Danfoss DBA 8080 Airflex DBA Brake Assemblies Installation Guide

: May 15, 2024
: Danfoss

DBA 8080 Airflex DBA Brake Assemblies

Specifications

Product: Airflex DBA Brake Assemblies

Model: DBA 8080

Manual Number: AN449367934931en-000102

Product Information

General Information

Warning: Forward this manual to the person
responsible for Installation, Operation, and Maintenance to prevent
personal injury or equipment damage.

Caution: Genuine Airflex replacement parts are
recommended for optimal performance and to maintain the Danfoss
warranty.

How It Works

The Airflex DBA brake assemblies function by utilizing various
components such as mounting flange, disc, friction discs, pressure
plate, springs, diaphragm, end plate, and other parts to enable
efficient braking operations.

Condition of Operation

Ensure proper installation, operation within specified pressure
and speed limits, and regular maintenance to maintain the
functionality and safety of the brake assemblies.

Product Usage Instructions

Installation

Preparation: Prepare the mounting area
ensuring it is clean and free from debris.
Mounting: Follow the provided instructions to
securely mount the Airflex DBA brake assemblies.
Air System: Connect the brake assemblies to
the air system following the specified guidelines.

Operation

Pressure and Speed Limits: Operate the brake
assemblies within the recommended pressure and speed limits to
ensure optimal performance.
Initial Operation: Perform initial testing and
operation procedures as outlined in the manual.
Periodic Inspection: Regularly inspect the
brake assemblies for any signs of wear or damage.

Maintenance

```
1.  **Maintenance Overview:** Understand the  
```
maintenance requirements and schedule outlined in the manual.
Wear Limits: Monitor wear limits of components
and replace as necessary.
Wear Adjustment: Adjust wear components as per
guidelines provided.

Frequently Asked Questions (FAQ)

Q: Can I use non-genuine replacement parts for the Airflex DBA

brake assemblies?

A: The use of non-genuine Airflex replacement
parts could result in substandard product performance and may void
your Danfoss warranty. It is recommended to use genuine Airflex
replacement parts for optimal performance and warranty
compliance.

Installation Guide
Installation, operation and maintenance of Airflex DBA brake assemblies

DBA 8080

AN449367934931en-000102

Airflex DBA brake assemblies
General information

! Warning
Forward this manual to the person responsible for Installation, Operation and Maintenance of the product described herein. Without access to this information, faulty Installation,Operation or Maintenance may result in personal injury or equipment damage.

! Caution
Use Only Genuine Airflex® Replacement Parts
The Airflex Division of Danfoss Power Solutions recommends the use of genuine Airflex replacement parts. The use of non-genuine Airflex replacement parts could result in substandard product performance, and my void your Danfoss warranty. For optimum performance, contact Airflex:

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Table of contents

Section
1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5.0 5.1 6.0 6.1 7.0 7.1 8.0

Description
Introduction Description How it works Condition of operation
Installation Preparation Mounting Air system
Operation Pressure and speed limits Initial operation Periodic inspection
Maintenance Maintenance overview Wear limits Wear adjustment Replacement of Friction discs on single disc brakes: Replacement of Friction discs on dual disc brakes: Replacement of springs Replacement of diaphragm for models 17DBA & 21DBA Replacement of diaphragm for model 28DBA Correct assembly of the 21DBA brake 29DBA pressurization System static adjustment procedure
Ordering information / technical assistance Equipment reference
Parts Basic assemblies DBA rebuild kits Friction disc kits Revision page

Page No.
6 6 6 6 7 7 7 8 9 9 9 10 10 10 11 13 13 14 15 15 16 16 17 17 17 17 18 18 21 21 22

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Airflex DBA brake assemblies
General information

1 6

23 4 7 8 44

15 21 19 20
26 27 28 18

16 17

A

12

13

14 15

11

12

2 24 3 5 25 9 10
Dual Disc (Solid Disc)
Figure 1a

18 19 Single inner spring used on: 117S , 21 7S , 117V & 21 7V
18 19 20 Inner & outer spring used on : 121S , 221S , 1 21V, 221V 129S , 229S , 1 29V, 229V , 329V
Single Disc (Solid Disc) Figure 1b

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Airflex DBA brake assemblies
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A
7 58

54 51 52
12

Table 1 Item Description for fig. 1a (DBA Brake)

Item

Description

1

Mounting flange

2

Stud

3

Clamp tube

4

Disc

5

Friction dis2c0

6

Flat head screw

7

Pressure plate

8

Spring housing

9

Locknut

10

Outer clamp ring

11

Diaphragm

12

End plate

13

Inner clamp ring

14

Hex head screw

15

Lock washer

Item

Description

16

Hex head screw

17

Lock washer

18

Spring retainer plate

19

Inner spring

Outer spring

21

Hex head screw

22

Gear

23

Reaction plate

24

Reaction spring

25

Wear spacer

26

Nameplate

27

Self tapping screw

35

Warning decal

44

Washer

53 55 57 59

Air piping Figure 1c

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Airflex DBA brake assemblies
General information

1.0

Introduction

Throughout this manual there are a number of HAZARD WARNINGS that must be read and adhered to in order to prevent possible personal injury and/or damage to the equipment. Three signal words ” Danger “, “Warning”, and “Caution ” are used to indicate the severity of the hazard, and are preceded by the safety alert symbol.

Danger Denotes the most serious injury hazard, and is used when serious injury or death WILL result from misuse or failure to follow specific instructions.

Warning Used when serious injury or death MAY result from misuse or failure to follow specific instructions.

Caution Used when injury or product / equipment damage may result from misuse or failure to follow specific instructions.
It is the responsibility and the duty of all personnel involved in the installation, operation and maintenance of the equipment on which this device is used to fully understand the
Danger , Warning , and, Caution procedures by which hazards are to be avoided.

Caution This device uses 120 psig compressed air, compressed springs, bonding chemicals and lubricants. All safety precautions (Local, State & Federal) shall be adhered. The device, chemicals and lubricants shall be used per the manufacturer’s instructions.

1.1

Description

1.1.1 The Airflex Model DBA brakes were designed for heavy duty industrial applications where spring set
(power off) braking is required.

1.1.2 All Airflex DBA brakes are supplied with long wearing, NON-ASBESTOS friction material.

1.1.3 Airflex DBB brakes are available in three basic sizes, namely, 17″, 21″, and 29″ and can be supplied as single disc, dual disc or triple disc units. The model number identifies the number of discs and the disc diameter. For example, 221DBA indicates the brake uses two 21inch diameter discs. When size, such as 21DBA is referred to in this manual, it means that the information given applies to all DBA models using 21 inch diameter discs; i.e. 121DBA, 221DBA etc…

1.1.4 The disc type is indicated by an S for solid or a V for ventilated, in the brake model designation.Solid discs are used in applications requiring a heat sink and/or where engagement is infrequent. Ventilated discs are recommended for cyclic applications.

1.1.5 Minimal adjustment is required for lining wear.Single disc units require no wear adjustment,dual disc units require only one wear adjustment and three disc units require only two wear adjustments during the long life of the friction material.

1.1.6 The quantity of springs can be varied to customize the torque of the brake to suit a particular application. Consult the factory for brake torque of units with nonstandard spring configurations.

1.1.7 The large friction area of the DBA brake allows brakes to absorb and dissipate high energy loads associated with high cyclic and high inertia stops.

1.2

How it works

Note: Refer to Figure 1a, Figure 1b, Figure 1c, and Table 1 for Brake layout and parts list.

1.2.1 The brake is spring applied and air released. When the air pressure is exhausted, the spring force “clamps” the disc (4) between the Friction discs (5) on the Mounting flange (1) and the Pressure plate (7) and in the case of dual disc units, a Reaction plate (23). To disengage the brake, air pressure is applied through the end plate (12) into the diaphragm (11) cavity. As the air pressure increases, the end plate (12) moves away from the stationary Spring housing (8). The Pressure plate (7) is bolted to the end plate (12) and travels in the same direction with it, compressing springs (19), and (20) used in the larger units, and releasing the brake.

1.3

Condition of operation:

Danger
Maximum speed of the disc(s) (4) must not exceed the RPM listed in Table 4. Exposure to speeds in excess of this amount may cause the disc(s) to burst. Do not risk injury!

2.0 Installation

Danger Prior to installation of the DBA Brake, make sure that the machinery will remain in a secured position. Failure to do so could result in serious personal injury or possibly death.

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Airflex DBA brake assemblies
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Caution Before performing any work, study this manual and the brake figures 1a, 1b, and 1c. Know what needs to be done. Do not risk injury – follow the instructions.

Warning A protective means must be used to prevent oil or grease from coming into contact with the disc(s) (4) or the Friction discs (5) during installation and operation. Oil or grease on the discs or the Friction discs will signifcantly reduce the torque capacity of the brake and decrease its ability to hold the machinery in a safe position. Do not risk injury!

Caution If the brake is used in a very dirty or contaminated atmosphere,a protective means should be provided between the Outer clamp ring (10) and the Spring housing (8) to assure a long diaphragm (11) life .

Caution Excessive air pressure can cause diaphragm (11) or end plate (12) failure. Do not apply air pressure greater than 120 psi (8.3 bar). Insufficient air pressure can cause the brake to partially release and generate heat. The minimum recommended operating DBA air pressure is indicated on the nameplate and is given in Table 2 below:

Table 2 Alignment requirements

DBA brake model

Concentricity (Parallel,TIR) of shaft and element inches (mm)

Perpendicularly (Angular,TIR)

of Mounting flange to shaft*

Inches

(mm)

117, 217

0.01

(0,25)

0.008

(0,20)

121, 221

0.01

(0,25)

0.01

(0,25)

129, 229, 329 0.01

(0,25)

0.014

(0,36)

*Perpendicularity measured near the O.D. of the Mounting flange.

Caution Proper alignment Is necessary to assure that the discs (4) will track properly between the Friction discs (5) and not cause excessive disc (4) and Friction disc (5) wear or binding. Refer to Figure 2.

2.1 Preparation
2.1.1 Figures 1a, 1b, & 1C show the relationship between the brake mounting surface and the end of the gear (dimension “A”). The gear is bored and keyed for a resulting Class FN2S interference fit for inch shafing and ISO System S7h6 for metric shafting.
2.1.2 Alignment The DBA Brake must be concentric and at right angles to the shaft. See Table 2 for alignment requirements for each model brake.

Correct track

Figure 2

Incorrect track

2.1.3 Apply a light coat of Castrol Molub-Alloy 936SF Heavy grease or equivalent to the driving gear teeth (22) and slide the brake assembly onto the gear. This also ensures proper movement of disc (4) Note: Reference Danfoss Airflex Part number 000153X1182 for the specified grease.
Caution Gear (22) and disc (4) teeth must be kept free of dirt and debris to assure proper operation of the disc (4).
2.2 Mounting The DBA Brake must be mounted to a clean. rigid surface with flat washers and screws. Refer to section Table 3 for grade, quantity, size and torque values.
2.2.1 The driving gear (22) must be positioned axially along the shaft so that the disc (4) will not run out of travel as the Friction discs (5) wear. Refer to dimension “A” in Figure 1a, 1b, 1c and to Table 4. It is important to pre- fit the key in both the gear (22) and the shaft keyways and check the bore, with respect to the shaft diameter, to assure proper fit at assembly.

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Airflex DBA brake assemblies
General information

Table 3 Fastener description and assemblyTorque – ft.-lb. (Nm)

Item

Description

Units

17DBA

(9)

Locknut

lb-ft (Nm)

500 (678)

(6²)

Flat head screw

lb-ft

20

(Nm)

(27)

(14²)

Hex head screw

lb-ft

10

(Nm)

(14)

(16²)

Hex head screw

lb-ft

50

(Nm)

(68)

(21²)

Hex head screw

lb-ft

20

(Nm)

(27)

Mounting screw

lb-ft (Nm) SAE Metric

112 lube/148 dry (152) lube/(200) dry 3/4-10NC M18

*Note:
1. Threads on which Item #9 is mounted are lubricated. 2. Threads of items 6, 14, 16 & 21 are dry. 3. All Screws to be S.A. E. Grade 2 minimum. For plated bolts use lubed Torque. 4. If hardened washer is used with screws, use lubed Torque.

21DBA
500 678
20 (27)
10 (14)
75 (102)
20 (27)
163 lube/255 dry (221) lube/(345) dry 1-8NC M24

29DBA
500 678
20 (27)
20 20
150 (204)
20 (27)
163 lube/255 dry (221) lube/(345)dry 1-8NC M24

Table 4
`A’ Dimension on figure 1 inches/(mm)

DBA Model Solid disc
Ventilated disc

Inches (mm)
Inches (mm)

117
1.88 (48,0)
1.00 (25,0)

217
1.88 (48,0)
1.75 (44,0)

121
1.88 (48,0)
2.12 (54,0)

2.2.2 Grease driving gear teeth (22) at installation with a thin coat of Molub-Alloy OG Heavy grease or equivalent.This ensures proper movement of disc(4).

Caution Gear (22) and disc (4) teeth must be kept free of dirt and debris to assure proper operation of the disc (4).

2.3 Air supply system:

2.3.1 It is recommended that pneumatic piping be used to supply control air to the brake. See Figure 3. To assure an adequate air supply, it is recommended that an air receiver tank and an adequate actuation valve be used along with the piping sizes identified in Table 5.

221
1.88 (48,0)
2.12 (54,0)

129
2.25 (57,0)
2.25 (57,0)

229
2.25 (57,0)
2.75 (70,0)

Figure 3

329 2.25 (57,0) 2.75 (70,0)
16 17 54
51 52
53 55 57 59 58

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Airflex DBA brake assemblies
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Table 5 Air supply piping size

Pipe Size

17DBA

1/2-14 NPT

S

V

X

3/4-14 NPT

X

1-11 1/2 NPT

S = Solid disc models V = Ventilated disc models

21DBA SV
XX

29DBA SV
XX

2.3.2 Pneumatic piping should be free of foreign material such as pipe thread sealer, metal chips, etc. Pipe ends must be reamed after cutting to prevent reduction of effective pipe diameter. Use minimum length of piping between the actuation air valve and brake. Excessive piping and other restrictions will slow down the response time of the brake.

Caution Do not use rigid pipe to connect the end plate (12) to the air supply. Any restrictions in the movement of the end plate will cause the brake to malfunction.

2.3.3 DBA models with ventilated discs are shipped from the factory with flexible hose and a flow control valve. To install the flow control valve, refer to Manual CP 3084

3.0

Operation

3.1 Pressure and speed limits

3.1.1 Maximum applied pressure is 120 psig (8.2 bar). Minimum releasing pressure for low pressure brakes is 60 psig (4.1 bar).

Warning Maximum applied pressure is 120 psig(8.2 bar). Operation at pressures exceeding maximum may result in damage to the DBA components.

3.1.2 The minimum recommended DBA operating air pressure is indicated on the nameplate and is given in Table 6 below

3.1.3 Maximum disc speeds are shown on Table 7.

Warning Operation at disc speeds exceeding the maximum allowable, as shown on Table 7,may result in exposure to personal injury or product/equipment damage.

Table 6 DBA Minimum operating air pressure

Air pressure
60 psig (4.1 bar) 85 psig (5.9 bar) 100 psig (6.9 bar) S = Solid Disc Models V = Ventilated Disc Models

17DBA
SV X
X

21DBA
SV X
X

29DBA SV
X
X

Table 7
Brake size 17DBA 21DBA 29DBA

Maximum disc speed solid disc rpm
2300
1900
1500

Maximum Disc Speed Ventilated Disc rpm
1300
1000
900

3.2

Initial operation

3.2.1

The non-asbestos friction material used on DBA brakes may not develop rated torque as a short wear in period is required.

3.2.2 If the brake engagement appears harsh, a flow control valve (58) may be installed in the brake air supply line. When using a flow control valve, install so free flow is to the brake and restricted flow is away from the brake. Figure 1c shows the flow control valve. Airflex pneumatic component Part numbers for each size DBA brake can be found in Section 6.1.4 (Air Manifold)

Caution Excessive restriction of the brake exhaust air will result in long stopping times and inconsistent stopping position.

3.2.3

If the DBA brake is used in combination with a clutch, clutch/brake overlap may occur which will result in excessive heat generation and motor overload. Overlap may be detected by monitoring the drive motor current at the beginning and end of each machine cycle. A current surge at the beginning of the cycle usually indicates clutch overlap which can be correctd by restricting the air flow to the clutch or increasing the air pressure to the brake. A current surge at the end of the machine cycle usually indicates brake overlap which can be corrected by installing and adjusting a flow control valve in the brake air supply line, as indicated in 3.2.2.

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Airflex DBA brake assemblies
General information

3.3 Periodic inspection

3.3.1 As the friction material wears, the brake torque will be reduced somewhat and adjustment of the stpoping position controls (flow control or limit switch) will be necessary. See the MAINTENANCE section for the friction material wear limit and replacement procedure.

3.3.2 Periodically check for air leakage in the area of the piston seals (21,23). For replacement, refer to the Maintenance section.

3.3.3 Periodically observe the Friction disc assembly(s) with the brake released. Dragging Friction discs may be caused by wear or contamination at the gear/ring gear contact areas.

3.3.4 Pneumatic and electrical control interlocks should be periodically checked for correct settings and operation.

4.0

Maintenance

Danger Prior to adjustment or disengagement of the DBA Brake, make sure that the machinery will remain in a secure position. Failure to do so could result in serious personal injury or possibly death.

Caution Before performing any work, study this manual and the brake figures 1a, 1b, 1c. Know what needs to be done. Do not risk injury – follow the instructions.

4.1

Maintenance overview

This section provides the necessary information for

the maintenance and repair of the single disc and

the dual disc DBA Brakes. Pay attention to the brake

model and type as dimensional data is different for

several models. To be assured that the brake will

function properly, all replacement parts should be

purchased from Danfoss Power Solutions, Airflex Division.

Inspections should be performed when the brake

torque decreases, and the brake is not engaging

or disengaging properly or when normal machine

maintenance or overhaul is performed. The frequency

of required maintenance will vary depending upon

the application and frequency of use of the brake.

4.2

Wear limits

4.2.1 Wear limits for the DBA components are shown on Table 8. If any wear limit has been reached or exceeded, that component must be repaired or replaced.

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Airflex DBA brake assemblies
General information

Table 8 Wear limits for DBA components

Item

Description

5

Friction disc

Friction Wear Surface for

2 Mounting flange

23 Reaction Plate;

7 Pressure plate

4

Disc (Ventilated) Friction Wear Surface

Minimum Rotor Thickness

4

Disc (Solid)

Friction Wear Surface

Minimum Rotor Thickness

12

Clamp tube

Reaction Area

11

Diaphragm

Inner clamp ring/Outer

Clamp Ring Seal Area

19

Inner spring

Original

Spring Free Height

`

19

Inner spring

Minimum

Spring Free Height

20

Outer spring

Original

Spring Free Height

20

Outer spring

Minimum

Spring Free Height

24

Reaction Spring Original

Spring Free Height

24

Reaction Spring Minimum

Spring Free Height

Size/Remarks
Fully Worn at Bottom of wear groove. See Figure #8. Friction Material must also be replaced if contaminated with oil or grease.
117DBA, 217DBA 121DBA, 221DBA 129DBA, 229DBA, 329DBA
117DBA, 217DBA 121DBA, 221DBA 129DBA, 229DBA, 329DBA
Maximum wear is .015″ (.38mm)
Cracks or holes. 21DBA
17DBA 21DBA 29DBA
17DBA 21DBA 29DBA
17DBA 21DBA 29DBA
17DBA 21DBA 29DBA
17DBA 21DBA 29DBA
17DBA 21DBA 29DBA

Remarks
Mulit-disc brakes have adjustment provision by removing wear spacers (25)
1.44 (36.5) 1.44 (36.5) 1.56 (39.6)
0.94 (23.8) 0.94 (23.8) 0.94 (23.8)
Wear will be in the form of a notch or step on the side of the tube.
Wear will be in the form of cracks or leaks.
4.5″ (114) 5.1″ (130) 5.6″ (142)
4.28″ (109) 4.84″ (123) 5.32″ (135)
n/a 5.1″ (130) 5.6″ (142)
n/a 4.84″ (123) 5.32″ (135)
3.01″ (76) 3.01″ (76) 2.57″ (65)
2.78″ (71) 2.78″ (71) 2.37″ (60)

4.3. Wear adjustment
4.3.1 Single disc DBA Brakes do not have a provision for adjustment. When the Friction disc is worn to the bottom of the wear step, the Friction discs must be replaced. The multi disc DBA Brakes do provide for adjustment should the running clearance become excessive as explained below.
To determine if the running clearance is excessive. release air (engage brake), and measure the distance “X” as shown in Figure 4. Compare this measurement to the value given in Table 9 for the proper brake model. “X” new is given in Table 9.

If Wear spacers are not present and if the “X” dimension is equal to or greater than “X Gap, Replace Friction discs” value given or the Friction disc wear step is no longer visible, replace the the Friction discs.

Note: ‘X Gap’ value shown in Table 9 is the gap after wear

adjustment. New or rebuilt brakes may vary slightly from this

value due to tolerances.

X

Note: The actual “X” dimension when new or rebuilt may vary slightly to “X” new dimension due to the stack up of tolerances.
Note: Be sure to note that the ‘X’ Gap measurement is taken from the bottom (machined surface) of the Pressure plate (7) to the bottom (machined surface) of the Spring housing (8).

If Wear spacers are present and if the “X” dimension

is equal to or greater than the “X-Gap Adjust, Remove

One Set of Wear spacers” value given in Table 9 then

Figure 4

adjustment is done as given below.

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Airflex DBA brake assemblies
General information

Table 9 DBA Wear measurements X Gap – inches (mm)

DBA Size 117DBA
121DBA
129DBA
217DBA
221DBA 229DBA
329DBA

Quantity of Discs
1 Inches (mm)
1 Inches (mm)
1 Inches (mm)
2 Inches (mm)
2 Inches (mm)
2 Inches (mm)
3 Inches (mm)

X-Gap* New Gap
1.62″ (41,16)
1.62″ (41,16)
2.37″ (60,21)
1.75″ (44,35)
1.75″ (44,35) 2.50″ (63,40)
2.61″ (66,37)

(X-Gap)** Adjust Remove 1 set of spacers
n/a n/a
n/a n/a
n/a n/a
2.24″ (56,98)
2.24″ (56,98) 2.99″ (76,03)
3.17″ (80,58)

(X-Gap)*** Replace Friction Discs
2.14″ (54,37)
2.14″ (54,37)
2.89″ (73,42)
2.27″ (57,56)
2.27″ (57,56) 3.02″ (76,61)
3.13″ (79,58)

Note: Values shown is also gap after wear adjustment. New or rebuilt brakes may vary slightly from this value due to tolerances.
** Perform wear adjustment when X-Gap reaches or exceeds this value. *** Replace Friction discs when wear step is no longer visible.

4.3.2 To adjust, remove locknuts (9) and washers (44) (Ref: Figure 5) in alternating sequence (Ref: Figure 6) in increments of 1/4 of the exposed stud thread length.
Caution If a stud (2) comes loose from the Mounting flange (1), clean stud threads thoroughly. Apply Loctite 277, or equivalent. Stud must be threaded back into the Mounting flange hole until it bottoms.

25

9

2

1 3

6 4

1

12

5

8

9

4

3

5

2

DB A brak e models 117, 217, 121,221

10

7

6

11

2

DB A brak e model s 129, 229,329

Figure 6

4.3.3 With locknuts (9) removed, the end plate (12), Spring housing (8), and the Pressure plate (7) can be removed as an assembly.

4.3.4 Remove one set of Wear spacers (25) from the studs.

Caution Only remove Wear spacers (25) in complete sets only.

4.3.5 Reassemble the end plate (12), Spring housing (8), and Pressure plate (7) as an assembly on the studs (2) with the Wear spacers (25) now located on the outside of the Spring housing as shown in Figure 9. Install washers (44) under the Wear spacers as shown.
4.3.6 Lubricate stud threads with 30 wt. oil or “Never Seez.” Assemble locknuts (9) and wo.shers (44) on the studs and torque locknuts to torque values secified in Table 3, for proper brake model, using the sequence shown in Figure 6

Caution After adjustment, a minimum of 0.040″ running clearance between each Friction disc (5) and each disc (4) must exist.

25 9

2

8

44

W ear spacer location
Figure 5

12

44 8
W ear spacer storage
Figure 7
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Airflex DBA brake assemblies
General information

4.4

Replacement of Friction discs on single

disc brakes:

4.4.1 This section covers the replacement of Friction discs (5) for. DBA Brakes 117, 121 and 129. To determine if Friction discs need to be replaced, release air (engage brake) and check if the wear indicating step on the Friction discs is still visible.or if oil or grease has contaminated the surface (Reference Figure 8). If the step is visible and the surfaces are not oil or grease contaminated, no replacement is necessary. If the step is not visible. or if the surfaces are oil or grease contaminated, proceed to 4.4.2

Danger Prior to disengagement of the brake, make sure that the machinery will remain in a secureposition. Failure to do so could result in serious , personal injury or possibly death.

4.4.2 Remove locknuts (9) and washers (44) in an alternating sequence in increments of 1/4 of the exposed stud thread length (refer to Figure 8).

W ear indicating gro ove on O. D. of friction discs (typ)

Figure 8
Caution If a stud (2) comes loose from mounting flange (1), clean stud threads thoroughly. Apply Locktile 277 or equivalent. Stud must be threaded back in until it bottoms in Mounting flange (1).
4.4.3 Remove the end plate (12). Spring housing (8), and the Pressure plate (7) as an assembly.
4.4.4 Remove disc (4) from gear (22). Inspect disc (4)for wear. If either surface of the disc is worn more than 1/32″, replace the disc. Removal of the disc from the gear will expose the Friction disc mounted on the Mounting flange (1).

4.4.5 Remove the old Friction discs (5) and replace with new Friction discs. Apply a coating of Locktite 242 (blue). or equivalent, to the threads of the Flat head screws (6). Install and torque the screws (6) to the value specified in Table 3 for the proper brake model.
Note: Refer to Section 7.1 for Friction disc Kit Part numbers and quantities.

Caution
Before installing the new screws,make sure that the holes are clean to ensure that the new screws will lock properly.

4.4.6 Reinstall the disc (4).

4.4.7 Reassemble the end plate (12), Spring housing (8). and the Pressure plate (7) as an assembly

4.4.8 Lubricate stud (2) threads with 30 wt. oil or “Never Seez”.

4.4.9 Assemble the washers (44) and locknuts (9), torque the locknuts using the sequence shown in Figure 8 to the torque value specified in Table 3 for proper brake model.

4.5

Replacement of Friction discs on dual disc brakes:

4.5.1 This section covers the replacement of Friction discs (5) on DBA Brakes 217, 221, 229 and 329. To determine if Friction discs need to be replaced, release air (engage brake) and check if the wear indicating step on each Friction disc is still visible, or if oil or grease have contaminated the surfaces Reference Figure 8).If the step is visible and the surfaces are not oil or grease contaminated, replacement is not necessary. If the step is not visible, or the surfaces are oil or grease contaminated, replace the Friction discs, proceed to 4.4.2.

Danger Prior to replacement of Friction discs, make sure that the machinery will remain in a secure position. Failure to do so could result in serious personal injury or possibly death.

4.5.2 Remove locknuts (9) and washers (44) in an alternating sequence in increments of 1/4 of the exposed stud thread length. (Refer to Figure 8).

E-CLCL-II010-E October 2015

13

Airflex DBA brake assemblies
General information

Caution If a stud (2) comes loose from Mounting flange (1), clean stud threads thoroughly. Apply Loctite 277 or equivalent.Stud must be threaded in until it bottoms in Mounting flange (1).
4.5.3 Remove the end plate (12), Spring housing (8), and the Pressure plate (7) as an assembly.
4.5.4 Remove springs (24), Clamp tubes (3), discs (4), and Reaction plate (23). With these parts removed, all Friction discs (5) are accessible.
4.5.5 Inspect the discs (4) for wear. If either surface of the disc is worn more than 1/32″, replace the disc.
4.5.6 Remove the old Friction discs (5) and replace them with new Friction discs. Apply a coating of Locktite 242 (blue), or equivalent, to the threads of screws (6). Install and torque the screws to the value specified in Table 8 for the proper brake model.
Caution Before installing the new screws, make sure that the holes are clean to ensure that the new screws will lock properly.
4.5.7 Reassemble springs (24), Clamp tubes (3), discs(4), and Reaction plate (23).
Caution Springs (24) are to be assembled on every other stud (2), The springs on either side of the re-action plate must be assembled on the same stud with the Clamp tubes. Improper assembly will result in cocking of the Reaction plate (23) and uneven brake release.
4.5.8 Reassemble the Wear spacers (25) and the end plate (12). Spring housing (8), and Pressure plate (7) as an assembly.
Caution While reassembling the end plate, Spring housing, and the Pressure plate assembly, take care to install the Wear spacers (25) in the proper position Refer to (Figure 5 & Figure 7)
4.5.9 Lubricate stud threads with 30 wt. oil or “Never-Seez”. Assemble the washers (44) and locknuts (9). Torque the locknuts using the sequence shown in Figure 6 to the torque value specified in Table 3 for proper brake model.

4.6

Replacement of springs:

Danger Prior to disengagement or removal of the brake, make sure that the machinery will remain in a secure position. Failure to do so could result in serious injury or possibly death.

4.6.1 Remove locknuts (9) and washers (44) in alternating sequence in increments of 1/4 of exposed stud thread length (Refer to Figure 6).

Caution
If a stud (2) comes loose from Mounting flange (1), clean stud threads thoroughly. Apply Loctite 277 or equivalent. Stud must be threaded in until it bottoms in Mounting flange (1).

4.6.2 Remove the end plate (12), Spring housing (8}, and the Pressure plate (7) as an assembly and place it on a clean working surface with the end plate (12) facing up.

4.6.3 Remove Hex head screw (16) and Lock washers (17) in alternating sequence, two turns at a time (Refer to Figure 9). With these removed, the end plate (12). diaphragm (11), Outer clamp ring (10). Inner clamp ring (13), Hex head screws (14) and (21). and Lock washers (15) can be removed as an assembly.

Alternating sequence f or endplate (1 2) Scre w / W asher (1 6)/(17) rem oval & inst allation

1

6

1

8

5

3

4

3

5

2

DB A brake models 117, 217

Figure 9

6

7

2

DB A brake models 121, 221,129, 229, 32 9

Caution Before removing the old springs, make note ofthe number used and the position that they are in so that the new springs may be installed similarly for proper brake functioning.
4.6.4 Remove Spring housing (8) exposing the springs (19) and (20) and Spring retainer plates (18).

14

E-CLCL-II010-E October 2015

Airflex DBA brake assemblies
General information

Note: DBA Brake models 117 and 217DBA use only spring (19).

head screw (21) and Lock washer (15). This will free

121,221, 129, 229 and 329DBA use inner and Outer springs (19)

Outer clamp ring (10) for removal.

and (20).

4.7.3 Remove Hex head screw (14) and Lock washer (15).

4.6.5 Remove Spring retainer plates (18) exposing the

This will free Inner clamp ring (13) for removal.

springs (19) and (20).

4.7.4 Replace the diaphragm (11).

4.6.6 Replace springs (19) and (20). Refer to note in 4.5.4.

4.7.5 Reinstall Outer clamp ring (10) and torque Hex head

4.6.7 Install Spring retainer plates (18).

screws (21) with Lock washer (15) to torque value

Note: No Spring retainer plates (18) should cross over the ribs in

specified in Table 8 for proper brake model.

the Spring housing (8).

4.7.6 Reinstall Inner clamp ring (13) and torque Hex head

Caution Clean the rubbing surfaces between the Spring

screws (14) with Lock washer (15) to torque value specified in Table 3 for proper brake model.

housing (8) and the Pressure plate {7) and the spring

Caution

housing and the diaphragm {11) and coat with Amsoil long life, multi-purpose, molycompound synthetic grease. This helps prevent wear between these parts.

Clean the rubbing surfaces between the Spring housing (8) and the diaphragm (11) and coat with Amsoil long life, multi-purpose molycompound synthetic grease.

4.6.8 Install Spring housing (8). making sure the pockets line up with the pockets on the Pressure plate (7).

4.6.9 Reassemble end plate (12). diaphragm (11), Outer clamp ring (10), Inner clamp ring (13). Hex head screws (14) and (21) and Lock washers (15) as an assembly. Assemble Hex head screws (16) and Lock washers (17) and torque the screws usingthe sequence shown in Figure 9. Torque the screws (16) to the torque value specified in Table 8 for proper brake model.

4.6.10 Reassemble the end plate (12). Spring housing (8). and the Pressure plate (7) as an assembly.

4.6.11

Lubricate stud threads with 30 wt. oil or “Never-Seez”. Assemble the locknuts (9) and washers (44) and torque the locknuts using the sequence shown in Figure 6 to the torque value specified in Table 3 for proper brake model.

4.7

Replacement of diaphragm for models

17DBA and 21DBA

Danger Prior to disengagement or removal of the brake, 1, make sure the machinery will remain in a secure position.Failure to do so could lead to serious personal injury or possibly death.

4.7.1 Perform steps 4.6.1 through 4.6.3

4.7.2 Place the end plate (12) with. the diaphragm (11) facing up on a clean working surface. Remove Hex

4.7.7 Carefully place newly assembled end plate (12) diaphragm (11), Outer clamp ring (10), and innt.,.. clamp ring (13) assembly on brake. AssembleHex head screws (16) and Lock washer (17) using the assembly sequence shown in Figure 9. Torque screws (16) to torque value specified in Table 3 for proper brake model.

4.8

Replacement of Diaphragm for Model 28DBA

Warning Prior to replacement of parts supplied in this diaphragm replacement kit, carefully read the following instructions and make sure what is stated in each step is fully understood. Failure to follow these instructions may result in personal injury or equipment damage.
Note: The 29DBA diaphragm replacement kit contains a new diaphragm and a tube of Loctite Superflex #596 sealant

4.8.1 Removal and disassembly

4.8.1.1

The end plate (12) and diaphragm (11) can be removed from the brake without removal or disassembly of the Spring housing (8) and Pressure plate (7), provided the locknuts (9) remain secured. The procedure is provided below in sections 4.8.1a through 4.8.1e. See Fig. 1 for item numbers.

Caution If replacing the diaphragm while the brake is installed, do not loosen the locknuts (9). If Spring housing/Pressure plate disassembly is desired, refer to the maintenance section which describes proper

E-CLCL-II010-E October 2015

15

Airflex DBA brake assemblies
General information

4.8.2

disassembly procedures.
a. While supporting the end plate, remove the Hex head screws (16) and lock washers (17). b. Remove the end plate/diaphragm assembly. Place it on a clean working surface with the diaphragm facing up.
c. Remove the Hex head screws (21), lock washers (92) and Outer clamp ring segments (10).
d. Remove the Hex head screws (14), lock washers (15) and Inner clamp ring (13).
e. Remove the diaphragm (11) and clean the end plate and clamp rings, smoothing any nicks or burrs. Replace any damaged components.
Diaphragm installation and assembly

4.8.2.1 Using a solvent, thoroughly clean the grooves in the end plate which hold the diaphragm beads.

4.8.2.8

Clean the rubbing surfaces between the Spring housing (8) and the diaphragm (11) and coat with Amsoil ® long life, multi-purpose moly-compound synthetic grease, or equivalent.

4.8.2.9

Position the end plate assembly on the Pressure plate. Align the match marks, making sure that the heads of the Hex head screws (14) will fit intothe corresponding counter-bores in the Pressure plate.

4.8.2.10 Assemble the end plate to the Pressure plate with Hex head screws (16) and lock washers (17). Using a crosswise sequence, torque the screws to 150 ft.-lb, lubed.

4.9

Correct assembly of the 21DBA brake

Note: Follow appropriate safety precautions when working with solvents.

4.8.2.2

Using a petroleum based solvent, clean any contamination or residue from both diaphragm beads. Allow the solvent to fully evaporate prior to continuing with the assembly.

Warning For the Airflex model 21DBA spring applied brakes, it is possible to incorrectly install a part of this brake so that the brake will not achieve full torque holding capacity. Assemble per the following instructions. NOTE: The Airflex 21DBA spring applied brake models are:

Note: Apply solvent only to bead area of the diaphragm.

4.8.2.3

Apply a continuous layer of Loctite Superflex #596 sealant (approximately .030″ to .045″ thick) to the bottom of the inner and outer bead grooves in the end plate. Spread the sealant evenly to form a layer in the groove bottom, contacting both sides of the groove.

4.8.2.4

Noting the proper orientation, install the diaphragm on the end plate, making sure the beaded edges are seated properly in the grooves. The side of diaphragm which should be facing up has the words “THIS SIDE UP” molded on the face.

Note: Loctite Superflex will begin to skin over approximately ten minutes after being applied. The diaphragm MUST be
installed in the end plate within ten minutes of applying the sealant.

4.8.2.5 Position the Outer clamp ring segments on the plate.

Model number
121DBA 121DBA 121DBA 221DBA

Part number
146145A 146145P 146145M 146151A

Model
221DBA 221DBA 221DBA 221DBA

Part number
146151F 146151K 146151M 146151P

Note: Both the Airflex model and Part numbers appear on the nameplate attached to the end plate of the brake. The end plate is the plate to which the air supply is connec.ted
Note: The 21DBA has six main studs and large locknuts that are located near the O.D. of the end plate. The end plate has six clearance notches on he O.D. of the plate. When the plate is properly installed with the clearance notches opposite the studs, the notches provide the clearance to prevent the end plate form contacting the studs and locknuts. It is absolutely necessary for these notches to be positioned correctly or else the brake will not operate correctly.
4.9.1 It is imperative that a visual inspection be made of all 21DBA brakes to make sure that the end plate is correctly installed (this includes all brakes).

4.8.2.6

Apply Loctite #242 Threadlocker to the threads of the Hex head screws (21). Attach the clamp ring segments with the screws and washers (92), and tighten to 20 ft.-lb.

4.8.2.7 Attach the Inner clamp ring (13) with Hex head screws (14) and Lock washers (15). Tighten the screws to 20 ft.-lb, dry.

4.9.2 If the end plate is not positioned correctly, the end plate must be removed, rotated and reinstalled.
Danger Prior to any adjustment, disconnect power to the machinery and air supply to the brake and make sure the machinery will remain in a safe position. Failure to do so could result in serious personal injury of possibly death.

16

E-CLCL-II010-E October 2015

Airflex DBA brake assemblies
General information

4.9.3 Remove the eight hex head cap screws and Lock washers located at the I.D. of the end plate and disconnect the air supply. Carefully rotate the end plate until the clearance notches line up with the studs. Due to the four internal screws which hold the diaphragm Inner clamp ring, the end plate will only fit in four positions . Therefore, rotate 90 deg at a time until the proper match of notches is achieved. Reinstall the eight hex head cap screws and Lock washers. Torque the screws in a crosswise manner to 50 lb-ft. Reconnect the power and air supply.

4.10 29DBA pressurization

Warning All end plate fasteners must be installed.

4.10.1

It is extremely important that all fasteners used in the 29DBA brake assembly be properly assembled and tightened prior to pressurization and actuation of the brake, particularly those that secure the end plate (12) to the Pressure plate (7). All eight of the Hex head screws (17) should be installed with lock washers (16) and tightened to 150 lb-ft, lubed. The end plate should NOT be pressurized without proper assembly of ALL eight (8) of these fasteners. (Reference Figure 1a and Figure 3).

Warning Failure to install and properly tighten all fasteners that secure the end plate to the Pressure plate prior to applying air pressure to actuate the brake may result in failure of the end plate and possible severe personal injury or death.
4.11 System static adjustment procedure: Before the machinery is started up, a static actuation check of the brake is recommended as follows:

Danger Prior to adjustment or disengagement of the brake, make sure that the machinery will remain in a secure position. Failure to do so could lead to serious injury or possibly death.

4.11.1 Bypass any interlocks or use manual overrides on actuation valves so static actuation may be made.

4.11.2 Check for proper installation of filter, regulator and air receiver tank.

4.11.3 Set minimum operating air pressure according to Table 2. The maximum operating pressure is 120 psi (8.3 bar).

4.11.4 Check for “all clear” in and around machinery.

4.11.5 Energize actuation valve(s).
4.11.6 Check for air leaks- correct if required.
4.11.7 Check all quick release valves for proper operation. Refer to QRV 9090.
4.11.8 De-energize actuation valves.
4.11.9 Repeat steps 3.7.5 and 3.7.8 several times.
4.11.10 Reset any interlocks which may have been bypassed in step 3.7.1.
4.11.11 Check pressure gauge for pressure loss and recovery.
Note: If loss is over 10 psi (0.7 bar) andrecovery is slow, add air receiver tank, if one does not exist. Check restrictions in all air line components, including undersized piping. Refer to CP 3083 regarding “Overlap”.

5.0

Ordering information/technical assistance

5.1

Equipment reference

5.1.1 In any correspondence regarding Danfoss/Airflex Equipment, refer to the information on the product nameplate and call or write:

Loctite and Loc-Quic are registered trademarks of Henkel Corporation. Castrol Molub-Alloy 936SF Heavy is a registered
trademark of Castrol Limited. Molykote is a registered trademark of Dow Corning Corp.

E-CLCL-II010-E October 2015

17

Airflex DBA brake assemblies
General information

6.0

Parts

6.1

Basic assemblies

6.1.1 17DBA

Item

Description

117DBA S

146148CP

Part number

Qty

217DBA S

117DBA V

146152CP

146148CA

Part number

Qty

Part number Qty

1

510282

1

510282

1 510282

1

2

Stud

307261-01

6

307261-03

6 307261-01

6

3

Clamp tube

306542-03

6

306542-01

6 306542-04

6

4

Disc

413295

1

413295

2 413490

1

5

Friction disc

414686

2

414686

4 414686

2

6

Flat head screw

000294×0405

18

000294×0405

36 000294×0405

18

7

Pressure plate

510284

1

510284

1 510284

1

8

Spring housing

510286

1

510286

1 510286

1

9

Locknut

000110×0073

6

000110×0073

6 000110×0073

6

10

Outer clamp ring

413647

1

413647

1 413647

1

11

Deaphragm

413648-02

1

413648-02

1 413648-02

1

12

End plate

510712

1

510712

1 510712

1

13

Inner clamp ring

306944-02

1

306944-02

1 306944-02

1

14

Hex head screw

000001×0205

3

000001×0205

3 000001×0205

3

15

Lock washer

000068×0007

21

000068×0007

21 000068×0007

21

16

Hex head screw

000001×0615

6

000001×0615

6 203840

6

17

Lock washer

000068×0019

6

000068×0019

6 000068×0019

6

18

Spring retainer plate 306624

18

306624

18 306624

18

19

Inner spring

306625

27

306625

27 306893

27

20

Outer spring

n/a

21

Hex head screw

000001×0208

18

000001×0208

18 000001×0208

18

22

Gear*

413113- 1

413248- 1 413113- 1

23

Reaction plate

n/a

510304

1 n/a

24

Reaction spring

n/a

306546

6 n/a

25

Wear spacer

n/a

306896

6 n/a

26

Nameplate

307007-01

1

307007-02

1 306626-01

1

27

Self tapping screw

000153×0644

4

000153×0644

4 000153×0644

4

35

Warning decal

203627

1

203627

1 203627

1

44

Washer

000153×0641

6

000153×0641

6 000153×0641

6

*Note: The gear is not included with the assembly. Order separately. Numbers given are for straight bores. Tapered bore gears also available

217DBA V 146152CX Part number
510282 307261-04 306542-02 413490 414686 000294×0405 510284 510286 000110×0073 413647 413648-02 510712 306944-02 000001×0205 000068×0007 203840 000068×0019 306624 306893 n/a 000001×0208 413248-## 510304 306546 306896 306626-02 000153×0644 203627 000153×0641

Qty
1 6 6 2 4 36 1 1 6 1 1 1 1 3 21 6 6 18 27
18 1 1 6 6 1 4 1 6

18

E-CLCL-II010-E October 2015

Airflex DBA brake assemblies
General information

6.1.2 21DBA

Item

Description

121DBA S

146145CP

Part number

Qty

221DBA S

146151CP

Part number

Qty

121DBA V

146145CA

Part number

Qty

1

Mounting flange

509792

1 509792

1

509792

1

2

Stud

307261-01

6 307261-03

6

307261-01

6

3

Clamp tube

306542-03

6 306542-01

6

306542-04

6

4

Disc

413053

1 413053

2

510549

1

5

Friction disc

414685

2 414685

4

414685

2

6

Flat head screw

000294×0405

36 000294×0405

72

000294×0405

36

7

Pressure plate

509794

1 509794

1

509794

1

8

Spring housing

509796

1

509796

1

509796

1

9

Locknut

000110×0073

6

000110×0073

6

000110×0073

6

10

Outer clamp ring

412601

1

412601

1

412601

1

11

Deaphragm

408080-02

1

408080-02

1

408080-02

1

12

EndPlate

509798

1

509798

1

509798

1

13

Inner clamp ring

412603-02

1

412603-02

1

412603-02

1

14

Hex head screw

000001×0205

4

000001×0205

4

000001×0205

4

15

Lock washer

000068×0007

28 000068×0007

28

000068×0007

28

16

Hex head screw

203802

8

203802

8

203802

8

17

Lock washer

000068×0019

8

000068×0019

8

000068×0019

8

18

Spring retainer plate 306920

24 306920

24

306920

24

19

Inner spring

306922

24 306922

24

306928

24

20

Outer spring

306921

24 306921

24

306927

24

21

Hex head screw

000001×0209

24 000001×0209

24

000001×0209

24

22

Gear*

413534- 1

413535- 1

413534- 1

23

Reaction plate

n/a

510170

1

n/a

24

Reaction spring

n/a

306546

6

n/a

225

Wear spacer

n/a

306896

6

n/a

26

Nameplate

306626-10

1

307007-10

1

306626-10

1

27

Self tapping screw

000153×0644

4

000153×0644

4

000153×0644

4

35

Warningdecal

203627

1

203627

1

203627

1

44

Washer

000153×0641

6

000153×0641

6

000153×0641

6

*Note: The gear is not included with the assembly. Order separately. Numbers given are for straight bores. Tapered bore gears also available

221DBA V 146151CA Part number
509792 307261-04 306542-02 510549 414685 000294×0405 509794 509796 000110×0073 412601 408080-02 509798 412603-02 000001×0205 000068×0007 203802 000068×0019 306920 306928 306927 000001×0209 413535-## 510170 306700 306896 306626-10 000153×0644 203627 000153×0641

Qty
1 6 6 2 4 72 1 1 6 1 1 1 1 4 28 8 8 24 24 24 24 1 1 6 6 1 4 1 6

E-CLCL-II010-E October 2015

19

Airflex DBA brake assemblies
General information

6.1.3 29DBA

Item Description

121DBA S

229DBA S

121DBA V

221DBA V

146145CP

146151CP

146145CA

146151CA

Part number Qty Part number Qty Part number

Qty Part number

Qty

1

Mounting flange 414624

1 414624

1

22 Stud

307261-02

12 307261-05

12 307261-02

12 307261-05

12

3

Clamp tube

306542-05

12 306542-02

12 306542-06

12 306542-07

12

4

Disc

413579

1 413579

2 510607

1 510607

2

5

Friction disc

414665

2 414665

4 414665

2 414665

4

6

Flat head screw

000294×0407 72 000294×0407 144 000294×0407 72 000294×0407 144

7

Pressure plate

510619

1 510619

1

8

Spring housing

510616

1 510616

1

9

Locknut

000110×0073 12 000110×0073 12 000110×0073 12 000110×0073 12

10 Outer clamp ring 414922

8 414922

8

11 Diaphragm

404517-02

1 407517-02

1

12 End Plate

413581

1 413581

1

13 Inner clamp ring 407684-02

1 407684-02

1

14

Hex head screw

000001×0205 4 000001×0205 4 000001×0205

4 000001×0205

4

15 Lock washer

000068×0007 4 000068×0007 4 000068×0007

4 000068×0007

4

16

Hex head screw

203806

8 203806

8

17 Lock washer

000068×0025 8 000068×0025 8 000068×0025

8 000068×0025

8

18

Spring retainer plate 413583

24 413583

24

19

Inner spring

307044

30 307044

30 304668-02

24 304668-02

24

20

Outer spring

307045

30 307045

30 304668-01

24 304668-01

24

21

Hex head screw

000001×0209 24 000001×0209 24 000001×0209 24 000001×0209

24

22

Gear*

413801- 1 414126- 1 413683- 1 413585- 1

23

Reaction plate

n/a

413586

1 n/a

415331

1

24

Reaction spring

n/a

306909

12 n/a

307077

12

25 Wear spacer

n/a

306896

12 n/a

306896

12

26 Nameplate

306626-10

1 306626-10

1

27 Self tapping screw 000153×0644 4 000153×0644 4 000153×0644

4 000153×0644

4

35 Warning decal

203627

1 203627

1

44 Washer

000153×0641 12 000153×0641 12 000153×0641 12 000153×0641 12

*Note: The gear is not included with the assembly. Order separately. Numbers given are for straight bores. Tapered bore gears also available

329DBA 146210CA Part number Qty

414624

1

307261-06

12

306542-11

12

510607

3

414665

6

000294×0407 216

510619

1

510616

1

000110×0073 12

414922

8

407517-02

1

413581

1

407684-02

1

000001×0205 4

000068×0007 4

203806

8

000068×0025 8

413583

24

304668-02

24

304668-01

24

000001×0209 24

415080- 1

415331

2

307077

18

307501

24

306626-10

1

000153×0644 4

203627

1

000153×0641 12

20

E-CLCL-II010-E October 2015

Airflex DBA brake assemblies
General information

6.1.4 DBA Air Manifold

Item Description

117DBV V 146148CA Part no.

217DBA V 146152CA Qty Part no.

121DBA V 146145CA Qty Part no. Qty

221DBA V 146151CA Part no.

129DBA V 146162CA Qty Part no.

229DBA V 146163CA Qty Part no. Qty

51 Air tube

—

413959

1 413959

1 511061

1

52 Air tube

511066

2 511066

2 413960

1 413960

1 511062

1

53 90 deg Street elbow 000079×0009 1 000079×0009 1 000079×0008 1 000079×0008 1 000079×0008 1 000079×0008 1

54 90 deb Male Elbow 000153×0425 2 000153×0425 2 000153×0838 2 000153×0838 2 000153×0838 2 000153×0838 2

55 Cross

000153×0427 1 000153×0427 1 000153×0428 1 000153×0428 1 000153×0428 1 000153×0428 1

57 Hose assembly 000318×0004 1 000318×0004 1 000250×0020 1 000250×0020 1 000250×0020 1 000250×0020 1

58 Flow Control Valve000042x0215 1 000042×0215 1 000042×0215 1 000042×0215 1 000042×0215 1 000042×0215 1

59 Bushing

000085×0005 1 000085×0005 1 —

—

Note: Reference Figure 1c and Figure 3 for components and piping layout

329DBA V

146210CA

Part no.

Qty

511061

1

511062

1

000079×0008 1

000153×0838 2

000153×0428 1

000250×0020 1

000042×0215 1

—

7.0

DBA Rebuild Kits

7.1

Friction disc Kits

DBA Brake

Model

Kit No.

Description

117DBA 217DBA
121DBA 221DBA 2229DBA 329DBA

106885D
Contact Danfoss Engineering for Part number 107074H
107074J
106901J
Contact Danfoss Airflex Engineering for part number

Part number Quantity
Part number Quantity
Part number Quantity
Part number Quantity
Part number Quantity
Part number Quantity

Locknut Item (9)
000110×0073 6
000110×0073 6

Flat head screw Item (6)
000294×0405 18
000294×0405 36

000110×0073 6
000110×0073 6
000110×0073 12
000110×0073 12

000294×0405 36
000294×0405 72
000294×0405 144
000294×0405 216

Friction disc Item (5)
414686 2 414686
4
414685 2 414685 4 414665 4 414665 6

Loctite n/a
n/a
000153×1016 1 000153×1016 2 000153×1016 3 000153×1016 4

E-CLCL-II010-E October 2015

21

Airflex DBA brake assemblies
General information

8.0 Revisions

Original publication date: November 2013

Revision date August 2015

Description
Added Section 6 and Section 7 complete Added Section 5 ordering information and trademarks Revised Section 1 to ‘Introduction’ and added Introduction text rewrite of Section 1.0 thru 1.1.8 Deleted size 14 brake from all references Created new Table 1 (Parts Description) Table 2 was Table 4; Table 3 was Table Tables 3 & 8; Table 4 was Tables 5 & 5a Table 5 was Table 6; Table 6 was Table 2; Table 7 was Table 1 Created new Table 8; Table 9 was Table 7 Figures 1a, 1b & 1c replaced Figures 1 thru 4. Figure 2 was Figure 5; Figure 3 is new; Figure 4 was ‘B’ dimension Figure 6 Figure 5 was Figure 7; Figure 6 was Figure 8; Figure 7 was Figure 9 Figure 8 was Figure 10; Figure 9 was Figure 11 Created new Figures 10 and 11. Rewrite of Section 2.1 thru Section 2.3.3 Section 3.0 was Maintenance Revised Maintenance section to Section 4.0 thru Section 4.10.1 Section 4.9 is new Added Sections 4.10 & 4.11

22

E-CLCL-II010-E October 2015

Airflex DBA brake assemblies
General information
Notes

E-CLCL-II010-E October 2015

23

Products we offer:
· Cartridge valves
· DCV directional control
valves
· Electric converters
· Electric machines
· Electric motors
· Gear motors
· Gear pumps
· Hydraulic integrated
circuits (HICs)
· Hydrostatic motors
· Hydrostatic pumps
· Orbital motors
· PLUS+1® controllers
· PLUS+1® displays
· PLUS+1® joysticks and
pedals
· PLUS+1® operator
interfaces
· PLUS+1® sensors
· PLUS+1® software
· PLUS+1® software services,
support and training
· Position controls and
sensors
· PVG proportional valves
· Steering components and
systems
· Telematics

Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and electric components. We specialize in providing state-of-the-art technology and solutions that excel in the harsh operating conditions of the mobile off-highway market as well as the marine sector. Building on our extensive applications expertise, we work closely with you to ensure exceptional performance for a broad range of applications. We help you and other customers around the world speed up system development, reduce costs and bring vehicles and vessels to market faster. Danfoss Power Solutions your strongest partner in mobile hydraulics and mobile electrification. Go to www.danfoss.com for further product information. We offer you expert worldwide support for ensuring the best possible solutions for outstanding performance. And with an extensive network of Global Service Partners, we also provide you with comprehensive global service for all of our components.
Local address:

Hydro-Gear www.hydro-gear.com
Daikin-Sauer-Danfoss www.daikin-sauer-danfoss.com

Danfoss Power Solutions (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239 6000

Danfoss Power Solutions GmbH & Co. OHG Krokamp 35 D-24539 Neumünster, Germany Phone: +49 4321 871 0

Danfoss Power Solutions ApS Nordborgvej 81 DK-6430 Nordborg, Denmark Phone: +45 7488 2222

Danfoss Power Solutions Trading (Shanghai) Co., Ltd. Building #22, No. 1000 Jin Hai Rd Jin Qiao, Pudong New District Shanghai, China 201206 Phone: +86 21 2080 6201

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.