this manual.
 The customer/user is responsible for
keeping the brake and hydraulic power unit
clean, and free from dirt, grease, oil and
corrosion.
 The customer/user is responsible for
ensuring the air gap between brake pads
and brake disc never exceeds the air gap
recommended.
 Always ensure at least one copy of this
manual provided to the service /
maintenance personnel.
MEB-0300-062 Page 3
 The machinery in which the brake is to be
installed, must be designed/constructed to
ensure adequate lighting in the work area
and secure access for installation and
maintenance work on the brake and
hydraulic power unit.
 The personnel working on the brake system
must have the relevant electrical, hydraulic
and mechanical skills in order to work safely
with the products.
Do not work on the brake/system before
attending all the following matters:
Electrical junction box/control panel:
 The control signals have been shut off and
blocked before working on the system.
 The electrical power has been shut off.
Hydraulic power unit:
 There is no hydraulic pressure on the
hydraulic power unit or circuit.
 The oil pressure in the accumulator(s) has
been relieved.
 Do not adjust valves or pressure switches to
higher operating pressure than specified in
the manual.
 Do not change the size or type of
components.
 Do not use hydraulic fluids not
recommended in this manual.
 Do not startup / operate the hydraulic power
unit before correctly filling the reservoir / oil
tank with oil.
Brakes:
 The brake disc is locked and not able to
rotate before adjusting the brake and/or air
gap.
 Lock/secure the brake piston by using the air
gap bolt/air gap nut if working on a spring
applied brake.
 Do not use higher operating pressures than
specified on the brake nameplate or in the
brake manual.
 Do not change the size or type of spring
pack.
 Do not use the brake pads when they are
worn to the minimum thickness specified in
the brake manual.
 Do not operate the brake if there is dirt or
corrosion protection on disc or brake pads.
 Do not operate the brake before bleeding
the hydraulic system and re-filling with oil.
Installation and Maintenance Manual - BSAK 300-MS30S-200
Personal Protective Equipment and
safety:
During installation or service / maintenance
of the braking system, service personnel
must use Personal Protective Equipment
(PPE).
 Safety footwear and working gloves - to
avoid injuries wear protective footwear,
EN345/ ISO20345 - category S3 and
working gloves, EN 420/EN388 - category 2
when working on the system.
 Protective disposable gloves - to avoid
prolonged skin contact when working with
hydraulic fluids, grease and lubricants,
always wear protective gloves - ideally
disposable latex or nitrile gloves or similar,
EN420/EN374 category 3.
 Eye protection - when working work with
hydraulic oil/pressure connections it is highly
recommended to wear eye protection.
 Filtering half masks - during operation, dust
emission from disc and brake pad friction
material will occur. To protect against
exposure to particles when working close to
the brake pads, wear filtering half masks, EN
149, class FFP2S.
 If using solvent cleaners, carefully follow the
manufacturer’s instructions before use.
Heavy equipment
Be careful when lifting the brake or brake
components - they are heavy and not meant
manually lifting. Use proper lifting equipment
in order to prevent personal injury.
Fingers warning
Never place your fingers between the brake
pad and the brake disc when the brake is
connected to the hydraulic system.
Pressure warning
Never apply higher pressures than the
maximum operating pressure stated on the
nameplate.
MEB-0300-062 Page 4
1.3 Safety terms/symbols used in this
manual
To make sure that you perform certain tasks
properly, please take note on the following
symbols used throughout this manual.
WARNING: Information to prevent personal
injury when trying to complete a task.
CAUTION: Information to prevent damage
to the components when trying to complete
a task.
IMPORTANT: Information that you MUST
follow to complete a task.
NOTE: Tips and additional information to aid
in completing a task.
Figures within brackets ( ) relate to position
number and appendix number i.e. (15-C)
refers to position number 15 in appendix C
on both drawing and bill of material (parts
list).
1.4 Original language
The original language of this manual /
instructions is English.
All other languages are translations of
oiginal.
1.5 Disclaimer
Svendborg Brakes reserves the right to
revise this document without prior
notification. These documents have been
proofread for errors in translation and
accuracy. Despite this, technical and
typographical deviations can sometimes
occur.
This document is updated on a regular
basis; changes will be published in future
printings. Improvements and/or changes to
the described products or manual can be
implemented at any time without preceding
notice.
In no event shall Svendborg Brakes be liable
for any special, incidental, consequential or
punitive damages. This includes, but is not
limited to: damage to other property or
person, inconvenience, loss of goodwill, lost
profits or revenue, loss of use of this product
or any associated equipment, cost of
substitutive equipment, downtime costs or
claims of any party such damages, resulting
from any misspellings or inaccurate
information in this users guide.
Installation and Maintenance Manual - BSAK 300-MS30S-200

This document or parts hereof may in no FIGURE 1.1

event be copied, reproduced, changed or
translated to other languages without explicit
written permission from Svendborg Brakes.
10/2014
1.6 Conversion factors
BSAK 300-MS30S-200
All units in this manual are in metric units.
0 - 55.000 0 - 12,5
If you have needs for conversion between
metric and imperial units the following 1-100013564 490-3443-801
figures can be used.

Table 1.1
Conversion factors The nameplate is positioned on the brake as
Length: per figure 1.2.
1 inch = 25.4 mm (millimetre)
NAMEPLATE FIGURE 1.2
1 mm = 0.0394 inch / SIGN
(millimetre)
Mass:
1 kg (kilogram) = 2.2046 lb (pound)
1 lb (pound) = 0.4536 kg (kilogram)
Force:
1 N = 0.2248 lbf.
(Newton) (pound force)
1 kN = 224.8089 lbf.
(kiloNewton) (pound force)
Pressure:
1 Bar = 0.1 MPa
(Mega Pascal)
1 Bar = 14.5038 PSI (pound per
square inch)
1 MPa (Mega = 1 N/mm² The information found in the name plate is:
Pascal) TYPE - The type is the brake type/brake
1 N/mm² = 145.038 PSI (pound per name.
square inch)
Torque: SERIAL NUMBER - The serial number is a
1 Nm (Newton = 0.7376 lbf.ft. unique number which identifies the brake.
meter) (pound foot)
1 lbf.ft. = 1.3557 Nm ITEM NO. - This is the item number of the
(pound foot) (Newton meter) brake.

Examples: OPR. PRESSURE - This is the pressure

125 bar = 12.5 MPa = 1812.98 PSI range needed for operating the brake, where
320 N/mm² = 46412.00 PSI the lower value is the hydraulic pressure
305 Nm = 224.96 lbf.ft needed to ensure the brake operates and
the higher value is the maximum pressure
1.7 Nameplate/serial numbers allowed in the brake.
Before contacting Svendborg Brakes or your
CLAMPING FORCE - This the minimum
local sales representative, please record the
clamping force (nominal) provided by the
serial number of the product as minimum but
brake at zero hydraulic pressure (assuming
the item number would also be helpful.
correctly adjusted).
This will aid the process of identifying the
actual product supplied and will help in
Production year - The year and week
locating possible problems.
number of manufacture are stated in the
upper area of the nameplate. A brake
The information is found on the nameplate
manufactured in week 10 in 2014 is marked
mounted on the brake.
“10/2014”.

MEB-0300-062 Page 5
Installation and Maintenance Manual - BSAK 300-MS30S-200
1.8 How the brake works
The brake is designed to transfer a clamping
force into a braking torque from the brake
calliper to a brake disc - either in order to
stop the rotation of the brake disc or for
preventing it in rotating when stopped
(parking brake).
The BSAK 300 Mono Spring is designed as
a hydraulically applied disc brake.
The clamping force increases when the
hydraulic pressure increases.
The Mono Spring brake contains one piston
only - this is located inside the active calliper.
FIGURE 1.3
The active calliper is mounted / joined
together with the passive calliper using bolts
and spacers (spacers only where
applicable).
The assembled / joined unit is floating on the
base plate via the two shafts and bearings
inside the passive calliper.
When braking - the piston inside the active
calliper (and brake pad no. 1) will move
towards the brake disc.
The brake pad no. 2 and the passive calliper
will then lift towards the brake disc and
provide a braking force on both sides of the
disc because the active and passive calliper
are assembled / joined and is floating on the
shafts.
Please notice that the brake pad (no. 2) in
the passive calliper does not move.
Only the brake pad in the active calliper
moves - therefore the pad holder in passive
calliper is lower than in the active calliper.
Only limited movement of the brake disc and
brake is allowed. The sliding capabilities of
the brake are limited in both directions of the
mounting surface - forward and backwards.
MEB-0300-062
When moving too close towards the
mounting surface, the brake will touch the
base plate preventing it from sliding freely.
In worst case this may cause damages to
the brake / brake disc / hub / coupling and or
mounting structure.
When moving backwards from the mounting
surface the forces / torque on the shafts and
base plate will increase resulting in reduced
lifetime.
Check the mounting and dimension drawing
for exact dimensions, tolerances and
allowed movement.
In order to allow the passive calliper to slide
correctly on the shafts it is necessary to use
flexible hydraulic hoses as a final part /
section of the connection when connecting
the pressure ports on the brake to the
hydraulic power unit.
1.9 Function
The BSAK 300 brake is designed as a
hydraulically applied disc brake.
The clamping force is obtained from the
hydraulic pressure applying force to the
piston and to the brake pad against the
brake disc.
The reaction force is transferred via the
yoke.
FIGURE 1.4
Connecting and disconnecting hydraulic
pressure to the pressure ports operates the
brake.
The brake applies the clamping force when
the hydraulic oil pressure is applied /
supplied to the hydraulic chamber / unit
causing the piston to execute movement
towards brake disc.
The braking force decreases when hydraulic
oil pressure is removed from the hydraulic
chamber / unit causing the piston to execute
a short stroke towards the yoke - away from
the brake disc.
Page 6
Installation and Maintenance Manual - BSAK 300-MS30S-200

The pad retraction springs (mounted in the

brake pads) will then pull the pads away,
allowing the disc to rotate freely.
 FIGURE 1.6

A pad worn indicator can be used for

indication of wear of the brake pads and
when to replace the brake pads.

1.10 Transport
When leaving the factory the brake is always
packed / wrapped to ensure maximum
security for the product during transport.
The weight of the brake is approx. 75kg
excluding brake pads.

IMPORTANT These bolts (if mounted) will have to be

The brake has one O-ring (8-B) mounted on
each shaft between the base-plate and the
passive calliper. The O-rings are split / open
and are mounted with a piece of yellow tape
and - they are for transportation only and
must be removed before usage of the brake.
FIGURE 1.5
removed during mounting of the brake and
refitted during the adjustment process.
1.11 Connections
The brake is as standard provided with two
pressure connections 1/4” BSP (8-C) and
one drain connection 1/8” BSP (7-C) - see
figure 1.7 and 1.8

PRESSURE DRAIN PORT FIGURE 1.7

PORT 1/4” 1/8” BSP
BSP (2x)

O-RING & YELLOW TAPE

IMPORTANT
If the brake is supplied with a positioning
system (optional) the bolts and springs (pos
 on fig. 1.6) may already be mounted from
Pressure ports
the factory. This will be done to prevent the
The pressure ports are used to operate the
calliper to slide on the shafts during
brake. The connection at the lowest position
transport.
shall always be used as a pressure
connection when connecting the brake to the
hydraulic system.
The brake should always be bled from the
highest port when mounted.
The highest pressure connection can be
used if flushing is required.
Flushing is depending on the design of the
hydraulic system and may not be an option.

MEB-0300-062 Page 7
Installation and Maintenance Manual - BSAK 300-MS30S-200
Drain ports
The drain connection (7-C) provides access
to the chamber between the outer seal (12-
C) and the wiper (13-C) through a hole in the
yoke.
NOTE
It is recommended to use / connect the drain
connection because this can prevent leaking
oil from reaching the brake disc resulting in
reduced braking force.
A plastic hose (preferably clear) can be
connected from the drain port to a drain
bottle or similar.
FIGURE 1.8
The drain connection could also be
connected directly to the tank of the
hydraulic power unit.
If using drain bottles it is recommended to
use one bottle for each brake as this makes
detecting of potential leakage easier.
CAUTION
1.13 Storage
Never apply any pressure to the drain
connection (7-C).
Applying pressure could damage the seals
because the hydraulic oil / pressure then
enter the chamber between the seal and the
wiper and will blow off the wiper and most
likely destroy the seal.
IMPORTANT
In order to allow the passive caliper to slide
correctly on the shafts it is necessary to use
flexible hydraulic hoses as a final part /
section of the connection when connecting
the pressure ports on the brake to the
hydraulic power unit.
1.12 Lubrication
Various types of hydraulic fluid can be used
for brake operation.
When selecting the type of hydraulic oil
please ensure that it is capable of operating
at the correct temperature range and please
be aware that the reaction time/operating
time may vary dramatically depending on oil
type and temperature chosen.
MEB-0300-062 Page 8
For further details see Appendix J -
Recommended fluids.
When quick brake reaction times are critical
and operating at temperatures below 0°C
(+32°F) it is recommended to use the oil
types listed in cold section as these types
provides the most constant reaction times.
Different types of lubrication are used in
different situations.
This can be either for lubrication of the seals
or disc springs during servicing or when
tightening bolts.
The following symbols are used on drawings
to indicate where lubrication is needed
during service:
 Grease - Molykote P74
 Grease - Molykote Long-term 2 Plus
 Hydraulic oil
MoS2 Molybdenum Disulfide
Molykote is produced by Dow Corning
Molybdenum Disulfide (MoS2) can be in
various forms; either spray, fluid or solid
state.
For lubrication of threads Molykote P74
lubricant is recommended as it provides the
most constant results but other MoS2 based
lubricants, with similar properties, can be
used.
General minimum storage requirements are:
 All equipment containing hydraulic parts
incl. brakes must be stored indoors and
above +5°C to avoid condensation.
 All electrical equipment must be stored
indoors, in dry, non-condensing conditions
above +5°C
 Equipment/boxes must not be in direct
contact with water/rain and must be stored
under cover.
Brake(s), steel parts, hydraulic and electrical
parts shall be stored indoors within a
temperature range of +5°C to +40°C.
Maintenance of the brake is needed for
storage longer than 12 months. In order to
prevent the seals drying out and sticking to
the piston, the brake piston must be
operated at full stroke at least 20 times every
12 months.
The hydraulic unit must be stored indoors
within a temperature range of +5°C to
+40°C.
Installation and Maintenance Manual - BSAK 300-MS30S-200
Oil should be added to the tank and pumps
should be started up for storage longer than
12 months.
Bolts, nuts and washers etc. should not be
removed from their original product
packaging and must be kept dry indoors.
Temperature control is not required.
Brake pads must be stored indoors.
Temperature control is not required.
Spare seal kits should be kept away from
direct sunlight and should be stored in their
original bag, ideally in a box or dark area.
Control panels must be stored indoors in an
upright position within a temperature range
of +5°C to +40°C. Battery maintenance will
be required for storage longer than 12
months.
Brake discs, couplings and hubs are treated
with corrosion protection. If stored outdoors,
the equipment must be stored in a sealed
plastic bag in its wooden box. The box must
be placed under cover but does not need
controlled temperature.
The brake(s)/bracket(s) are treated at the
factory with corrosion protection.
1.15 How to order spare parts
Corrosion protection should be reapplied if
removed during transporting or handling.
1.14 Disposal
General
The operator and / or user are responsible
for the proper disposal of the brake and the
associated components.
If any doubts about the correct disposal
please do not hesitate to contact Svendborg
Brakes or your local dealer or regional
disposal enterprises for further information.
Brake pads
The brake pads are made of a steel back
plate and some brake pad material / lining.
The brake pad material is either made of an
organic compound or of the sinter metal
type.
Either type is asbestos free and free of lead
The brake pads can be treated as steel
waste/scrap.
MEB-0300-062 Page 9
Hydraulic oil
Hydraulic oil may not enter the environment
and must be professionally treated when
disposed.
The oil must be removed from the brake and
from the hydraulic system / unit and stored in
proper containers until delivery to local
disposal enterprises.
Brake
The brake is in general made of cast iron or
machined steel.
Once the hydraulic oil has been removed
from the brake, and the seals have been
removed the brake can be treated as steel
waste/scrap.
Seals
The seals and o-rings used in the brake are
made of either Polyurethane (PUR), PTFE
(Teflon) or rubber (NBR).
They can all be treated as normal waste.
Electronics
If equipped with any
electronic equipment like
sensors, indicators or similar
- this equipment should be
treated as electronic waste.
Please refer to the specific item number
and/or position number and item description
from the appendices when ordering spare
parts.
Each brake is tested individually and has a
unique serial number.
To ensure the correct spare parts please
provide both the brake type and serial
number from the name plate(s) on the brake
as this will ensure correct spare parts.
See the section “Nameplate/serial numbers”
for location of the serial numbers.
For contact information when ordering spare
parts please see the section Who to contact
or www.svendborg-brakes.com.
Installation and Maintenance Manual - BSAK 300-MS30S-200
2. Installation
2.1 Lifting and handling
The BSAK 300 Mono spring brake is
equipped with eyebolts on the calliper and
should only be lifted by means of placing a
hook through them.
The eyebolts mounted on the brake can be
moved to the back of the passive calliper
half or they can be mounted in the brake pad
holders for lifting.
If the eye bolts are mounted in brake pad
holders please remove eyebolts again be for
use of the brake.
In order not to damage any parts on the
brake do not fit any hook or tie any rope,
chain or strap around indicators, hoses,
positioning system, etc.
When lifting please note that the total weight
of the complete brake is approx. 75kg.
2.2 Cleaning the brake disc
Before installing the brake callipers the
brake disc must be cleaned from any dirt or
anti corrosive protection.
The anti corrosive protection can normally
easily be removed in two steps:
1) By using kerosene or similar for the initial
cleaning.
2) Using solvent cleaners to remove the
remaining dirt completely.
Use a cleaning solvent for the final cleaning.
Solvent cleaners could be clear methylated
or white spirits or isopropyl alcohol.
Any residual oil or anti-corrosion preparation
will reduce the coefficient of friction greatly.
WARNING
Solvent cleaners can be flammable,
poisonous and can cause burns.
To avoid serious personal injury when you
use solvent cleaners, you must read the
manufacturer’s instructions before using a
solvent cleaner, and then carefully follow
these instructions.
Also follow these procedures:
 Wear protective eye protection.
 Wear clothing that protects your skin.
 Work in a well-ventilated areas.
Always follow local rules and regulations for /
when working with solvents.
MEB-0300-062 Page 10
2.3 Cleaning of the mounting surfaces
The mounting surface of the bracket or
customer post / gearbox must comply with
the relevant arrangement drawings and
mounting data drawings.
If the mounting surface is not within the
specification this can cause the base plate to
permanently distort and prevent the calliper
from sliding on the shafts / axles.
It is critical that the base plate is bolted to the
mounting surface in compliance with the
tolerance specified on the calliper dimension
drawing.
IMPORTANT
The joint between the base plate and the
customer post / gearbox is classified as a
friction joint.
Therefore NO lubricant or other compound
shall be applied between the calliper and
mounting surfaces.
The mounting of the calliper does NOT rely
on the shear capacity of the mounting bolts
but of the friction joint. This friction joint is
created by the clean, dry, lubricant free
surface machined to the correct surface
finish and of the tension created by the
mounting bolts.
The mounting surfaces for the base plate
should be cleaned in the same way as the
brake disc - see section 2.2 - Cleaning the
brake disc.
WARNING
Solvent cleaners can be flammable,
poisonous and can cause burns.
Please follow the manufacturer’s instructions
and see section 2.2 - Cleaning the brake
disc.
2.4 Handling / mounting the brake
pads
Friction material is a very essential part of
the brake system and the brake pads should
be handled carefully to avoid damages to the
brake pads / friction material.
The brake pads should be kept as clean as
possible - be careful to protect the pads from
grease and oil. Even a small amount of oil
can reduce the friction coefficient
considerably.
Installation and Maintenance Manual - BSAK 300-MS30S-200

sliding the brake pad towards the centre of

NOTE the main shaft.
All brake pads supplied by Svendborg
Brakes are asbestos free and free of lead. Mounting is done in reverse order.
Certificate is available on request.
For information on the tightening torque for
Brake pads can be supplied in several types the loose pad-holders please refer to Table
and with different brake pad materials 2.2 - Bolts for brake pad holders / pads.
depending on the actual needs in the
application. If the hub is too large the brake pad can be
In general there are two types of brake pads: removed by removing the 2 bolts M12 (5-C)
and the pad holder (4-C).
 Brake pads with organic / composite The brake pad can be removed by sliding
linings. the brake pads sideways out of the brake.
 Brake pads with sintered metal pucks / Mounting is done in reverse order.
material.
FIGURE 2.2
2.4.1 Brake pads with organic brake pad material
is quite sensitive to dirt, grease and oil and
they are normally packed / sealed in plastic
to protect them from contamination - please
keep the pads in the packet for as long as
possible.
Organic materials are very sensitive to
grease and oil and cannot be cleaned. They
must in most cases be discarded and must
be replaced if exposed to this.

2.4.2 Brake pads with sinter metal brake pad

material is less sensitive to dirt, grease and
oil and can in some cases, where not fully
soaked up with oil - be cleaned with solvent
and re-used.
WARNING
Solvent cleaners can be flammable,
poisonous and can cause burns.
Please follow the manufacturer’s instructions
and see section 2.2 - Cleaning the brake
disc.
2.4.3 The brake pads are mounted with loose pad
holders on the pad (bolts).
CAUTION
It is essential that sinter metal brake pads
are oriented correctly before usage.
On some brake pads the sinter metal pucks
are oriented to absorb the heat as effectively
as possible.
If using sinter metal brake pads with pucks
(round or rectangular shape) oriented in a
curved pattern the brake pad should be
oriented with the curve towards the
perimeter of the brake disc.

FIGURE 2.1 FIGURE 2.3

LOOSE PAD HOLDER / GUIDE

It is possible, when assuming that the space

is available for the hub, to change the pads
just by removing the 2 innermost bolts
(M8x16) on each pad and thereafter by

MEB-0300-062 Page 11
Installation and Maintenance Manual - BSAK 300-MS30S-200

FIGURE 2.5
NOTE
The pad holder on the active calliper is
higher / larger than the one on the passive
calliper. This is because the brake pad on
the passive calliper does not move whereas
the brake pad in the active calliper moves
the full distance.

2.4.4 After mounting the pad holders the pad

retraction springs should be mounted into
the brake pads.

FIGURE 2.4
Pad retraction
spring & bolt O-RING & YELLOW TAPE

2.5.3 Check that the mounting surface of the

bracket or customer post / gearbox does
comply with the relevant arrangement
drawings and mounting data drawings i.e. is
flat and at right angles to the brake disc,
before mounting the base plate.

2.5.4 Ensure that the mounting surfaces are clean

of dirt and oil - otherwise clean as per
section 2.3 - Cleaning of the mounting
surfaces.

2.5.5 Position the brake on the mounting flange

and mount the lowest bolt - without fully
Pad retraction
spring & bolt tightening it.

2.5.6 If possible tip the brake backwards using the

2.5 Mounting the brake lower bolt (M20) as pivot. Doing this will ease
2.5.1 Remove the indicator (if fitted) to prevent it the mounting of the brake pads on initial
from being damaged. installation.

2.5.2 The brake may have O-ring (8-B) mounted FIGURE 2.6
on each shaft between the base plate and
the passive calliper. They are only mounted
for avoiding damages during transport and
must be removed before usage of the brake.
These O-rings are split and are marked with
a piece of yellow tape.

If this is not possible mount the brake with

both bolts and tight them according to
section 2.5.11 / Table 2.4.

2.5.7 Align the brake on the shafts to the disc

(slightly in the middle).

2.5.8 Unpack the brake pads from the plastic

sealing / bag. Be careful and protect the

MEB-0300-062 Page 12
Installation and Maintenance Manual - BSAK 300-MS30S-200

pads from grease and oil, see section 2.4 - GENERAL FIGURE FIGURE 2.8
Handling / mounting the brake pads.

NOTE
If the brake has been tipped backwards /
pivoted it may be possible to mount the
brake pads and pad retraction springs
without having to remove the brake pad
holders.
Please note that the piston has to be fully
lifted in order to mount the pads.

2.5.9 Slide the brake pads into position and mount

the brake pad holder (4-C) and the two bolts
M12 (5-C) again.
FIGURE 2.9
GENERAL FIGURE FIGURE 2.7 Pad retraction
spring & bolt

Use the tightening torque specified on the

spare parts drawing or from Table 2.2 - Bolts
for brake pad holders.
Pad retraction
Table 2.2 spring & bolt
Bolts for brake pad holders / pads
Bolt size Torque 2.5.11 If the brake was pivoted, please check the
Lubricated MoS2 Dry mounting surfaces and the brake disc for dirt
M8 8.8/A4 19 Nm 23 Nm and grease before rotating into place and
mount the brake with 4 x M20 bolts grade
M12 10.9 91 Nm 108 Nm
8.8.
“Lubricated” is based on Molykote - MoS2
Use the tightening torques from the spare-
2.5.10 Fit the pad retraction springs and bolts and parts drawing or Table 2.4 - Mounting bolts
mount these - tighten firmly according to for base plate.
Table 2.3 - Bolts for pad retractions springs.
Table 2.4
Mounting bolts for base plate
Table 2.3
Torque
Bolts for pad retraction springs Bolt size
Lubricated MoS2 Dry
Torque
Bolt size M20 8.8 305 Nm 365 Nm
Lubricated MoS2 Dry
“Lubricated” is based on Molykote - MoS2
M10 8.8 20 Nm 27 Nm
“Lubricated” is based on Molykote - MoS2 2.5.12 Check that the brake disc can rotate freely,
without touching the brake and that the
brake is aligned parallel to the brake disc.

MEB-0300-062 Page 13
Installation and Maintenance Manual - BSAK 300-MS30S-200

2.6 Inspecting the alignment of the FIGURE 2.11

brake
2.6.1 Check that the brake pads can move freely
within the brake pad holders. The pad
retraction springs will reduce the movement
somewhat, but the brake pad must not be
stuck to the brake.

IMPORTANT
The axial movement of the brake disc must
not exceed 0.3mm - see mounting drawing.

2.7 Back-stop set

The back-stop set can be mounted to
minimize the piston movement and thereby
decreasing the reaction time for the brake.
2.7.1 Apply hydraulic pressure to the brake.
2.7.2 Turn the M6 bolts until they touch the brake
pad.
If the brake is mounted in horizontal position
even higher gravitational forces will occur. In
this situation a special positioning system is
recommended needed.
FIGURE 2.12

2.7.3 Unscrew the bolts until the desired air gap.

The pitch for the bolt is 1mm.

2.7.4 Tighten the nuts and release the pressure.

2.8 Positioning system

If the mono spring brake is mounted in
perfect vertical position the brake pads on
the passive side of the brake will just slightly
touch the brake disc. Please note that in this situation wear will be
If axial movement of the disc is present and on the active side.
wear becomes a problem - a positioning
system can be mounted on the brake. To prevent the gravitational forces from
wearing the pads off - the mono spring can
be equipped with a positioning system.
FIGURE 2.10

In general the positioning system has two

functions:

1) Adding forces to absorb/minimize the

gravitational forces - using springs in
either direction.
2) To align the brake within the air gap i.e.
to position the brake with equal amount of
space between the brake disc and the
brake pads on both sides.

The positioning system on the BSAK 300

mono spring consists of:
If the brake is not mounted at level i.e. it is 2 bolts, 2 springs, 2 guides and 2 nuts.
mounted downwards like in a wind turbine,
the gravity will provide a force on the brake, The springs are placed on the shafts. See
making the brake pads on the passive side Appendix G.
touch the disc - this will result in wear on the
pads and a positioning system is highly
recommended.

MEB-0300-062 Page 14
Installation and Maintenance Manual - BSAK 300-MS30S-200
FIGURE 2.14
Remember to mount / fit the nuts before
entering the thread in the passive caliper.
2.9 Adjusting the positioning system
This section is only valid if the brake is
equipped with a positioning system.
For exact location of the positioning system
check Appendix B - position 11.
After initial installation the positioning system
shall be adjusted i.e. the distance between
the brake pad and the brake disc should be
adjusted to be equal.
2.9.1 Measure the air gap. The air gap is the
space between the brake pads and the
brake disc, when the piston is completely.
Measure the air gap using a feeler gauge.
FIGURE 2.15
If the positioning system is mounted the
springs will push the passive calliper towards
the base plate and the air gap will be located
on the passive side only.
2.9.2 Adjust the air gap to be symmetrical by lifting
the passive calliper by turning the bolt (1-G).
Check the air gap again before locking the
nut (2-G).
MEB-0300-062 Page 15
FIGURE 2.16
(Equal air gap)
2.10 Bleeding the calliper
2.10.1 The calliper’s hydraulic system must always
be bled in conjunction with assembly, repairs
or when making changes in the system.
Failure to bleed the brakes will allow air to
remain in the brake system.
This will / could prevent the hydraulic
pressure in the brake system from rising /
increasing enough to lift the brakes correctly.
This could cause that the brake pads will still
touch the brake disc and heating of the
brake pads and brake disc could occur.
Air in the system could also destroy / blow
the seals (diesel effect) within the brake /
calliper.
2.10.2 The calliper must be bled at the highest point
on the brake through the pressure port (8-C).
A special bleeding plug (Mini mess / test
point) ¼” BSP and a hose can be supplied
from Svendborg Brakes.
2.11 Installing the Indicator
The brake can be mounted with a pad worn
indicator.
The mechanical switch is tamper-proof and
is preset from the factory.
2.11.1 The indicator for “Pad worn” must be
mounted in the yoke.
Remove the plug (1/2” BSP) and fit the
indicator.

FIGURE 2.17
Installation and Maintenance Manual - BSAK 300-MS30S-200

2.12 Bedding in 2.13 Removing the brake

To obtain the rated coefficient of friction
between the brake pad and the brake disc,
and to ensure the pad surface is aligned to
the disc, it is essential that the pads are
bedded to the disc surface.
2.13.1 Remove the pad retractions springs (and
bolts) from the active calliper.
2.13.2 Remove the brake pad holder (4-C) and the
brake pad (12-B) from the active calliper.

The coefficient of friction may drop by 2.13.3 The brake can now be removed safely by
approx. 20% when not bedded in. removing the 4 mounting bolts going through
the base plate (M20).
This can be done by making a series of load-
tests with increasing load or speed until
sufficient coefficient of friction is achieved.
If the brake disc is new the time of bedding
in will be longer because the disc also has to
be bedded in. Always use new pads with a
new disc. Never use used pads with a new
disc.

Organic pads:
Organic pads can normally be bedded in by
driving the disc through the pads with a
minimum of 25% of the rated clamping force
applied, or if that is not possible by making a
series of activations with increased load or
increased speed.

Sinter-metal pads:
The bedding in process for sinter-metal pads
is the same as for organic pads, but with a
slightly higher clamping force when bedding
in - approx. 40% of the rated clamping force
applied.

During the process of “bedding in”, the disc

temperature should be monitored to ensure
that the disc does not overheat.

Instruction for the bedding in process is

packed together with the brake pads.

2.12.1 Connect a hand pump and a pressure gauge

into one of the pressure ports (8-C).

2.12.2 Start the application / rotating of the brake

disc.

2.12.3 Apply the hydraulic pressure to the correct

pressure level. Run until bedded in.

Example:
25% of clamping force needed
25% of the operating pressure of 11.5MPa =
2.88MPa (29 bar)
The hydraulic pressure of 29 bar should be
applied during bedding in.

MEB-0300-062 Page 16
Installation and Maintenance Manual - BSAK 300-MS30S-200

Pad retraction
3. Maintenance spring & bolt
FIGURE 3.1

3.1 Pad worn signal

During usage the brake pads will wear.

When the signal for Pad Worn switches it is

an indication that the brake pads should be
replaced.

3.2 Replacing the brake pads

The brake pads must be replaced when
each pad has been worn 5mm.

The brake pad thickness can be checked

with a gauge:
All brake pads for the brake consist of a Pad retraction
steel back plate and a friction material. The spring & bolt
brake pad has a total thickness of 24mm, i.e.
all brake pads must be replaced when the 3.2.3 Remove the brake pad holders (4-C) and the
thickness of friction material + back plate is 2 bolts M12 (5-C) from both the active and
minimum 19mm. passive calliper.

Brake pads with organic brake pad

material/lining are sensitive to dirt, grease FIGURE 3.2
and oil and are normally packed/sealed in
plastic to protect them from contamination.
Please keep them in their packaging for as
long as possible.

Brake pads with sinter metal brake pad

material are less sensitive to dirt, grease and
oil. In some cases, where not fully soaked
with oil, they can be cleaned with solvent and
re-used.
As they are not that sensitive, sinter metal
brake pads are not necessarily wrapped in
plastic.

Be careful to protect the pads from grease
and oil. Even a small amount of oil can
reduce the friction coefficient considerably.
See section 2.4 - Handling / mounting the
brake pads for proper handling of the brake
pads.
3.2.1 Remove the indicator if fitted.
3.2.4 Remove the brake pads by sliding them
sideways out of the brake.
3.2.5 Slide the brake pads into position and mount
the brake pad holders (4-C) and the two
bolts M12 (5-C) in each again.
GENERAL FIGURE FIGURE 3.3

3.2.2 Remove the pad retraction springs and bolts

from the active calliper and passive calliper.

WARNING
Under no circumstance place your fingers
between the brake pad and the brake disc.

MEB-0300-062 Page 17
Installation and Maintenance Manual - BSAK 300-MS30S-200
Use the tightening torque specified on the
spare parts drawing or from the table 2.2 -
Pad holders.
3.2.6 Fit the pad retraction springs and bolts. The
tightening torque as specified in section 2.5 -
Mounting the brake / Table 2.3.
3.2.7 Readjust the back stop if equipped - see
section 2.7 - Back-stop set.
3.2.8 Readjust the positioning system if equipped -
see section 2.8 - Positioning system.
3.2.9 Remember to bed in the brake pads before
taking the brake into full load situations - see
section 2.12 - Bedding in of the brake pads.
3.3 Replacing other components
Some minor components can be replaced
with the brake mounted on site, but it is
highly recommended to take the brake to a
workshop for repairs.
NOTE
Depending on the work that needs to be
done on the brake it might be worth
considering only taking the active calliper to
the workshop.
CAUTION
When lifting please note that the total weight
of the complete brake is approx. 75kg - the
active calliper itself weighs approx. 20kg.
FIGURE 3.4
3.3.1 Either remove the brake completely
according to section 2.13 - Removing the
brake by removing the M20 mounting bolts
(4pcs) or remove the active calliper only by
removing the M20 (9-B) mounting bolts
instead.
MEB-0300-062 Page 18
WARNING
Always ensure there is no hydraulic pressure
in the brake before starting work.
3.4 Dismantling the active calliper
General
The greatest possible cleanliness must be
observed when working on a hydraulic
system of any type.
Each part must be cleaned thoroughly
washed in solvent cleaners.
Solvent cleaners could be clear methylated
or white spirits or isopropyl alcohol.
WARNING
Solvent cleaners can be flammable,
poisonous and can cause burns.
See section 2.2 - Cleaning the brake disc for
additional information.
Parts must be stored in a clean and dust free
environment. All assembly work must also
be carried out in clean and dust free
environment.
Dirt shortens the lifetime of the seals
considerably and may also damage the
calliper / hydraulic unit.
The surface of the internal components i.e.
piston (2-C) and the yoke (1-C) that are in
contact with the seals are all ground or
polished.
Please check that these surfaces are not
damaged or scratched in any way and
handle them with care to avoid damaging the
surfaces.
A damaged piston will immediately ruin the
seals resulting in leakage.
3.5 Replacing the seals
If the brake has been leaking it is
recommended to replace all seals not only
single seals.
IMPORTANT
Please note that the sealing solution / design
can vary over time. The actual seals of a
brake can therefore vary from the
replacement seal kit supplied.
All sealing solutions used are fully
interchangeable and backwards compatible.
For specific details on the different seal
types and how they should be mounted -
Installation and Maintenance Manual - BSAK 300-MS30S-200
please see the Spare part drawing -
Appendix C for details.
As of November 2007 the wiper has been to
a version that can withstand higher
temperatures.
IMPORTANT
Ensure that there is no pressure on the
calliper.
3.5.1 Remove the piston by hand.
IMPORTANT
Handle the piston carefully. A scratched
piston can immediately destroy the new
seals.
3.5.2 Place the piston at a safe location while
replacing the seals.
IMPORTANT
Section 3.5.3 is valid for the replacing
current (new) type seal kit (after December
2007).
For replacement of the old type seals (before
December 2007) to new type see section
3.5.4.
3.5.3 Remove the wiper (13-C) (and o-ring 14-C if
present) and the seal (12-C & 11-C).
FIGURE 3.5
3.5.4
 Use a screwdriver to lever the seal, and the
wiper out of the grooving.
Be careful not to damage the edges on the
grooves.
 Clean and dry the involved parts, see
section 2.2 - Cleaning the brake disc for
details.
MEB-0300-062 Page 19
 Open the new seal kit and place the seals on
the table in correct order.
 Mount the new seal (11-C) and O-ring (12-
C) and the wiper (13-C) and O-ring (14-C).
The dust lip of the wiper must be facing
outwards and the o-ring must be facing the
front of the brake.
For easing the mounting of the wiper it
should squeeze in a kidney style - see figure
3.6.
FIGURE 3.6
CAUTION
Only use your fingers to squeeze out any
kinks. Be very careful with the edges on the
piston as rod seals are quite sensitive.
IMPORTANT
Section 3.5.4 is valid for the old type seal kit
(before December 2007) only.
It is highly recommended to replace old type
seal kits with the new type.
Remove the wiper (13) and the seal (12) and
O-ring (11) as per figure 3.7.
FIGURE 3.7
12
11
13
 Use a screwdriver to lever the seal, and the
wiper out of the grooving.
 Be careful not to damage the edges on the
grooves.
Installation and Maintenance Manual - BSAK 300-MS30S-200

 Clean and dry the involved parts, see

section 2.2 - Cleaning the brake disc for
details.
 Open the new seal kit and place the seals on
the table in correct order.
NOTE
Mounting must in general ALWAYS be
carried out using new bolts, nuts and
washers; otherwise the clamping force of the
bolt connection may not be present.

 Mount the new seals (11-C, 12-C) and the
wiper (13-C) and O-ring (14-C). The dust lip
of the wiper must be facing outwards - see
figure 3.5.
For easing the mounting of the wiper it
should squeeze in a kidney style - see figure
3.6.
3.6 Lubrication of the brake
Lubrication is only necessary after
dismantling the active calliper for internal
maintenance / replacement of the spring
package.
When replacing the spring package, every
single cup spring must be greased.

For details on where to lubricate internally

CAUTION see appendix C - Spare parts drawing.
Only use your fingers to squeeze out any
kinks. Be very careful with the edges on the
piston as rod seals are quite sensitive.

IMPORTANT
The following sections are valid for the all
seal kit versions.

3.5.5 Lubricate the seals and yoke according to

the lubrication note in the Appendix C -
Spare parts drawing.

3.5.6 Place the piston (2-C) in the yoke (1-C).

3.5.7 Push the piston down as far as possible.

3.5.8 Depending on how the brake / active calliper

has been brought to the workshop it is now
ready for being mounted again. Refer to
section 2.5 - Mounting the brake.

3.5.9 If the calliper half was removed from the

complete brake the mounting bolts must be
fitted again using the tightening torques from
the spare-parts drawing or from Table 3.1 -
Mounting bolts for calliper half.

Table 3.1
Mounting bolts for calliper half
Bolt size Torque
Lubricated MoS2 Dry
M20 10.9 430 Nm 510 Nm
“Lubricated” is based on Molykote - MoS2

MEB-0300-062 Page 20
Installation and Maintenance Manual - BSAK 300-MS30S-200

4. Trouble shooting
Fault Cause Action

The brake applies slowly.
Air in the hydraulic system.
Abnormal throttling in the
hydraulic system or
valve in wrong position.
Abnormal throttling in the
hydraulic system caused by dirt.
The hydraulic oil in pressure lines
between brake and tank has too
high viscosity (too thick).
Bleed system at highest point
and at brake.
Check that all valves are in the
correct position.
Clean and check pipes, hoses
and valves.
Check that the oil is the
recommended grade and the
temperature is not too cold.

Long braking time or long Load too heavy or speed too high. Check the load and speed values.
braking distance or
insufficient braking force.
Oil, paint or grease on brake disc Clean the brake disk - see section
or brake pad. 2.2.
Replace or clean the brake pad -
see section.

Check the hydraulic system does

not leak.

Not all brakes are braking / Check valves where applicable -

connected. check that the individual brake is
working.
Leakage. Worn seals. Replace seals.

Uneven wear on pad.
The brake is incorrectly aligned.
Positioning system not adjusted
correctly (if mounted).
Excessive disc throw or shaft
Deflection.
Check the alignment and that the
passive calliper can float on the
shafts.
Adjust positioning system.
Replace the brake disc and check
the shaft deflection.

Abnormally heavy wear on Increased brake utilisation. Check that the load speed and
pad. frequency do values.

MEB-0300-062 Page 21
Installation and Maintenance Manual - BSAK 300-MS30S-200

This page is intentionally blank.

MEB-0300-062 Page 22
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix A - Dimension drawing, Brake

SVENDBORG BRAKES

CONFIDENTIAL

MEB-0300-062 Page 23
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix B - Assembly drawing, Brake exploded

SVENDBORG BRAKES

CONFIDENTIAL

MEB-0300-062 Page 24
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix B - Assembly parts list, Brake

BSAK 300-MS30S-200
490-3453-801 BSAK 300 MS30S-200

POS. QTY ITEM NAME

1 1 PCS BSAK 300-S-100 ½ - SEALS -35/+200°C

2 1 PCS PASSSIVE CALIPER

3 1 PCS BASE PLATE COMPLETE
4 1 PCS TOP PLATE
5 2 PCS BOLT
6 2 PCS WASHER

9 1 PCS BOLT SET FOR 30MM BRAKE DISC

10 2 PCS EYE BOLT M10
11 1 PCS POSITIONING SYSTEM
12 1 PCS BACK-STOP SET

THE FOLLOWING PARTS ARE NOT INCLUDED IN 490-490-3453-801 AND

MUST BE ORDERED SEPERATELY
7 1 PCS PAD RETRACTION SPRING SET

13 1 PCS BRAKE PAD SET MD 550 (SINTER METAL)

14 1 PCS INDICATOR “ON/OFF” & “PAD WEAR” 10MM WITH 5M

CABLE WITH STRAIGHT PLUG
INDICATOR “ON/OFF” & “PAD WEAR” 10MM WITH 5M
SHIELDED CABLE WITH STRAIGHT PLUG

MEB-0300-062 Page 25
Installation and Maintenance Manual - BSAK 300-MS30S-200

This page is intentionally blank.

MEB-0300-062 Page 26
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix C - Spare parts drawing, Calliper half exploded

SVENDBORG BRAKES

MEB-0300-062 Page 27
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix C - Spare parts drawing, calliper half

SVENDBORG BRAKES

MEB-0300-062 Page 28
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix C - Spare parts list, calliper half

490-3421-802 CALIPER HALF BSAK 300 - S - 100 ½ SEALS -35/+200°C

POS. QTY ITEM NAME

1 1 PCS YOKE BSAK300
2 1 PCS PISTON BSAK 300
3 1 PCS HYDRAULIC PLUG 1/2” BSP WITH SEAL
4 2 PCS PAD HOLDER
5 4 PCS BOLT M12 X 50 10.9
6 4 PCS WASHER
7 1 PCS HYDRAULIC PLUG 1/8” BSP WITH SEAL
8 2 PCS HYDRAULIC PLUG 1/4” BSP WITH SEAL
9 1 PCS SIGN
10 4 PCS BLIND RIVET

SEAL KIT BSAK300 ½ - -35/+200°C

11 1 PCS O-RING Ø81,92X5,33
12 1 PCS ROD SEAL Ø75X6,3
13 1 PCS WIPER Ø75X6
14 1 PCS O-RING Ø78,97X3,53

MEB-0300-062 Page 29
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix D - Mounting Drawing

ed
eas
Rel

CONFIDENTIAL

MEB-0300-062 Page 30
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix E - Spare parts drawing, Passive Caliper

ed
eas
Rel

SVENDBORG BRAKES

CONFIDENTIAL

Appendix E - Spare parts list, Passive Caliper

PASSIVE CALIPER - 490-1899-802

POS. QTY ITEM NAME

1 1 PCS PAS. CALIPER GGG50 W/BEAR.
2 4 PCS SLIDE BEARING Ø55X50X40
3 2 PCS PAD HOLDER BSFI300-MS
4 4 PCS BOLT M12X50 10.9
5 4 PCS WASHER Ø13X24X2,5

MEB-0300-062 Page 31
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix F - Spare parts drawing, Base plate

ed
eas
Rel

CONFIDENTIAL

Appendix F - Spare parts list, Base plate

BASE PLATE - 490-0419-802

POS. QTY ITEM NAME

1 2 PCS SHAFT Ø50
2 2 PCS SPRING PIN SLOTTED Ø6X20
3 2 PCS SPRING PIN SLOTTED Ø4X20
4 1 PCS BASE PLATE

MEB-0300-062 Page 32
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix G - Positioning system

Name: DEB-0300-027

DATA SHEET Date: 09.06.2015

Revision: D

Positioning system for BSFI 300-MSXXX

Standard (S) and offshore (R) versions

Adjusting
1) Adjust the brake to the desired air gap (standard is 1mm)
2) Mount the spacers (5) and the springs (4) on both shafts (if not done already)
3) Mount the nut (2) on bolt (1). Nut must be at the head of the bolt (1)
4) Mount the bolts (1) with nuts (2) and washer (3) in both threaded holes in passive calliper
5) Adjust the calliper to an air gap of 0.5mm (half of the air gap) on each side of the disc,
by turning the bolts (1) - secure the bolt with nut (2). Repeat for both bolts.

Spareparts
490 2122-801 (Standard version)

Item Qt Parts no. Description

1 2 4490 0613-013 Bolt M10x160
2 2 4490 0614-001 Nut, M10
3 2 2151 2022-173 Washer
4 2 3490 0032-001 Spring
5 2 490 0515-001 Spacer

490 2122-803 (Offshore version)

Item Qt Parts no. Description

1 2 4490 0641-015 Bolt M10x160 A4
2 2 4490 0666-090 Nut, M10 A4
3 2 2151 2022-172 Washer A4
4 2 3490 0032-001 Spring
5 2 490 0515-001 Spacer

www.svendborg-brakes.com

MEB-0300-062 Page 33
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix H - Brake switch / Indicator

Name: DEB-INDI-018

DATA SHEET Date: 21.06.2011

Revision: C

BRAKE SWITCH – “PRE PAD WORN” & “PAD WORN” – 30VDC

ITEMNUMBERS: 490-3777-xxx
Hydraulically applied (active) brakes and spring applied brakes with Automatic Wear Adjustment
General 30V Connections
The indicator provides two signals:
A “Pre Pad Worn” signal that indicates that the brake pad is soon to be Connections
replaced.
A “Pad Worn” signal that indicates that the brake pad must be replaced
immediately.
See datasheet DEB-INDI-019 for information on itemnumbers and ordering
information.
Pre PAD PAD WORN
WORN signal signal
Function COLOR CODE:
Two micro-switches are mounted inside the housing of the switch. The plunger l
BK = BLACK, BN = BROWN, WH = WHITE
detects the brake pad movement through extender pins (if applicable). GY = GREY, BU = BLUE
The “Pre Pad Worn” switch triggers approximately 1,5mm before the brake INDICATOR NOT MOUNTED 30 VDC
pad needs to be replaced. Pre PAD WORN switch (1-4)
Pre PAD WORN switch is OPEN
The “Pad Worn” switch triggers when the brake pad is worn and must be
replaced. PAD WORN switch (3-2-5)
PAD WORN switch is OPEN (2-3)
The actual switch points vary according to the specific brake type / switch and
are not adjustable. The brake switch is available in 30 VDC only. It can be
supplied in different cable options. The cable is connected to the switch by a BRAKE "OFF", PAD NOT WORN **)
standard M12 connector (angled as standard). Indicator mounted & brake is OFF
Brake "Lifted"
Pre WORN switch is CLOSED (1-4)
Fail Safe operation PAD WORN contact is made
For fail-safe operations the switch should be wired to have a signal/connection PAD WORN switch is CLOSED (2-3)
when everything is ok (i.e. closing a normally open switch (NO)). The
connection should disappear when switching i.e. having wear or in case of BRAKE "ON", "Pre PAD WORN" *)
faults like broken cable, poor connections etc. Indicator mounted & brake is activated
Brake released
NOTE - The indication for “Pre Pad Worn” and “Pad Worn” is only active Pre PAD WORN switch is OPEN (1-4)
during braking and disappears when the brake is lifted.
PAD WORN contact is made
PAD WORN switch is CLOSED (2-3)
Mounting
1. Mount the brake and brake pads - refer to manual. BRAKE "ON", "PAD WORN" *)
2a. On Active brakes: the signal is given by measuring directly on the pad Indicator mounted & brake is activated
Brake released
through the threaded holes in the yoke - next to the pad holders or Brake Pre PAD WORN switch is OPEN (1-4)
through a hole in the adjusting screw. Remove the plug (1/2” BSP) from PAD WORN contact is broken
the yoke or from the adjusting screw. PAD WORN switch is OPEN (2-3)
2b. On AWA brakes: the measurement is done through the push-rod in the
centre of the end cap. Remove the plug or the plactic cover from the end BRAKE "OFF", "PAD WORN" **)
cap. Indicator mounted & brake is OFF
Brake "Lifted"
3. Mount the indicator (figure C) into the threaded hole or mount the adaptor Pre PAD WORN switch is CLOSED (1-4)
(BSFI 3000 AWA) on the indicator before mouting (figure D).
PAD WORN switch is CLOSED (2-3)
4. Mount the M12 connector on the switch – for electrical connections see because NO indication for PAD WORN
connection diagram. or Pre PAD WORN when brake is lifted
*) = Brake “ON” = Braking
**) = Brake “OFF” = No braking i.e. brake “lifted”
Technical data
DWG:490-2796-013
Operating temperature : -400C to +850C
Max. Voltage / Current : 30 VDC / 100 mA
Ø32 Fig.C
Switching tolerance : +/- 0.2mm
87 (97 with adaptor (fig D))

Max. Stroke : 16mm

+ min 15mm to remove plug

Protection grade : IP 65 (mounted)

Max. Tightening torque 1/2” BSP : 20 Nm
Max. Tightening torque M12 : finger tight
Max. no. of operations : 1 million
Cable length : 5, 10 or 15meters Fig.D
57

Plug type : angled (standard) or straight

Cable type/material : PUR
Cable dimension : 5 x 0.34mm2
Thread size (indicator) : 1/2” BSP (G 1/2”)
Spanner size (SW) : 30mm

www.svendborg-brakes.com

MEB-0300-062 Page 34
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix I - Technical data

Name: DEB-0300-043

DATA SHEET Date: 15.05.2009

Revision: A

TECHNICAL DATA AND CALCULATION FUNDAMENTALS FOR

DISC BRAKE BSAK 300

BRAKING TORQUE
The braking torque MB is calculated from following formulas:
Where:
(D  0,13)
ΜΒ  a  FΒ  Ο [Nm] a is the number of callipers acting on the disc
2 FB is the braking force according to table above [N]
DO is the disc outer diameter [m]
FΒ  FC  2   [N] FC  A  P  10 [N] FC is the clamping force [N]
A [cm2], P [bar] and µ see values below
The actual braking torque may vary, depending on friction coefficient.

CALCULATION FUNDAMENTALS Standard Monospring

Weight of caliper with bracket: 56 kg 73 kg
Weight of caliper without bracket: 40 kg
Overall dimensions (20mm disc) 331 x 320 x 321 mm 260 x 420 x 300 mm
Pad width: 130 mm 130 mm
Pad area: (organic) 29.000 mm2 (*) 29.000 mm2 (*)
Max. wear of pad: (organic) 10 mm (*) 7 mm (*)
Pad area: (sintered) 20.000 mm2 (*) 20.000 mm2 (*)
Max. wear of pad: (sintered) 7 mm (*) 7 mm (*)
Nominal coefficient of friction: = 0.4 = 0.4
Total piston area - each caliper half: A=44,2 cm2 A=44,2 cm2
Total piston area - each caliper: 88,4 cm2 44,2 cm2
Volume for each caliper at 1 mm stroke: 8,8 cm3 4,4 cm3
Volume for each caliper at 3 mm stroke: 24,6 cm3 13,2 cm3
Actuating time (guide value for calculation): 0.3 sec. 0.3 sec.
Pressure connection/port: 1/4" BSP 1/4" BSP
Drain connection port R: 1/8" BSP 1/8" BSP
Max. operating pressure: P=125bar P=125bar
Recommended pipe size: 10/8 mm 10/8 mm
Operating temperature range
General usage: -20°C to +70°C
For brake applications in wind turbines: -40°C to +60°C
(For temperatures outside this range contact Svendborg Brakes)

(*) On each brake pad

www.svendborg-brakes.com

MEB-0300-062 Page 35
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix J - Recommended fluid

Name: DEB-DIVE-005

DATA SHEET Date: 04.02.2016

Revision: J

RECOMMENDED FLUID FOR DISC BRAKES & HYDRAULICS

PRESSURE FLUIDS / OIL TYPES
The following oil types are recommended by Svendborg Brakes – other types corresponding to these can be used.

The general temperature range for our standard ranges of products using hydraulic oil are -20°C to +60°C (-4°F to
+140°F) however the BSAK and BSAB brake series are generally approved for lower temperatures.
These are approved for usage at -40°C in wind turbines and for -30°C in other applications.

When quick brake reaction times are critical and operating at temperatures below 0°C (+32°F) it is recommended to use
the oil types listed in the Cold section as these types provides the most constant reaction times.
Extreme temperature applications may require special options. Please contact Svendborg Brakes.

Cold / special option Standard Special option

-40°C - +60°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Mineral oil
-40°F - +140°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Shell Tellus S4 VX 32 Tellus S2 V32 Tellus S2 V46 Tellus S2 V68
Mobil /
- DTE 10 Excel 32 DTE 10 Exel 46 DTE 10 Exel 68
EXXON
Texaco Rando Ashless 8401 Rando HDZ32 Rando HDZ46 Rando HDZ68
Valvoline - Ultramax HVLP32 Ultramax HVLP46 Ultramax HVLP68
Castrol Brayco 717
-40°C - +50°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Synthetic oil
-40°F - +122°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Mobil - SHC 524 SHC 525 SHC 526
Bio Oil(1) -40°C - +50°C -20°C - +30°C +10°C - +60°C +30°C - +70°C
(Ester or Colza oil)-40°F - +122°F -4°F - +86°F +50°F - +140°F +86°F - +158°F
Shell - Naturelle HF-E15 Naturelle HF-E32 Naturelle HF-E46
General: Mineral Pressure Fluids according to DIN 51524 Part 3
(1) There must be less than <200PPM water in the oil, due to the seals.

Viscosity
Recommended viscosity range: 20-200 cSt at working temperature. Generally Svendborg Brakes systems are designed
to allow higher viscosity in short periods.

Filtration
The oil in a hydraulic system and the oil added to the hydraulic system must always be filtered. The level of cleanliness
in a hydraulic system is an important factor to the lifetime of the system.
When refilling the hydraulic tank, it is stipulated that the oil added to the system is filtered through a 10-micron purity off-
line filter unit to the classes listed below.

The hydraulic system, supplied by Svendborg Brakes, has a build-in oil filter with a standard 10-micron purity filter. To
maintain a reliable system it is recommend that only hydraulic oil of the following classes of purity is used: NAS 1638,
Class 8, or ISO 4406, Class 19/17/14.
It is recommended that the filter is changed at a minimum, once every six months or more often depending on the level
of exposure to contamination.

Service life of pressure fluids

Mineral oil: 8.000 Hours or at least once a year.
Other fluids: 2.000 Hours or at least once a year.

Change of pressure fluid

Note: The mixing or blending of different brands or types of pressure fluid can cause unintended chemical reactions,
such as sludging, gumming etc. The complete hydraulic system should be thoroughly flushed prior to changing from one
oil type to another.
The respective manufactures should be contacted prior to changing from one pressure fluid to another.

Seal material
Brakes from Svendborg Brakes are normally supplied with PUR-seals (PolyURethane).
PTFE (PolyTetraFlourEthylene) seals can be delivered on request for most of the brake types.
Note: the BSFG 400 brake series are supplied with NBR rubber fabric seals (acrylNitrile Butadiene Rubber).

www.svendborg-brakes.com

MEB-0300-062 Page 36
Installation and Maintenance Manual - BSAK 300-MS30S-200

Appendix K - Recommended spare parts

Recommended spare parts for one brake

Brake pad set

Sinter metal MD550 490-0402-803

Seal kit
Seal kit (-35°C/+200°C) 490-3427-802

Brake pad retraction springs

Pad retraction spring set 490-0666-804

Back-stop set 490-3481-802

Positioning system
Positioning system - standard 490-2122-801

Ø32 Fig.C
Ø32
87 (97 with adaptor (fig D))
+ min 15mm to remove plug
+ min 15mm to remove plug

Indicators
Mechanical indicators Fig.D
57
87

Pad Worn 10mm Indicator (straight

57

plug) - standard cable 490-3777-510

Pad Worn 10mm Indicator (straight

plug) Shielded cable 490-3777-610

MEB-0300-062 Page 37