Operating instructions

Gearbox AFM 04, AFM 05, AFM 06

1197 EN/US 229 113 49 720 IS 913.20 1

 Manufacturer Mannesmann Dematic AG
P.O. Box 67, D-58286 Wetter
Telephone (+ 23 35) 92-0, Telefax (+ 23 35) 92 76 76
Internet http://www.dematic.com

Contents 1 Safety recommendations 3

1.1 Work safety symbols 3
2 Description 4
2.1 General description 4
2.2 Direct drive 4
2.3 Coupling drive 4
2.4 Motor 4
2.5 Gearbox variants 4
3 General 4
4 Putting into operation 4
4.1 Positioning 5
4.2 Mounting position 5
4.3 Modification of gearbox 5
4.4 Assembly of torque arm 6
5 Maintenance 8
5.1 Maintenance schedule 8
5.2 Oil lubrication 9
6 Brake motor KDF 63 10
6.1 Measuring brake displacement path 10
6.2 Replacing brake disc 11
7 Brake motor KMF 80, 90 and 100 13
7.1 Adjusting the brake with shims 13
7.2 Changing the brake disc 14
7.3 Changing the fan 16
8 Brake motor KBF 71, 80, 90 and 100 18
8.1 Adjusting the brake 18
8.2 Replacing the brake lining 18

Enclosures

Hollow-shaft gearbox AFM 04 229 105 49 721 IS 913.20

component part lists AFM 05 229 106 49 721 IS 913.20
AFM 06 229 107 49 721 IS 913.20

Motors for hollow-shaft gearboxes AFM 04 - AFM 06 229 108 49 721 IS 910
KDF 63
KMF 80-100
KBF 71-100

Operating instructions for motors KD 63 229 109 49 720 IS 918

KM 80 / 90 / 100 229 110 49 720 IS 917
KB 71 / 80 / 90 / 100 229 111 49 720 IS 911

2 Technical Data AFM 03 - AFM 06 202 980 44 714 IS 913.20

1 Safety information

1.1 Work safety symbols These symbols are used throughout the operating instructions in order to visually
indicate hazard warnings.
Hazard warning
These symbol appears in the operating instructions next to all instructions relating to
safety at work whereever a potential danger to life and limb exists.
Follow these instructions at all times and be particularly careful and cautious.
Inform personnel involved with working on the friction wheel travel drive of the safety
information.
In addition to the safety information always obey all general safety rules.

Warning of dangerous electrical voltage

Contact with parts under voltage can result in immediate death. Covers and enclo-
sures marked with the warning label may only be opened by trained and authorised
personnel.
Before opening, all voltages, control voltages or other voltages must be disconnect-
ed.

Operating safety of system in case of danger

This symbol is placed in the operating instruction manual next to all information that, if
disregarded, will result in damage to the gearbox.

Modifications of the gearbox may only be performed by authorized technicians. All

relevant safety and accident prevention regulations must be followed.
Follow all safety information to prevent dangerous situations!
The gearbox AFM 04, AFM 05 and AFM 06 is manufactured to the latest production
methods and meets all current safety regulations. All work on mechanical and electri-
cal components must be performed in accordance with the present safety regula-
tions. Repairs may only be performed by authorized personnel. The gearbox may be
operated only in unobjectionable condition.

3
 2 Description

2.1 General description The drive unit comprises a two-stage or three-stage spur reduction gearbox and an
electric motor.

The gearbox AFM is available in two types.

2.2 Direct drive The direct drive compreses a gearbox and a motor. The motor shaft is equipped with
an internal cone. The pinion is glued into the internal cone of the motor shaft and
interposes torque movement from the motor to the gearbox.

2.3 Coupling drive The coupling drive comprises a gearbox and a motor. The gearbox and the motor
shaft are connected by a two part coupling which permits axial movement of the
motor shaft.

2.4 Motor The gearbox is driven by an electric motor which is rated in accordance with relevant
international codes. The KM motor is protected by enclosure type KM IP 55 and KB
motor by the enclosure type IP 54 (and the brake of the KB brake motory by IP 20).
Additional details are provided in the motor operating instructions.

2.5 Gearbox variants The gearbox must be assembled according to all stated requirements since the lubri-
cation, ventilation and brake spring depend on the mounting form/mounting code
(und bei Bauform M auch von der Einbaulage). Only if a different mounting form is
required than was deliverd see „Modification of gearbox“. Only if a different mounting
form is required than was delivered see “Modification of gearbox”.

The gearbox with hollow output shaft is fitted directly to the drive shaft.
3 General According to the specific requirements, the hollow-shaft gearbox can be combined
with a special brake motor, e.g. high power motor, torque motor, slipring motor, DC
motor, travel motor or micro-speed motor. Fitting the hollow-shaft gearbox is very
simple as couplings, chain drives, special foundations or base plates are unneces-
sary.
Suitable torque arms must be provided to secure the gearbox against turning.
The base mounted gearbox must be accurately aligned on a solid vibration-free base
plate. If the gearbox is supplied with a solid output shaft, pinions, couplings or
sprocket hubs must be fitted or removed using a suitable tool to avoid damage to the
gearbox bearings. Never hammer such parts into place. The tapped hole in the end
of the output shaft can be used for pressing the part oto be fitted onto the shaft. It
may be practical to heat the part to approx. 100°C (210° F) to facilitate fitting.
During manufacture the gearbox is carefully checked and filled with a suitable lubri-
cant. On receipt, the unit should be checked for any damage which may have oc-
curred in transit (fractures, cracks, leaks, etc.).

4 Putting into Before starting operation

All necessary data regarding the voltage and power supply is listed in the motor oper-
operation ating instructions.
Follow all safety information started.
Check the gearbox for any damage which may have occured in transit (fractures,
cracks or leaks).
Clean drive shaft.
Lubricate shaft spline and hollow shaft with DG 69 grease part. no. 472 915 44.

4
 The screw plug fitted for transport in the hightest position of the gearbox must be
replaced with the vent pulg supplied. Failure to change the plugs may cause leaks as
a result of overpressure building up in the gearbox.

Vent plug to be fitted in the highest position on the gearbox

Oil Grease Oil Grease Oil Grease

AFM 04 = 0,4 l 0,5 kg AFM 04 = 0,4 l 0,5 kg AFM 04 = 0,4 l 0,5 kg
AFM 05 = 0,5 l 0,6 kg AFM 05 = 0,5 l 0,6 kg AFM 05 = 0,5 l 0,6 kg
AFM 06 = 0,6 l 0,7 kg AFM 06 = 0,6 l 0,7 kg AFM 06 = 0,7 l 0,8 kg

Oil Grease Oil Grease Oil Grease

AFM 04 = 0,4 l 0,5 kg AFM 04 = 0,4 l 0,5 kg AFM 04 = 0,4 l 0,5 kg
AFM 05 = 0,6 l 0,7 kg AFM 05 = 0,6 l 0,7 kg AFM 05 = 0,5 l 0,6 kg
AFM 06 = 0,8 l 1,0 kg AFM 06 = 0,8 l 1,0 kg AFM 06 = 0,7 l 0,8 kg
Fig. 1 41035544.eps

4.1 Positioning The base mounted gearbox must be accurately aligned on a solid vibration-free base
plate.

4.2 Mounting position The gearbox must be assembled according to all stated requirements, since the
lubrication, ventilation and brake spring depend on the mounting form/mounding
code (and, in the case of the M model, also the mounting position).

4.3 Modification of The following models, which can be modified susequently, are available:
gearbox • M with torque arm
• base design B 3, B 6, B 7, B 8, V 5, V 6
• flange mounted design B 5, B 14, V 1, V 3, V 18, V 19
For mounting information to modify gearbox see mounting code key 202 971 44
714 IS 913.20.
When the required mounting form is established, the base form and mounting posi-
tion of the gearbox must be taken into consideration (und Einbaulage bei Bauform M).
For oil quantity see fig. 1.

5
 Tightening torque value
Direct drive Tightening torque for screws in Nm (lb/ft)

Motor-gear housing
Gear housing
Supporting KD 63 KM 80 KM 90
Gear size
material Screw

DIN 912 VERBUS RIPP

AFM 04 AL 8,5 45 45 -

AFM 05 AL 8,5 45 45 -

AFM 06 AL 15 45 45 45

22911304.tbl
Coupling type Tightening torque for screws in Nm (lb/ft)

Intermediate flange - Motor

Motor
Foot Flange Gear
Supporting Motor KD Motor KM Motor KB Gear
Gear size plate B5 housing
material housing
63 80 90 100 71 80 90 100
Screw
VERBUS
DIN 912 VERBUS RIPP
RIPP
AL - - 8,5 18 35 35 18 45 45 45
AFM 04
GG 30 15 - - - - - - - -
AL - - 8,5 18 35 35 18 45 45 45
AFM 05
GG 35 35 - - - - - - - -
AL - - 15 18 35 35 - 18 45 45 - 45
AFM 06
GG 75 75 - - - - 75 - - - 65 35
22911305.tbl

4.4 Assembly of torque Data for connection to supporting structure

arm When the gearbox is mounted to the supporting structure it is necessary to use the
proper torque arm.
Only the correct torque arm secures the gearbox against turning. Please find the
mounting dimensions in the following table.
Mounting screw Mounting hole pattern

Gear size
Tightening
Size Qty. d H11 f1 ±0,3 h1 h2 h4 q4 u
torque

AFM 04 2 - 27,5 142,5 70 14,5±7

AFM 05 M12 115Nm 14,5 35 160 63,5 28±7

4 25 20,5
AFM 06 186 66,5 25±7

22911306.tbl
h2

q4
d
h4

h1

Screw
f1 Grade 10,9 DIN 933
u

Set nut Washer

DIN 6919
Grade 8
6 Fig. 2 40140244.eps
Gearbox AFM 04
Order No. 811 950 44
1 Safety nut VM 12,
DIN 980-8 1 23 4 5
47,5
2 Washer 13x30x6, DIN 7349
30

15,5
3-4 Dämpfungselemente
2,5
5 Hed. hd. screw M12x85,
DIN 931-8.8

31
27,5
Tightening torque 50 Nm (37 lb/ft)

68
Ø14
35 27,5 12
90 83,5

k1
15
11
q4
Fig. 3 41180044.eps 41037644.eps

Gearbox AFM 05
Order No. 818 645 44 1 Safety nut VM 12, 1 23 4 70 5 6 110
DIN 980-8
35 88
2 Washer 13x35x5, DIN 6340

7
3 Spring element 13x35x12
4 Spring element 13x35x27

25 20,5 29

44
14
5 Washer 13x24x3, DIN 6916-HV
92
6 Socket head screw M12x100,
28

Ø13
DIN 912-10.9
Tightening•t torque 100 Nm
35 52,5 18
100

Fig. 4 41234044.eps

Gearbox AFM 06
Order No. 818 649 44
1 Safety nut VM 12,
DIN 980-8 1 23 4 70 5 6 110
2 Washer 13x35x5, DIN 6340 35 88
3 Spring element 13x35x10 7
4 Spring element 13x35x25
25 20,5 29

5 Washer 13x24x3, DIN 6916-HV

44
14

6 Socket head screw M12x100,

92

DIN 912-10.9 28
Ø13

Tightening torque 100 Nm

35 52,5 18
100

Fig. 5 41234044.eps

The thickness of the paint coating between torque arm and sufrace to be mounted
against should not exceed 60 µm (0.002 in.).

7
 5 Maintenance

Under normal service conditions the gearbox is almost maintenance free.

• Cleaning of gear housing in regular intervals.

• Remove dust and production debri to ensure uninterrupted heat exchange with
the surrounding air.
• Cleaning of ventilating plug to assure proper pressure inside gearbox.
• Check the gearbox for leakage and examine the seal rings.

Under normal, 8 hour/day medium duty operating time, the gearbox should be recon-
ditioned by a trained technician after 8 - 10 years of operation.
Our trained specialists can carry this work out for you, either as a special order or as
part of a low-priced inspections agreement.
Our experts are highly experienced and have first class tools. They carry common
wearing parts with them or can obtain them rapidly from local service centers.

5.1 Maintenance schedule

1st servicing after

Daily Every Every Every
Maintenance work
3 12 check month 12 months 4 years
Months Months
Check brakes <
< Check path of displacement and adjust as required <
< Check bolted connections and securing screws on the torque arm <
< Check electrical switchgear, cabling and wiring <
Oil change <
< Check corrosion protection and improve or replace if necessary <
22911307.tbl

For repiars use only original Demag parts (see component part list).
The maintenance schedule is based on normal operating conditions.
If routine maintenance reveals that the intervals are too long or too short, they should
be adapted to the existing conditions.

Using parts other than those approved by Mannesmann Dematic results in cancella-
tion of all liability and warranties.

8
5.2 Oil lubrication Under normal operating conditions, the oil should be changed after 10,000 hours of
service. The oil should, however, be changed at least every 4 years.
Under exceptional conditions, e.g. increased ambient temperatures, we recommend
that oil changes be adapted to suit these conditions.

Oil change
Drain the old oil at operating temperature.
Remove the vent plug located at the top of the gearbox, then the plug at the bottom,
thus alowing the oil to run out.
The oil used to flush the gearbox should have a viscosity of 46-68 mm²/s at 40°C.
For this purpose use twice the amount of oil specified for lubrication. After a few min-
utes of idle running the oil may be drained.
Repeat the flushing operation several times, preferably in both directions of rotation,
and again without load, to ensure that all remains of the old lubricatn are drained
together with the flushing oil.
Fill the gearbox with the quantity of new oil specified on the data plate.

Oil grades
For ambient temperatures of approx. - 10°C to + 50°C a gear oil of 220 mm²/s at
40°C with mild high-pressure additives should be used, DIN 51502 CLP 220,
e.g. BP ENERGOL GR-XP 220, Esso Spartan EP 220, SHELL Omala Oel 220, Mo-
bilgear 630 or Aral Degol BG 220.
At higher or lower ambient temperatures, the type of oil used should be adapted to
the specific conditions.

Order-No. 472 900 44 2,5 l

472 902 44 1,0 l

Grease lubrication
If the gearbox casing is filled with low-viscosity grease, we recommend that this be
changed after every 10,000 hours of service.
For this purpose, open the gearbox casing and flush it thoroughly with a commercial
cleaning agent. Flollowing this, fill the casing with new grease. The required quantity
of grease is indicated on the data plate.

Grease quality
For ambient temperatures ranging from approx. -10°C to +50°C (14° to 122° F) a
low-viscosity gear grease with a dripping point of approx. 150°C (300° F) and a
worked penetration of 380 to 430 1/10 mm should be used e.g., DIN 51502 GP 00F,
z.B. BP Energrease HT EP 00, SHELL Special low-viscosity gear grease H, Esso
Fibrax EP 370 or Aralub FD 00.

Order-No. 472 918 44 0,2 kg

9
 6 Break motor KDF 63

To check the brake displacement path of the long or cross travel motor the following
must be observed: (see 6.1 for measuring the brake displacement path)

Conditions for maintenance work

• Maintenance work may only be performed by authorised electricians who are
familiar with the relevant safety and accident prevention regulations
(DIN-VDE 0100/0113/0160)
• The motor must be de-energized
• The motor must be at standstill
• All loads acting on the motor shaft must be secured

Open terminal box

Remove power supply cable conductors L1, L2, L3 and brake supply cables 33 and
34 from the terminals (see connection diagramm in terminal box)

Terminal block connections for Terminal block connections for

2 and 4-pole motors 8/2-pole motors

U V W 1U 1V 1W 2U 2V 2W
PE 1 2 3 31 32 33 34 PE 1 2 3 4 5 6 31 32 33 34

PE L1 L2 L3 PE L1 L2 L3 L2 L3 L2 oder
Fig. 6 41108244.eps L3 41108344.eps

Connect power supply cable conductors L1, L2 to terminals 33 and 34. The brake
function can be checked by applying the power supply voltage via conductors L1
and L2.
When the maintenance work on the brake has been completed, connect power sup-
ply cable conductors L1, L2, L3 and brake supply cables 33 and 34 in accordance
with the connection diagram in the terminal box.

6.1 Measuring brake All relevant safety regulations and section one (1) safety recommendations must be
followed!
displacement
It is imperative to ensure, by regular maintenance, that the brake disc is replaced
path when the maximum displacement of 1.2 mm (0.047 in.) is reached.

Push cover off motor end by light tap with hammer Pull off fan with removal tool

10 Fig. 7 41106244.eps 411063444.eps

 The brake displacement path must be between
min. 0.3 mm (0.012 in.) - max. 1.2 mm (0.047 in.).
Measure the brake displacement path through both
openings in the brake housing with a caliper in
running and brake position. Develop a medium
dimension from the two measurements. If the
maximum brake displacement path of 1.2 mm
(0.047 in.) is reached the brake disc must be
replaced. If the dimension is within the give range,
then re-assemble the motor.

1. Push in plug
2. Push fan onto shaft
3. Push on cover
Remove plug, measure brake displacement The brake disc must be replaced when the maxi-
path with the depth measuring part of caliper mum brake displacement has been reached.
min. 0.3 mm. See 6.2 Replacing the brake disc
Fig. 8 41106444.eps

6.2 Replacing the Only authorised technicians may perform this work! Follow all relevant safety regula-
tions!
brake disc

Loosen and remove the 4 nuts Remove brake cover

Fig. 9 41106544.eps 40991044.eps

Pull cable slowly until resistance is felt Remove armature plate Remove friction plate with lip seal

Fig. 10 40990944.eps 40991444.eps 40991244.eps 11

 Remove brake disk and seal, fit new brake disk and
seal.
Long hub side facing motor.
Fit lip seal to friction plate.
Fit friction plate with lip seal.

Fig. 11 40991344.eps 40991144.eps 40991244.eps

Use 6 mm dia. bolts or pins (as assembly aid) to

Fit armature plate Ensure correct fit of lp seal. Cable duct guide the brake springs.
must be arranged in the lip seal opening.
Fig. 12 40991444.eps 40990744.eps 40991544.eps

Seal

Fit brake casing and keep cables pulled tight

during assembly.
Subsequently remove assembly guide.

Cable duct Seal in brake enclosure must always

be in contact with th cable duct.

Fig. 13 40990844.eps 41107444.eps

Tighten the 4 nuts with a tightening torque of Press fan onto shaft. Press cover into place.
3 Nm and fit plugs (1).

12 Fig. 14 41107544.eps 41107644.eps 41107744.eps

7 Brake motor KMF 80, 90 and 100

The drive is supplied with the brake adjusted for the minimum brake displacement
path of approx.
1.5 - 2,0 mm Motor 80, 90
1.8 - 2,3 mm Motor 100
As the brake lining wears down, the brake displacement path increases. The brake
must be adjusted when the brake displacement has reached a maximum of
3.0 mm Motor 80, 90
3.5 mm Motor 100
It is therefore imperative to ensure, by regular maintenance, that the brake is
adjusted before the maximum brake displacement path is reached.

The adjustment can be repeated several times.

It is advisable to have a spare brake disc on hand.

No. of shims required

Motor Quantity Shim thickness

80 2x5 0,8 mm (0.03 in.)

90 2x6 0,8 mm (0.03 in.)

100 2x9 1 mm (0.04 in.)

22911303.tbl

7.1 Adjusting the brake Only authorized technicians may perform this work!
Follow all relevant safety regulations! All relevant safety regulations and section one (1)
with shims “Safety recommendations” must be followed!
It is imperative to ensure, by regular maintenance, that the brake disc is replaced
when maximum displacement path is reached.

Measure brake displacement path.

Measure motor KMF 100 in brake
and running position.

Fig. 15 41062044.eps

Push off brake shield

Fig. 16 41062144.eps 41062344.eps 41062444.eps

13
 Remove shims to adjust brake dis-
placement path.
Equal number of shims on both sides! Tightening torque Mot. 80 - 90
Mot. 80 - 90 = 10,5 Nm Check the brake displacement path
Mot. 100 = 25 Nm (approx. 1.5 - 2 mm)
Fig. 17 41062544.eps 41062244.eps 41062644.eps

Tightening torque Measure brake displacement path.

Mot. 80 - 90 = 3 Nm Measure motor 100 in brake and running
Mot. 100 = 5 Nm position.
(Displacement approx. 1,8 - 2,3 mm )
Fig. 18 41062144.eps 41062044.eps

7.2 Changing the Only authorized technicians may perform this work! Follow all relevant safety regula-
tions!
brake disc

Push off brake shield

14 Fig. 19 41062144.eps 41062344.eps 41062444.eps

Remove fan with brake shield Lock brake disc with screw driver and remove
screws.
Fig. 20 41062744.eps 41063244.eps 41063144.eps

After changing the brake disc fit the new shims

supplied with the brake disc.

Equal number of shims on both sides!

Lock brake disc with screw driver and torque

screws with torque wrench.
Tightening torque
Remove brake disc Mot. 80 - 90 = 10,5 Nm
Mot. 100 = 25 Nm

Fig. 21 41062844.eps 41062944.eps

3 3 1

1. Guide for brake release stirrup

2. Spline to assist in assembly
1. Brake release stirrup Fit brake shield
3. Ensure that fan clips are correctly seated in
bearing bushing
Fig. 22 41054844.eps 41054944.eps 41063044.eps

Match markings on fan and fan cap Tightening torque

Mot. 80 - 90 = 10,5 Nm
Put cover of release stirrup in place Mot. 100 = 25 Nm

Fig. 23 41055144.eps 41067344.eps 41062244.eps 15

 Measure brake displacement path.
Mot. 80 - 90 Tightening torque Measure motor 100 in brake and running posi-
Check the brake displacement path Mot. 80 - 90 = 3 Nm tion. Brake displacement path
(1.5 - 2 mm) Mot. 100 = 5 Nm (approx. 1.8 - 2.3 mm)
Fig. 24 41062644.eps 41062144.eps 41062044.eps

7.3 Changing the fan Only authorized technicians may perform this work! Follow all relevant safety regula-
tions!

Fig. 25 41062144.eps 41062344.eps

Push off brake shield Remove fan with brake shield Press fan clips in direction of arrows and
remove fan

16 Fig. 26 41062444.eps 41062744.eps 41055744.eps

 Fit fan onto brake shield

Fig. 27 41055244.eps 41055344.eps 41055444.eps

3 3 1

1. Guide for brake release stirrup

2. Splines to assist in assembly 1. Brake release stirrup Fit brake shield
3. Ensure that fan cups are correctly seated
in bearing bushing
Fig. 28 41054844.eps 41054944.eps 41063044.eps

Put cover of release stirrup in place Match markings on fan and fan cap Tightening torque
Mot. 80 - 90 = 10,5 Nm
Fig. 29 Mot.100 = 25 Nm
41055144.eps 41067344.eps 41062244.eps

Mot. 80 - 90 Tightening torque Measure brake displacement path.

Check the brake displacement path Mot. 80 - 90 = 3 Nm Measure motor 100 in brake and running position.
(1.5 - 2 mm) Mot. 100 = 5 Nm Brake displacement path
(approx.1.8 - 2.3 mm)
Fig. 30 41062644.eps 41062144.eps 41062044.eps
17
 8 Brake motor KBF 71, 80, 90 and 100

Demag drive units are supplied with the brake adjusted for the minimum rotor dis-
placement path lv.
As the brake lining wears down, the path of rotor displacement increases from lv min to
lv max. (see table 1). The brake must be adjusted as soon as lv max is reached.
The rotor displacement path between running and braking position can be measured
on the brake side when the louvers have been removed. This measurement must be
taken both when the motor is running and when it is at standstill.

It is imperative to ensure, by regular maintenance, that the brake is adjusted

before the maximum rotor displacement is reached.

The adjustment can be repeated several times.

It is advisable to have a spare brake lining in stock. Depending on the design of the
motor, different instructions apply to brake adjustment and replacement for various
motor sizes. (See description of adjustment and replacement of the brake lining.)
Table 1

Axial shaft displacement Tightening torque for screw (5)

Displacement path
Size in mm (inches) Screw size Tightening torque
Iv min Iv max
71, 80, 90 1,5 (0.06) 3 (0.12) M5 6 Nm

100 1,8 3,5 M6 11 Nm

22911301.tbl
For work performed on the brake all loads to the motor shaft move be
removed!
8.1 Nachstellen der 1. Measure the path of displacement lv.
Bremse 2. Remove louver (6).
3. Remove screws (5).
4.2 Insert 2 screws (5) into the tapped holes of adjusting nut (4) and tighten until
brake disc (1) is separated from adjusting nut (4).
5. Turn adjusting nut (4) anticlockwise until displacement path Iv min as shown in
table 1 has been reached.
6. Replace and tighten screws (5).
7. Refit louver (6).

8.2 Replacing the brake 1. Remove louver (6) and brake cover (2).
lining 2. Remove retaining ring (7).
3. Remove screws (5) and separate brake disc (1) from adjusting nut (4) (see previ-
ous section item 4).
4. Remove adjusting nut (4) and pull off brake disc (1).
5. Remove worn brake lining (3).
6. After moistening the rubber ring with water (never with oil) press new brake lining
12 3 4 6 (3) onto brake disc (1). Push brake lining (3) in all the way round by tapping with a
5 rubber hammer until it is flush. Make sure that the brake lining is not deformed. It
is best fitted with a special pressure plate.
For special requirements such as
• high brake loads
• high braking accuracy
7 • Short brake run-in periods it is recommendable to replace the brake disc com
pletely or to re-turn the brake lining after fitting. The cone angle is 21° for
KBF 71 - 100.
7. Fit brake disc (1) and adjust to displacement path Iv min (see table 1).
8. For completion of assembly, see previous section (item 6).
9. Screw on brake cover (2) and louver (6).

18 Fig. 31 41109544.eps
19
 Sales and Service Centers in North America
British Columbia
19292 60th Ave., Suite 116
Surrey, British Columbia V3S 8E5
Telephone: (604) 530-5155
Telefax: (604) 530-5189
California
5435 Industrial Parkway
San Bernardino, California 92407
Telephone: (909) 880-8800
Telefax: (909) 880-4469
Georgia
3625 Swiftwater Park Drive
Suwanee, Georgia 30174
Telephone: (770) 932-0000
Telefax: (770) 932-1903
lllinois
1800-E Howard Street
Elk Groove Village, lllinois 60007
Telephone: (841) 593-3100
Telefax: (841) 956-7621
Mannesmann Dematic Corporation
29201 Aurora Road
Cleveland, Ohio 44139
Telephone: (440) 248-2400
Telefax: (440) 248-3086
Internet: http://www.dematic-us.com
20
Ohio
29201 Aurora Road
Cleveland, Ohio 44139
Telephone: (440) 248-2400
Telefax: (440) 248-3874
Ontario
1155 North Service Road West
Oakville, Ontario L6M 3E3
Telephone: (905) 825-5900
Telefax: (905) 825-5901
584 Falconbridge Road, Unit #3
PO. Box 2368, Station “A”
Sudbury, Ontario P3A 4S8
Telephone: (705) 524-5044
Telefax: (705) 524-5045
Pennsylvania
2148 Embassy Drive
Lancaster, Pa 17603-2385
Telephone: (717) 396-9711
Telefax: (717) 396-9719
Quebec
2700 Sabourin
Ville St-Laurent, Quebec H4S 1M2
Telephone: (514) 336-5556
Telefax: (514) 336-4349
Texas
16430 Aldine-Westfield Road
Houston, Texas 77032
Telephone: (713) 443-7331
Telefax: (713) 443-7308
Washington
16771 N.E. 80th Street
Suite 205
Redmond, Washington 98052
Telephone: (206) 883-4668
Telefax: (206) 883-4828
Printed in Germany MBR 1198/1T
Improvements will be incorporated without prior notice