Document Number SM-DLS1D5T-01 PLEASE READ THIS MANUAL

Revision 01(PY180X26) BEFORE OPERATION.

Electric Control Hydraulic Disc and

Caliper Installation

SERVICE MANUAL

Beijing PSK New Technology of Petroleum Machinery Co.,Ltd.

Service manual Electric Control Hydraulic Disc and Caliper Installation Preface

Preface
This manual describes principle, structure, operation and
maintenance of PSK L series Hydraulic control hydraulic disc brake.
Please read this manual carefully before operating or repairing PSK
L series Hydraulic control hydraulic disc brake and perform
installation, operation and maintenance in accordance with this
manual.

Using efficiency and service life of this product closely relates to

rational using by users as well as design and manufacturing of
product. We will provide users high-quality products according to
quality assurance system, meanwhile we hope operators can read
carefully this manual before operating and make performance and
advantage of product be played fully and complete expected
operation successfully.

For product is in improving continuously, some contents in this

manual may not be consistent with the actual product, but it will not
affect understanding on product structure and performance by users,
also not affect operation. If you have any questions ， contact the
manufacturer.

With the continuous advancement of drilling technology, users will

have new requirements continuously. We are willing to, together with
you, improve our products constantly and meet your special
requirements. You are welcome to contact us.
Service manual Electric Control Hydraulic Disc and Caliper Installation Contents

Contents
I. Description ....................................................................................... 1
II. Main Technology Parameter ...........................................................3
III. Operating Principle and Features ..................................................5
IV. Installation ....................................................................................14
V. Adjustment .................................................................................... 18
VI. Rules of Operation ...................................................................... 22
VII. Maintenance ............................................................................... 25
VIII. Failure Examine and Repair ..................................................... 32
IX. Dismantle and Replace of Key Parts .......................................... 33
X. Consumable Parts ........................................................................39
Appendix ........................................................................................... 40
Service manual Electric Control Hydraulic Disc and Caliper Installation Description

I. Description
PSK L series Hydraulic control hydraulic disc brake is composed of
three sections: brake execute unit, hydraulic power source and
control unit.

Brake execute unit is connected with hydraulic power source by

hydraulic lines, and control unit is connected with hydraulic power
source by hydraulic lines, too.

Hydraulic power source provides necessary power for brake execute

unit; brake execute unit is the executor of braking and consists of
brake calipers, caliper support arms and brake discs, where brake
calipers is combined by main service calipers and safety calipers as
required; control unit is the control link of the installation and it
controls the operating valves in control desk and realizes the action
control of the brake execute unit.

PSK L series hydraulic control hydraulic disc brake has the following
five functions:

1. Service brake: adjust the positive pressure of the main service

caliper on brake disc by operating the control handle of the service
brake, as a consequence provide adjustable braking torque for
drawworks and meet different operating condition requirements such
as normal drilling, trip, etc.

2. Parking brake: when drilling rigs don‟t work or drilling worker

leaves control desk temporarily, turn on the parking brake to braking
position, so safety calipers brake the drawworks to prevent rotary
hook from slipping down.

3. Emergency brake: in case of emergency, press down emergency

brake button, then both main service calipers and emergency

1
Service manual Electric Control Hydraulic Disc and Caliper Installation Description

calipers brake the drawworks.

4. Over winding/crown-block protecting: when the rotary hook

raises to a position with heavy goods, the service brake fails to brake
the drawworks due to operational error or other reasons, the
crown-block protecting system gives signal, then both main service
calipers and emergency calipers brake the drawworks.

5. Air failure automatic brake: under the condition of air failure of

the brake system, the emergency brake brakes automatically to
prevent any accidents from occurrence.

6. Power off automatic braking: when the control system loses

power, emergency braking automatically applies to prevent
accidents.

2
Service manual Electric Control Hydraulic Disc and Caliper Installation
Main Technology Parameter

II. Main Technology Parameter

3
 Service manual Electric Control Hydraulic Disc and Caliper Installation
Main Technology Parameter

PSK Hydraulic Control Hydraulic Disc Brake

This set of specific product specification

Product model PS75/1800D

Drilling rigs XJ750
Retarding torque of
75
working brake（kN·m）
Retarding torque of
60
parking brake（kN·m）
Retarding torque of
135
emergency brake（kN·m）
Brake disc
1450×40
diameter（mm）×Thick（mm）
Number of
2
service caliper assembly
Number of
2
safety caliper assembly
Caliper model KQ-LS-00/BQ-L-00
System pressure（MPa） 8
Capacity of main pump 15L/min
Summer：HM46# anti-wear hydraulic oil
Working medium
Winter：HV32#anti-wear hydraulic oil
Capacity of oil box 90L
Installed total electric power 5kW

4
Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

III. Operating Principle and Features

Hydraulic control hydraulic disc brake consists of brake execute unit,
hydraulic power source and control unit.

3.1 Brake execute unit

Brake execute unit mainly consists of brake calipers, brake discs and
caliper support arms, where brake calipers includes main service
caliper and safety caliper. The structure and layout of brake execute
unit shall be as Figure 1.

1．Caliper Frame 2.Safety Caliper 3.Service Caliper 4.Brake Disc

Figure 1 Brake Execute Unit

3.1.1 Operating principle of brake caliper

All braking functions of Model PSK L disc brake are implemented by

the main components——brake calipers. The brake calipers of
Model PSK L disc brake consist of main service and safety calipers
with floating lever each. Fig.2 is a sketch of both calipers with floating
lever.

5
Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

（A）Service Caliper （B）Safety Caliper

Figure 2 Exterior view of caliper with floating lever

The operating principle of the main service caliper with floating lever
(Fig 2 (A)) is that the hydraulic force pushes the piston rightward
when the hydraulic oil is supplied to the caliper cylinder. The piston
and the cylinder push upper ends of right and left levers to move
outward through upper pins，and driving the brake pad inward, thus
pressing the brake pad on the rotating brake disc. With certain
amounts of normal load, the friction force between the brake disc and
the brake pad then affects the stop of the brake disc. In this way, it
can be seen that the braking force of main service caliper results
from the hydraulic force, and the higher the hydraulic oil pressure is,
the greater the braking force is.

If the pressure of the hydraulic oil entering the caliper cylinder

reduces to zero, the piston and the cylinder move inward by means
of the return spring mounted on ends of right and left upper pins,
while the brake pad moves in the opposite direction and then
disengages the brake disc, which enables the brake calipers to
release braking. The main service calipers brake the drawworks with
the oil pressure but release braking at the absence of hydraulic force.
Therefore, it is called the main service caliper.

6
Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

The operating principle of the safety caliper with floating lever (Fig.2
(B)) is that when the hydraulic oil is supplied to the caliper cylinder,
the hydraulic force pushes the piston to move rightward so as to
compress the disc spring and simultaneously pulls upper ends of
right and left levers to move inward (levers rotate around mid pins),
enlarging the distance between the right and left lower pins and
moving the brake pad outward. At this very moment, the brake pads
disengage the brake disc, and brake calipers release braking. When
the caliper cylinder drains oil, the disc spring bounces back and
pushes the piston leftward, and upper ends of right and left caliper
arms move outward to shorten the distance between the right and
left lower pins, thus making the brake pad and the brake disc keep
the contact. The brake pad force exerting on the brake disc is called
the disc spring force which generates the friction force to effect
braking. It can be seen that the braking force of the parking caliper
results from the spring force of the disc spring.

3.1.2 Brake disc

Brake disc in one of core components of a brake system and forms

brake assistant with brake pad. Each product is equipped with two
discs, which will be installed on both ends of the drum of drawworks,
in general. Each drawwork of some new type drilling rigs is equipped
with one disc which will be installed on the end of drum of
drawworks.

Brake disc is solid disc according to structural from. Heat dissipation

of the solid disc shall be done by its surface and it is used mainly for
work over rigs and small drilling rigs.

3.1.3 Caliper support arm

7
Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

Caliper support arm is the base of brake execute unit, both main
service caliper and emergency caliper are installed on the base.
Two-disc structure shall be equipped with two caliper support arms
which will be installed on the base of the draw works and on one side
of the drum.

3.2 Hydraulic power source

Hydraulic power source includes: oil tank components, pump unit,
control block assembly, oil filling components, electric control box
and operating valves, etc. Its hydraulic control principle refers to
Figure 3.

3.2.1 Oil tank components

Oil tank components include: oil tank, oil absorbing valve, oil
discharging valve, level thermometer, cooler and other elements,
where, the action of oil absorbing valve is to close the valve and
make oil tank disconnect with oil absorbing port of oil pump and
prevent any leakage of hydraulic oil during repairing oil pump. Oil
absorbing valve is in open state during normal working. Oil
discharging valve is equipped for replacing hydraulic oil and it is in
close state during normal working. Level thermometer is used for
observing level in oil tank and temperature of oil tank. Cooler is pipe
row type water cooled cooler and used to balance heat generation of
the whole system.

3.2.2 Pump unit

Pump unit is the heart of the hydraulic system. The system is

equipped with two same plunger pumps which is driven by explosion
proof motor separately, one for operating, and another for standby.

3.2.3 Control block assembly

8
Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

Control block assembly consists of mainly: oil pipeline block,

accumulator, cut-off valve, one-way valve, safety valve and high
pressure oil filter, etc.

The accumulator may reduce pressure fluctuation of the hydraulic

loop, supply certain energy storage when pump can not work
normally and ensure main service caliper to brake normally the
drawworks 4~6 times.

Cut-off valve is used for releasing oil pressure of the accumulator; it

must be closed during normal working. Otherwise, the system
pressure can not be reached.

One-way valve is used to separate oil ports of two pumps, make oil
of accumulator not flow back, and meanwhile form three oil pipelines
which are independent and correlated each other.

Safety valve is an overflow valve and used for safety protection.

High-pressure oil filter filters high pressure oil of system and keep
hydraulic system clean.

3.2.4 Oil filling components

Oil filling components is composed of a hand pump and a filter. Oil

filling of oil tank must be finished by oil filling pump unit to keep
cleanness of oil.

3.2.5 Electric control cabinet

Electric control cabinet of hydraulic power source is used mainly for

controlling starting and stop of motor and heater; electric control
cabinet shall be subject to explosion suppression treatment.

3.2.6 Operating valves

Operating valves include service brake valve components, parking

9
Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

brake valve components, emergency brake valve components and

pressure gauges, etc.

Service brake valve components include an electromagnetic

proportional reducing valves which are used for adjusting the oil
pressure.

Parking brake valve component include an electromagnetic shuttle

valve which is used for controlling the pressure supply and pressure
relief of safety calipers assembly.

Emergency brake valve components include an electromagnetic air

reversing valve, a pneumatic control reversing valve, a pneumatic
hydraulic directional valve and a hydraulic control reversing valve.
Emergency braking for power outage is achieved by operating the
electromagnetic directional valve, while emergency braking for gas
outage is achieved by operating the pneumatic directional valve.

There are three pressure gauge interfaces on the main oil circuit
block of the hydraulic power source, which are respectively
connected to display system pressure, safety caliper pressure, and
service caliper pressure. There are three pressure sensors (4~20mA)
installed on the auxiliary oil circuit block of the hydraulic power
source, which transmit three pressure signals to the control system:
system pressure, safety caliper pressure, and service caliper.

3.3 Control unit

Control unit includes electronic brake crank, parking brake switch,
emergency brake button and electric control box. Electric control box
includes air switch, power supply, amplifier and other electrical
elements.

10
 Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

3.Rotary Pressure Pipeline Oil

1. Refueling Hose 2. Hand Pump
Filter
4. Return Oil Filter 5. Air Cooler 6.Explosive-proof Motor 0.12kW
7. Temperature Controller 8. safety valve 9. Level Thermometer
10. Air Filter 11.High Pressure Globe Valve 12.High-pressure Rubber Hose
13.Explosive-proof Motor 3kW 14.Elastic Coupling 15.Pump Rack
16.Constant Pressure Plunger Pump 17.High-pressure Rubber Hose 18.Plug In One-way Valve
21.Flip Type Pressure Pipeline Oil
19.High Pressure Globe Valve 20.Direct-acting Overflow Valve
Filter
22.Accumulator 23.Pressure Testing Adapter 24.Pressure Hosepipe
26.High Pressure Globe Valve, 27.Explosive-proof Electric
25.Pressure Gang
Plate Type Cabinet
28.Hydraulic control directional valve 29.Quick Coupling 30.Explosion-proof solenoid valve
31.Pneumatic hydraulic directional
32.Gas Pressure Switch 33.Gas Pressure Sensor
valve
36.Explosion-proof
35.Pneumatic Operated
34.Solenoid Valve Electromagnetic Proportional
Directional Valve
Pressure Reducing Valve
37.Hydraulic Control One-way Valve
Figure 3 Schematic diagram of hydraulic system

11
Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

3.4 Operating principle

3.4.1 Service brake

When the electronic brake lever is in its original position, the

maximum pressure in the service caliper cylinder is the system
pressure, and the service caliper is in the braking state. Pull the
electronic brake lever to control the electromagnetic proportional
valve (36). The electromagnetic proportional valve (36) outputs
hydraulic oil with the corresponding pressure value to enter the left
and right service calipers, achieving working brake release. As the
angle of the brake lever increases, the braking force of the service
caliper also decreases accordingly. When the angle of the brake
lever is at its maximum, the braking force of the service caliper is
zero. The reset spring pulls the service caliper to reset, and the
service caliper is in a completely released braking state.

3.4.2 Parking brake

Parking brake is used as a change-over switch to control

electromagnetic reversing valve (30) of parking brake to obtain
electricity or electricity failure. It is electricity failure when the
change-over switch is on “brake” position, and emergency calipers
brake; it obtains electricity when the change-over switch is on “loose”
position, and emergency calipers release braking. The basic
principle of control is electricity failure braking. When releasing the
parking brake, the "electronic brake lever" must first brake the load,
then turn the transfer switch to the "loose" position and release the
emergency caliper.

3.4.3 Emergency brake

Emergency brake is used as an emergency button to control

12
Service manual Electric Control Hydraulic Disc and Caliper Installation
Operating Principle and Features

electromagnetic reversing air valve (34) for obtaining electricity or

electricity failure. Press button down, electromagnetic reversing air
valve will be under electricity failure and the system shall be in
emergency braking state; turn and raise up the button, then
electromagnetic reversing air valve obtains electricity, and release
emergency braking state. The basic principle of control is electricity
failure braking.When releasing the emergency brake, the "electronic
brake lever" must first brake the load before rotating the lift button to
release the emergency brake.

3.4.4 Over winding/crown-block protecting

When the rotary hook rises to a position with heavy goods, the
working brake fails to brake the drawworks due to operational error
or other reasons, the pneumatic limit valve installed near the crown
block (or over winding valve installed on the draw works) will act due
to collision by outside force and make air pipeline be connected, air
signal output by over winding/crown-block protecting vale controls
pneumatic control reversing air valve to change direction, cut off air
source and realize emergency braking.

13
Service manual Electric Control Hydraulic Disc and Caliper Installation Installation

IV. Installation
4.1 Installation of brake disc
4.1.1 Pulsation of the work surface of the brake disc to the drum
shaft shall not be more than 0.3mm.

4.1.2 Clean brake disc, any oil stains shall not be permitted on the
friction surface.

4.1.3 Water cooled brake disc also needs to connect with water inlet
pipe, outlet pipe.

4.2 Installation of brake caliper, caliper support arm

4.2.1 Fix upper, lower transitional board on the caliper support arm.

4.2.2 Install brake caliper on the caliper support arm. It should rotate
flexibly without any block and conflict phenomenon. During installing
brake caliper, let out oil to adjusting oil cylinder by oil discharging
valve and make the distance between two brake pads reach
maximum for caliper installation.

4.2.3 Install integrally to the drawworks.

Installation alignment requirements:

（ 1 ） Space between outer circle of brake disc and inner circle of

caliper support armyh shall be uniform (5±1mm), any interface with
caliper support arm shall not be permitted.

（2）Caliper support arm shall be in parallel with and aligned with the
brake disc, the deviation shall be ±1mm.

（3）Brake pad shall be covered within the brake disc.

（4）All brake pads shall be parallel and fully contacted to the brake
disc, contact face shall not be less than 75%.

14
Service manual Electric Control Hydraulic Disc and Caliper Installation Installation

（5）Weld upper, lower transitional boards on the design position on

the base and the transverse beam of the draw works after adjusting
and alignment.

4.3 Installation of hydraulic power source

Install hydraulic power source on the design position.

4.4 Installation of control unit

Install the control unit in the design position, and the electronic brake
lever and each brake button should be installed in a convenient
location for operation.

4.5 Connection of hydraulic pipeline

Hydraulic pipeline consists of high pressure tube, quick coupling and
pipe clamp. Connection of hydraulic pipeline is to connect hydraulic
power source and brake execute unit to a complete hydraulic system
by high pressure hose. Set up quick coupling on the position needs
to be disconnected and moved for dismantling easily. For connection
of them, please see sketch 4.

Figure 4 Sketch map of hydraulic pipeline connection

15
Service manual Electric Control Hydraulic Disc and Caliper Installation Installation

（ 1 ） Keep inside of pipeline to be used clean before installation.

There must be no rust inside metal pipe and pipe joint shall be
installed with sealing elements. Connect hydraulic pipeline strictly in
accordance with the mark of oil opening.

WARNING!

Please connect the pipeline between brake execute unit and the
hydraulic power unit strictly in accordance with the mark of oil
opening. If there is some error, the disc brake would not work
naturally so as to result in grave safety accident!

（ 2 ） Ensure quick coupling not to be affected by outer force and

weight under working condition. Do not insert and pull the quick
coupling with pressure. Must plug with cap after pulling out; keep
quick coupling clean during inserting for connection. Connection
must be solid.

（ 3 ） Hydraulic pipe line shall be provided with pipe clamp every

1.5～2m for fixing.

（ 4 ） Pipeline shall be arranged in safety zone to prevent any

damage.

4.6 Connection of air pipeline

Connection of air pipeline is to connect air signal of over winding
valve with pneumatic interface of hydraulic power source unit.

4.7 Connection of circuit

For wiring of electric control cabinet of hydraulic power source,
please refer to Figure 5 electric control schematic diagram of
hydraulic power source. Plug or socket for wiring shall meet relevant
technical standard and explosion protection specification.

16
Service manual Electric Control Hydraulic Disc and Caliper Installation Installation

Figure 5 Electric control schematic diagram of hydraulic power source

17
Service manual Electric Control Hydraulic Disc and Caliper Installation Adjustment

V. Adjustment
5.1. Preparation before adjustment:
（1）Check connection of manifold for errors.

（2）Check level of oil tank.

（ 3 ） Check accumulator for nitrogen filling pressure, maintain the

nitrogen filling pressure for 4MPa.

（ 4 ） Turn on the stop valve at the oil absorbing port and oil
discharging port of plunger pump; turn off the stop valve for
accumulator group. When cooler not required to work, then turn on
bypass stop valve of cooler; if cooler required to work, and then turn
off the bypass stop valve of cooler.

（5）Knock the motor, check its rotation direction for correctness (the
rotation direction of plunger pump is clockwise, i.e. the direction of
red arrow on the pump).

5.2 Adjustment:
（1）Start up motor

（2）Adjust rated pressure, maximum pressure of the system.

Adjusting steps shall be as follows:

A. Start up motor group for one pump.

B. Loosen nut of safety valve and turn it clockwise to 3/4 position.

C. Remove pressure relief valve protective cap of the pump and

loosen the nut of pressure relief valve of the pump. Turn screw
clockwise by inner hexagonal wrench to increase pressure. Observe
readings in pressure gauge of the system, stop when it is up to
12MPa. If pressure stops to increase during adjusting, turn the safety

18
Service manual Electric Control Hydraulic Disc and Caliper Installation Adjustment

valve little. Adjust the safety valve and the pressure relief valve of
plunger pump alternately until readings of pressure gauge is up to
12MPa.

D. Adjust safety valve downward until the readings of pressure

gauge is up to 11.5MPa, then tighten the nut of the safety valve.

E. Readjust the pressure adjusting screw downward until the reading

of MA is up to the rated pressure and maintain. Tighten nut, install
protective cap and tighten it.

Notice: maximum pressure of hydraulic power source has been

adjusted before ex-factory. Adjustment must be forbidden
unless required by special conditions.

（ 3 ） Observe the pressure gauge on hydraulic power source and

confirm whether it is on the rated value.

（4）Discharge air: connect air discharging pipe to the air discharging

connector on oil cylinder, then pull slightly the electronic brake
handle, and make the pressure of main service caliper is in about
2MPa until discharged oil not contains air foam. Discharge air for
main service calipers one by one. Discharge air for the emergency
calipers by the same way when the oil cylinder has pressure.

（5）When the electronic brake lever is stationary, the pressure of the

left and right working calipers reaches its maximum value, pull out
the emergency button, turn the parking switch to “loose” position,
three pressure gauges are up to the system pressure value, then
stop, hold the pressure for 10 minutes, the pressure drop should be
less than 0.2 MPa; observe MA pressure gauge of hydraulic power
source, if the pressure value is unchanged, then the system is
normal; if pressure value reduces, it indicates leakage, solve it in

19
Service manual Electric Control Hydraulic Disc and Caliper Installation Adjustment

time.

（6）Adjustment of brake clearance of brake caliper：

The distance between brake pad and brake disc is called brake
clearance when oil pressure of the main service caliper cylinder is
zero and oil pressure of safety caliper oil cylinder is maximum.

The normal brake clearance of the main service caliper (unilateral)

shall be 1～2mm; the normal brake clearance of safety caliper shall
be (unilateral)0.5 ～ 1mm. It shall be adjusted when the brake
clearance exceeds normal value.

The adjustment procedures for the brake clearance are as follows:

Notice: before the brake pliers clearance adjustment to ensure

that the hook hook load properly handle.

Main caliper clearance adjustment

The main service clamps automatically adjust the gap, without

manual adjustment, maintain the unilateral gap 1~ 2mm.

Safety caliper clearance adjustment

A. Unscrew the adjusting screw stud.

B. Adjustment tool to adjust the gap closed by adjusting stud, rotate

to adjust the plunger completely fit brake disc brake block plane, the
direction of rotation adjustment bolt 1/4 turn (this time the brakes and
brake blocks unilateral gap of about 0.5mm) Finally, tighten the
screws.

C. According to the above two steps in order to adjust the brake

caliper for each security clearance.

Notice: Make sure the oil pressure of main caliper assembly oil
tank is zero, and that of safety caliper assembly oil tank is the

20
Service manual Electric Control Hydraulic Disc and Caliper Installation Adjustment

maximal.

（7）Push down slowly “service brake handle”, check pressure of left

and right pipeline for increasing steadily, check actuation of main
service caliper for sensitivity and response. Operate repeatedly for
several times to ensure reliable performance.

（ 8 ） Backfit brake pads. Rotate brake disc, push slowly “service

brake handle”, make brake pads contact with brake disc, repeat for
several times.

（9）New brake pad must be contacted to 75% and above interface

area before using. Notice to control oil pressure of brake during
contacting, it will be running-in under 3MPa in general.

（10）Check crown-block protecting device；

（11 ）Must make oil pump run for 10～ 30 minutes before normal
using after installation and adjustment, and operate “brake handle”
repeatedly for several times. At the same time, check level, oil
pipeline system for good conditions, especially, the level of oil tank
shall be maintained between the highest and lowest level surfaces.

（12）The system can be used only after all are normal.

21
Service manual Electric Control Hydraulic Disc and Caliper Installation Rules of Operation

VI. Rules of Operation

6.1 Preparation works before start the machine.
（ 1 ） Check all the peripheral electricity wiring. (electricity supply,
electronic brake handle, proportional reducing valve (11),
electromagnetic reversing air valve (12), electromagnetic reversing
valve (15), emergency brake button, parking brake changeover
switch and emergency brake remote control signal).

（2）Check all pipeline junctions.

（3）Open the oil suction valve and plunger pump oil release valve.

（4）Close the accumulator group return oil valve.

（5）Turn on the air switch of the electric control box QM1.

（6）Connect the external power source.

（7）Turn on the power.

WARNING!

Before start the machine, make sure the opening of the valve of
oil suction and oil release of the plunger pump, or it will lead to
the serious damage of the plunger pump.

6.2 Rules of Operation

（1）Recall the electronic brake handle, emergency brake button and
parking brake switch, i.e. the service brake handle is in the position
of ‘loose’, emergency brake button is in the position of ‘brake’, and
the parking brake button is in the position of ‘brake’.

（2）Turn on the electric machinery, and then the system is in an

emergency brake condition.

（ 3 ） Unlock. First, ensure that the electronic brake lever is in its

22
Service manual Electric Control Hydraulic Disc and Caliper Installation Rules of Operation

original position,then move the parking brake switch, unplug the

emergency brake button to the position of ‘loose’.

（4）Working brake. When the electronic brake lever is in its original

position, it is in the braking state. Pulling the "electronic brake lever"
can slowly release the brake. When do the drilling, lightly pull the
brake handle to let the brake block lightly touch the brake disc, so as
to reduce the brake respond time, avoiding slip drill.

NOTICE!

When lowering the drill, especially lowering the heavy drill, it’s
necessary to apply with the assistant brake. That is lowering the
drill and casing by the use of disc brake and assistant brake. It’s
not allowed to lowering the drill automatically at any time, and it
is a must to decelerate continuously, to assure the safety of
process, reduce the brake load, and improve the liability and
durability of the braking system and whole drill equipment.

WARNING!

When lowering the drill, keep the connection between the

assistant brake and drawworks, or it will reduce the durability of
the disc brake, or lead to the damage of property and hurt or
death of worker due to the high speed and heavy motion.

（5）Parking brake. Pull the parking brake switch to the position of

‘brake’ to break the machine. When transit to the condition of working
brake, first pull the service brake handle to the position of ‘brake’ to
brake the load, then move the parking brake switch to the position of
‘loose’ to relieve the parking brake, finally implement the process of
working brake.

NOTICE!

23
Service manual Electric Control Hydraulic Disc and Caliper Installation Rules of Operation

There are only emergency calipers for brake when it is parking

brake. Therefore, for insure the enough elasticity of the heavy
stiffness plate spring inside the emergency cylinder, please
change the plate spring group at least one time every 12
months.

WARNING!

When the driller leaves the position, the parking brake should
be implemented, and slips should be applied to suspend the
heavy load. It’s prohibited to suspend heavy load long time use
the disc brake.

（ 6 ） Emergency brake. Press the emergency brake button to

perform the emergency brake. When transit to the working brake
condition, It is necessary to ensure that the electronic brake lever is
in its original position, so that it is in the "brake" position to brake the
load, then unplug the emergency brake button to release the
emergency brake, finally implement the process of working brake.

WARNING!

When lowering the drill, especially when fast lowering the drill,
it’s prohibited to implement the parking brake button and
emergency brake button, or it will lead to serious damage of the
drilling equipment.

24
Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

VII. Maintenance
Because the disc brake adopted hydraulic pressure system, this
enabled it is more complicate than traditional band brake. Especially
the hydraulic pump, hydraulic valve and hydraulic oil cylinder, they
are sensitive to pollutants, and need better maintenance than the
band brake. The key point of disc brake equipment maintenance is
on the hydraulic loop and brake caliper oil cylinder. Below mentioned
item and maintenance scheme should be implemented in usage.

7.1 Liquid surface

It is a must to check the liquid surface frequently and add oil timely.
When the liquid surface decreased below the warning line, it maybe
lead to the temperature raise, undissolvable air gathering, pump
malfunction due to the air pocket, electric heater exposure, and these
will cause the local high temperature, oil resolve and deteriorate, and
bring to the system accident. Surface decrease shows there are
some places leak oil, check and maintenance should be performed
timely.

7.2 Oil Temperature

The highest working temperature of hydraulic oil is 70°C, because
higher temperature will ageing the liquid, shorten the service life of
sealed parts and pipeline. So frequently supervise the oil
temperature of the tank is a must. If the temperature rises, it shows
the hydraulic oil may be polluted or formed to gel, or plunger pump
weared. Temperature raise is a warning sign, should stop the
machine immediately and check.

7.3 Pressure gauge

Frequently check the pressure gauge on the hydraulic resources,

25
Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

especially the systematic pressure gauge. The pressure should be

stable at the designed value.

7.4 Oil filter

Loop oil filter attached a block indicator estimate with eyes. When the
pointer is in the green area, the filter is in right condition. When the
pointer is in the yellow area, it indicates the filter is a little blocked.
When it’s in the red area, the filter is blocked seriously, and the shell
should be cleaned and the filter should be changed. Everyday, when
the working temperature reaches the normal value, at least one
check should be performed. Or when working shift, the next driller
should check. High pressure filter attached a block indicator
estimated with eyes. When the red pillar prop up, clean the filter shell
and change the filter. Everyday, when the working temperature
reaches the normal value, at least one check should be performed.
Or when working shift, the next driller should check. However, during
the temperature raising period, the red pillar may be propped up due
to the heavy flow resistance, please distinguish.

The air filter is only adopted when liquid surface in the tank is up and
down filtering the air inlet and outlet the tank. Every one to three
months check and clean or change the filter.

7.5 Accumulator
Frequently check the inflated pressure of the accumulator. When
perform the exam and assessment, stop the machine, lose the oil
pressure inside the accumulator, disassemble the inner and outer
protecting cap, connect the Nitrogen equipment, slightly screw the
knob, and measure the pressure. If the pressure is<4Mpa, connect
the Nitrogen cylinder, screw the knob and inflate. If losing pressure is

26
Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

needed, open all the valves to release the oil pressure of the
accumulator.

Figure 6 Accumulator group

7.6 Pump group

Check the two group of pump to insure that they are in good working
condition.

7.7 Crown block overhead traveling crane system

Over winding or Crown block valve should be checked frequently to
assure it’s liability. Especially in winter, the compressed air may
contain vapor, the air inlet and outlet may be freezing to block due to
the low temperature, and this will lead to the malfunction of the crown
block. The crown block system should be tested once everyday to
assure it’s right condition.

7.8 Main Service Caliper Assembly

The check of the thick of brake pad and the seal of the cylinder

27
Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

should be performing during the work shift. As the wear of the brake
pad, brake clearance should be adjusted in time. When the thick of
brake pad is only 12mm, a new one should be replaced.

7.9 Safety Caliper Assembly

The thick of the brake pad of the loose brake clearance ( once in
every week), and the seal of the cylinder should be checked
frequently. If the clearance between brake disc and brake pad is
larger than 1mm, it should be adjusted to 0.5mm. When the
emergency brake process is performed, it’s also needed to check
and adjust the loose brake clearance. When the thick of the brake
pad is wore to 12mm, it is a must to change a new one.

NOTICE!

Please adjust the loose brake clearance of Emergency Caliper

Assembly timely, or it may lead to the malfunction of emergency
brake or parking brake.

NOTICE!

At least change the plate spring in the oil tank once in every 12
months to assure the liability of the Emergency Caliper
Assembly.

7.10 Quick joint and hydraulic pipeline

Check the quick joint twice everyday to assure it’s right connection.
Especially after move or accidentally touch the pipeline, it is a must
to check the hydraulic pipeline, whether the pipeline is damaged,
whether the joint is false connected, and to insure the right condition
of the hydraulic pump and quick joint.

7.11 Cable plug and control cable

28
Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

Check the entire cable plug twice everyday to assure the right
condition. Especially after move or accidentally touch the cable, a
serious check should be performed, to insure the control cable and
plug joint are in right condition.

7.12 Structure piece

The check and maintenance of the structure piece is mainly the lever
caliper arm, bolt axis, oil cylinder, caliper support arm, brake disc,
joint and all the fasten pieces. Check whether these pieces are
damaged, deformed, cracked or meets other problems.

 Check all the fasten pieces to insure it’s tight.

 The key point of the maintenance of brake disc.

（ 1 ） Wear. The largest permittable wear of the brake disc is

10mm(5mm single side). Check the thick of the working surface of
every brake disc periodically.

（2）Heat fatigue crack. The brake disc heated to expand due to the
slide friction in the brake process, while cool down to contract. This
alternate will lead to the heat fatigue crack, which is a normal
phenomenon. As the time goes, the initial small crack will expand,
and this must arouse high attention and perform the maintenance.
For example, grind the crack area to check the crack deep, so as to
perform the weld amendment, and polish by abrasive wheel at last.

（3）Greasy dirt. It’s prohibited to infect the working gauge with any
greasy dirt, so as to prevent the lowering of the friction coefficient,
the reduction of brake ability and drill slip accident. However, during
the motion process of the cylinder, the oil on the steel cable may
spatter on the brake gauge, so check and clean it regularly.

 Check the welding pieces, especially to check whether there is

29
Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

crack or rust on the caliper support arm and brake pad plate,
repair and replace when necessary. At least check one time half
a year.

 Check whether there is adhesion phenomenon on the active part,

especially on the lever and pins.

7.13 storage and maintenance

For use in Marine atmospheric zone of the storage of the disc brake
device, should choose to store in a dry, cool, ventilated warehouse,
no corrosive medium.In the process of the use of the disk brake, can
regularly to clamp arm, oil cylinder, pin shaft and other parts outside
appearance brush anti-rust oil for maintenance, brush before should
be cleared surface dirt, keep the surface drying.

NOTICE!

Should avoid rust-proof oil immersed back brake block joint

aperture, brake block - brake disc joint surface, otherwise will
cause lower friction coefficient of danger!

To avoid rust-proof oil splash of contact with eyes or skin,

brush anti-rust oil, should be advised to wear goggles and
gloves ！ After brush anti-rust oil, residual oil and packaging
should be disposed of properly！

30
Service manual Electric Control Hydraulic Disc and Caliper Installation Maintenance

Maintenance Table
Maintenance
No. Check Content Requirement
period
Below the highest surface and above
the lowest surface. When adding oil,
1 Tank Oil Level add L-HM46 friction-guard oil or
L-HV32 low temperature friction-guard
hydraulic oil through the hand pump.
2 Oil Temperature Oil temperature not higher than 60℃
Every shift
3 System Pressure Re. the parameter
4 Oil Filter Block indicator should in the green area
Sound and Temperature No abnormal noise and high
5
of Working Pump Group temperature
Crown block Overhead Touch crown block valve to insure the
6
traveling crane system right setting of the brake
7 Seal of Oil Cylinder No leakage
Service Brake Caliper: 1～2mm
8 Brake Clearance
Emergency Brake Caliper: 0.5～1mm
9 Brake pad Thick Minimum thick 12mm
10 Pipeline and Joint Good seal, no leakage, no attaint Everyday
No leakage, damage and false
11 Quick Couple
connection
Clamp cylinder and the
12 Keep dry surface
pin exposed
The Adhesion Unload push, pull and turn the bolt axis
13
phenomenon of pins to insure it’s flexibility and no adhesion
Every Week
Nitrogen pressure of
14 Pressure is 4MPa
Accumulator
Check and fasten all the fixed screw
15 All Fixed Bolt
and bolt
1months
Clamp cylinder and the Clean up dirt, dry surface, coat with
16
pin exposed anti-rust oil
Dismantle and clean the Clean brake dust and replace damaged
17
lever and pins parts
Allowable wear thick 10mm ， Heat
Brake Disc Wear and fatigue crack should not affect the
18
Crack intensity and lose water, or it should be
6months
replaced
Caliper Support Arm Check if the welding line has cracks
19
Welding Line and fasten screw
Check all the structure pieces of brake
20 Structure Assessment
system
Emergency Cylinder
21 Replace all the Plate Spring 12months
Plate Spring

31
 Service manual Electric Control Hydraulic Disc and Caliper Installation
Failure Examine and Repair

VIII. Failure Examine and Repair

Below is some potential failure phenomenon and the reasons may
cause the failure for reader’s reference.
Phenomenon Reason Disposal Measure
Wrong intercalate of plunge pump and system
Reset
safety valve intercalate
Malfunction of Work failure of plunge pump and system safety
Check, repair or replace
system valve
pressure or Low oil in tank Fill oil
working Air in the oil route Exhaust
pressure
Block in the oil filter Replace filter
Wrong indication of pressure gauge Check,readjust or replace
Leakage in the system safety valve Reset
System safety valve Check, repair or replace
Over high oil
Low oil level in tank Fill oil
temperature
Stop working or reduce
Over high temperature circumstance
temperature
Low oil level in tank or low oil temperature Fill oil or raise temperature
Air in the pump system due to the loose
Fasten joint and exhaust
connection of absorbing and oil loop tank
Big noise or Defective or loose joint of plunge pump and
Check and repair
vibration electric power
plunge pump and electric power axis not
Check and repair
compatible
plunge pump and electric power axis base
fasten
loose
Check plunge pump,
Over low system pressure and working
system safety valve and
pressure
pressure relieve
Filter blocked Clean and replace
Brake caliper Over low Nitrogen absorbing pressure or Maintenance, reabsorbing
lack brake leakage of the accumulator Nitrogen
power Service brake valve blocked or failure Clean, repair and replace
Air in the oiling system of the brake clearance
Exhaust, keep the seal
adjustment or loose seal
Hydraulic oil leakage Check, repair and add oil
pins mal-lubricate Clean, repair and replace
Brake caliper Brake dust accumulate in the pin and pin hole clean
arm
malfunction Over rust of pins replace
Damage of relevant parts replace
Service oil loop block Check and dredge oil loop
caliper
release slows return spring invalidation replace
down

32
Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

IX. Dismantle and Replace of Key Parts

NOTICE!

 MUST first stop the pump and release accumulator pressure

before maintaining hydraulic power or pipeline. Otherwise,
it’s harmful.

 KEEP clean while maintaining hydraulic system.

Contamination is major reason of system’s failure. Clean the
outside before loosen the whorl. Seal the opening inside the
system by clean protecting cap, to prevent contamination.
Pay full attention not to contaminate hydraulic system.

9.1 Filter core of oil loop filter

First loose the cap of oil loop filter counter-clockwise. Then dismantle
the whole oil loop filter and upper and lower cap, take out the old filter.
Cleaning the inside by kerosene, and dry it. Put the new filter core,
screw the upper cap, and load the whole oil loop filter.

9.2 Filter core of the pipeline filter

Dismantle the lower part of the pipeline filter counter-clockwise,
change to the new filer core.

9.3 High pressure filter

Dismantle the high pressure filter, open the upper cap by spanner,
take out the old core, clean the inside shell by kerosene, and dry it.
Put the new core, cover the upper cap, and stall the filter to the
original.

NOTICE!

When replace the old filter core, it’s prohibited cleaning an old
one and reuse, but only replaced by a new one.

33
Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

9.4 Oil pump

When change a pump, the other pump can work normally, and the
accumulator can be not unload. Close the cut-off valve of oil
absorbing and oil loop of the pump to prevent the leakage of the oil
tank. Dismantle the pipeline and joint of the oil outlet, oil absorbing
and oil loop. Dismantle the two bolts connect pump and electric
machinery, and then take out the pump.

Check whether the coupling is invalid. If it’s usable, dismantle the

coupling and install to the new pump. If it’s not usable, replace the
whole set of coupling of the electric machinery. Then install the new
pump, connect the pipeline and joint of the oil absorbing and oil outlet.
Connect the inner leak oil pipe to the inner leak oil loop of the pump,
open the cut-off valve, full fill the shell of the pump with oil, and then
connect the pipeline. Open the cut-off valve of the oil absorbing
pipeline. After checking, perform the pump pressure adjustment.

NOTICE!

 When connecting the pipeline and joint, install the O Seal

Ring and Combined Seal Washer according to the technical
requirement, or it may arouse oil leakage.

 When install the coupling of the pump, it’s prohibited to

knock by the hammer. Adjust the axis and hole, key and
keyway, push in by little force, or it may lead to the damage
of the pump.

 Before start the pump, full fill the pump shell with oil, open
the cut-off valve of oil absorbing and oil loop, or it may lead
to the damage of the pump.

9.5 The place spring and seal parts of Safety Cylinder

34
Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

Assembly
The life span of the plate spring is one year. After one year, it must
be replaced in group; only change a few of the pieces is prohibited.
Pay attention to the assemble order of every plate spring during the
examine and repair, it’s prohibited to mix up or exchange it with other
group. If oil cylinder leak oil, it shows the invalidation of seals and
should be replaced.

The replacing method and step of the plate spring and seal parts is
as below:

（1）In the pressure condition, adjust the regulating plunger to open

the brake caliper to the largest clearance, then switchover to the no
pressure condition, unplug the fast joint, and dismantle pins on the
two sides of oil cylinder. Take off the oil cylinder, and clean the
outside by kerosene.

（ 2 ） Dismantle all the parts of oil tank according to the step of

Figure7.

1.Bolt of Emergency Cylinder 2.Washer 10 3.Bush 4.Cap

5.Bush 6.Spring 7.Working Plunger 8.B7 Seal Ring

9.Body,Cylinder 10.F3 Wiper,Rod 11.B3 Seal Ring 12.A5 Dust-Proof Ring

13.Combined Seal Washer 14 14.Elbow Body 15.PPT-3 16.Elbow Bolt

17.Inner Hexagon Screw 18.Conversion 19.Limit screw 20.Conversion Plunger

Thread Insert

Figure 7 Dismantle and install order of Safety Cylinder Assembly

35
Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

（3）Clean every piece of new plate spring with kerosene, then dry it,
lay on every plate spring with full lubricating grease. Begin the
installation after cleaning and drying the oil cylinder body, cap, piston
and elastic guide cover.

（4）Install new dust-proof ring, seals and guide band inside the oil
cylinder body.

（5）Install new guide band and seals on the piston.

（ 6 ） Assemble the new plate spring strictly according to the

requirements. The first plate is big opening face down, the second
plate is face up, the third is face down, the fourth up, the fifth down,
the sixth up, then load the cylinder cap.

（7）Pay attention to the guide band when assemble the piston. First
add some hydraulic oil, one person press on the piston, the other one
knock the piston with a bronze stick to fully positioning the piston.

（8）Assemble oil cylinder cap, screw tight the bolt evenly, fasten the
bolt equally with a spanner(100～120 N·m)

（9）Assembly the oil cylinder to the original position. Connecting the

pipeline, then adjust the brake clearance.

NOTICE!

Pay attention to keep clean during the assembly procedure,

prevent scratching and bumping the seals.

9.6 The seal parts of Service Cylinder Assembly

（1）Discharge the oil pressure inside the oil cylinder; adjust to the
largest clearance. After the piston return to the original position, take
off the quick joint and return spring, dismantle the circlips, remove
the pins and take off the oil cylinder assembly.

36
 Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

（2）Clean the oil cylinder assembly with kerosene.

（3）Dismantle each part according to the step of Figure 8.

1.Bolt 2.Washer 8 3.Cap 4. Guide band

5. Bush 6.Oil cylinder short piston 7.Pressure Joints 8.Outside hexagonal plug
9.Combined Seal
10. Cylinder block 11.Automatic valve 12.Y Seal Ring
Washer
13.Guide band 14.Oil cylinder long piston 15.Dust-Proof Ring 16.Respiration filter
Figure 8 The Dismantle and Installation Order of Main Cylinder Assembly

（4）First dismantle the air relieve screw of the oil cylinder, pull out
the piston and adjusting plunger.

（5）Take off the old guide band, seals and dust-proof ring inside the
oil cylinder.

（6）Clean and dry the piston and cylinder body with kerosene

（7）Assemble the new seals, new guide bands and dust-proof rings
into the cylinder.

（8）Apply some hydraulic oil on the inner wall of oil cylinder, put in
the adjusting plunger and piston. (Prevent the guide band front
dropping down).

（ 9 ） Assemble the oil cylinder assembly to the original position.

Connect the oil loop and adjust the gap.

9.7 Pad Assembly

When the pad assembly is validated due to wear and other reason,

37
Service manual Electric Control Hydraulic Disc and Caliper Installation
Dismantle and Replace of Key apparatus

replace a new one, or slip drilling and pause drilling may occur.

Preparation work on replacing the pad assembly:

 Emergency Caliper Assembly. In the pressure condition, adjust

the regulating plunger to fully open the brake clearance, and then
discharge the pressure inside the oil cylinder.

 Main Caliper Assembly. In the no pressure condition, reset the

piston; discharge the oil in the adjusting plunger by the oil
discharge valve to make the adjusting plunger fully return the
original position.

Screw loose the 6 bolts connecting the pad assembly, and take off
the old pad assembly. Orderly dismantle all the pads assembly which
needs to change, take off the pads assembly. First take off the
highest or lowest pad assembly of the brake caliper. Then orderly
take out the pads assembly in a round direction. At last, orderly
assemble and connect the pads assembly in an opposite direction.

NOTICE!

Readjust the brake gap after the new pad assembly replaced.

The new pad assembly should be replaced in group.

Face grinding should be performed on the pad assembly after

replace a new one; the face grinding should be reach 75%.

38
Service manual Electric Control Hydraulic Disc and Caliper Installation Consumable Parts

X. Consumable Parts
List of Consumable Parts:

No. Name Code/Model Remarks

1 Brake disc

2 Brake pad BQ-C-08

3 B7 Sealing ring BG-L-15 Figure7-8

4 B3 Sealing ring BG-L-13 Figure7-11

5 F3 Guide band BG-C-14 Figure7-10

6 Disc Spring BG-C-09 Figure7-6

7 A5 Dust-proof ring BG-C-12 Figure7-12

8 Guide band KG-LS-07 Figure8-4

9 Y Seal Ring KG-LS-05 Figure8-12

10 Guide band KG-LS-06 Figure8-13

11 Dust-Proof Ring KG-LS-08 Figure8-15

12 HP Filter Core 104050311

13 Pipeline Filter Core 104050511

14 Oil return Filter Core 104050211

15 Spring,Caliper Return KQ-C1-01

39
Service manual Electric Control Hydraulic Disc and Caliper Installation Appendix

Appendix
Information of after-sales service

Name of Company: Beijing PSK New Technology of Petroleum Machinery Co., Ltd

Address: 10F9, Building of Jidian, No.18 Xueqing Road. Haidian Distract. Beijing

Post Code: 100083

Service Tel.: 010－82755979

Sale Tel.: 010－82755989

Fax No.: 010－82413899

Website：www.psk.com.cn
E-mail：[email protected]

40
 版本号 操作前请阅读此手册!
Document Number SM-DLS1D5T-01
PLEASE READ THIS MANUAL
修订号
01(PY180X26) BEFORE OPERATION.
Revision

电控液压盘式刹车装置用户手册
Electric Control Hydraulic Disc and
Caliper Installation
SERVICE MANUAL

北京普世科石油机械新技术有限公司
Beijing PSK New Technology of Petroleum Machinery Co.
电控液压盘式刹车装置

用 户 手 册

北京普世科石油机械新技术有限公司
液控液压盘式刹车装置用户手册 前言

前 言
本手册讲述了PSK L系列液控液压盘式刹车装置的原理、结构、
使用方法和维护保养的原则，在使用或维修PSK L系列液控液压盘式刹
车装置前，请认真阅读本手册,并按照本手册进行正确的安装、使用、
保养和维护。
本产品的使用效能和使用寿命，与产品的设计和制造有关，也与
用户的合理使用密切相关。我们愿意凭借质量保证体系，为顾客提供
高质量的产品，同时也希望操作人员认真阅读本手册，使产品的性能
和优势得到最充分的发挥，顺利安全地完成预期的作业。
由于产品的不断改进，本手册中个别内容可能与实际不一致，这
些内容不会影响顾客对产品结构和性能的理解，也不会影响顾客的使
用。如有疑问，请与我们联系。
随着钻井技术的不断进步，顾客不断会有新的使用要求。我们愿
意和您一起，不断改进我们的产品，满足您的特殊使用要求。欢迎您
与我们联系。
 目 录
一 概述 .............................................................................................. 1
二、主要技术参数 ............................................................................... 2
三、工作原理及结构特征 .................................................................... 4
四、安装 ............................................................................................ 10
五、调试 ............................................................................................ 14
六、操作规程 .....................................................................................17
七、维护与保养 .................................................................................19
八、故障检修 .....................................................................................24
九、关键元器件的拆装与更换 ...........................................................25
十、易损件 ........................................................................................ 30
附 录 ................................................................................................. 31
液控液压盘式刹车装置用户手册 概述

一、概述
PSK L系列液控液压盘式刹车装置由三部分组成：刹车执行单元、
液压动力源及操纵单元。
刹车执行单元和操纵单元之间用液压管线连接，操纵单元与液压动
力源之间通过液压管线连接。
液压动力源为刹车执行单元提供必需的动力；
刹车执行单元是制动
的执行者，由刹车钳组、钳架、刹车盘三部分组成，其中刹车钳组由
开式钳和闭式钳根据需要组合而成；操纵单元是该装置的控制环节，
它通过控制操作台中的操纵阀组，实现刹车执行单元的动作控制。
PSK L系列液控液压盘式刹车装置具有以下五种功能：
1. 工作刹车：通过操作工作刹车的控制手柄，调节开式钳对刹车盘的
正压力，从而为主机提供大小可调的刹车力矩，满足正常钻进、起
下钻等不同工况的要求。
2. 驻车刹车：当钻机不工作或司钻暂时离开操作台时，拨动住刹车手
柄到刹车位，闭式钳刹车，以防大钩滑落。
3. 紧急刹车：遇到紧急情况时，按下紧急刹车按钮，开式钳、闭式钳
全部参与刹车，实现紧急刹车。
4. 过卷/防碰保护：当大钩提升重物上升到某位置，由于操作失误或其
它原因，应该工作刹车而未实施刹车时，钻机防碰系统会发出信号，
开式钳和闭式钳全部参与刹车，实施紧急刹车。
5. 断气自动刹车：系统断气时，紧急刹车自动刹车，以防事故的发生。
6. 断电自动刹车：控制系统断电时，紧急刹车自动刹车，以防事故的
发生。

1
液控液压盘式刹车装置用户手册 主要技术参数

二、主要技术参数

2
液控液压盘式刹车装置用户手册 主要技术参数

PSK 液压盘式刹车本说明书特定产品

产品型号 PS75/1800D
适用钻机、修井机级别 XJ750
工作刹车制动转矩（kN·m） 75
驻车制动转矩（kN·m） 60
紧急制动转矩（kN·m） 135
刹车盘直径（mm）×厚度（mm） 1450×40
开式刹车钳数量（个） 2
闭式刹车钳数量（个） 2
刹车钳类型 KQ-LS-00/BQ-L-00
系统压力（MPa） 8
主泵排量 15L/min
夏天：HM46#抗磨液压油
工作介质
冬天：HV32#抗磨液压油
油箱容积 90L
装机总电功率 5kW

3
液控液压盘式刹车装置用户手册 工作原理及结构特征

三、工作原理及结构特征
液控液压盘式刹车装置由刹车执行单元、液压动力源和操纵单元
三部分组成。

3.1 刹车执行单元
刹车执行单元主要包括刹车钳、刹车盘和钳架三部分，其中刹车
钳分为开式钳和闭式钳。其结构及布置如图一所示。

1.钳架 2.闭式钳 3.开式钳 4.刹车盘

图一 刹车执行单元

3.1.1 刹车钳工作原理
PSK L型盘式刹车的所有刹车功能都通过刹车钳这一主要部件实
施，本盘式刹车的刹车钳包括浮式杠杆开式钳和浮式杠杆闭式钳。图
二为浮式杠杆钳的结构示意图。

（A）开式钳 （B）闭式钳

图二 浮式杠杆钳外观图

4
液控液压盘式刹车装置用户手册 工作原理及结构特征

浮式杠杆开式钳（见图二（A））的工作原理为：当向钳缸供给压
力油时，液压力推动活塞右移，活塞与缸体通过上销轴分别推动左右
钳臂的上端向外运动，推动刹车块向内运动，从而将刹车块压在刹车
盘上，利用相互间的摩擦力对刹车盘实施制动。可见，开式钳的刹车
力来源于液压力，且压力油的压力越高，刹车力越大。
如果进入钳缸压力油的压力减小至零，活塞与缸体通过安装在左
右上销轴端部的回位弹簧向内运动，刹车块向外运动与刹车盘脱离接
触，刹车钳松刹。
浮式杠杆闭式钳（见图二（B））的工作原理为：当向钳缸供给压
力油时，液压力推动活塞右移压缩碟簧，同时拉动左右钳臂的上端向
内运动，带动刹车块与刹车盘脱离接触，刹车钳松刹。当钳缸泄油时，
碟簧力推动活塞左移，通过钳臂使刹车块压在刹车盘上，产生的摩擦
力实施刹车。可见，闭式钳的刹车力来源于碟簧的弹簧力。
3.1.2 刹车盘
刹车盘是刹车系统的核心部件之一，与刹车块组成刹车副。一般
每台产品配备两个刹车盘，安装在绞车滚筒两端。有些新型钻机绞车
一台只配备一个刹车盘，安装在绞车滚筒的一端。
按结构形式分为实心刹车盘，靠表面散热，主要用于车载钻机、
修井机和小型钻机。
3.1.3 钳架
钳架是刹车执行单元的基座，开式钳及刹车钳均安装在该基座上。
对于双盘式结构，需配备两个钳架，安装在绞车的底座上，位于滚筒
两侧的前方。对于单盘式结构，需配备两个钳架，安装在绞车底座上，
位于滚筒的一侧。

3.2 液压动力源
压动力源包括：油箱组件、泵组、控制块总成、加油组件和电控
箱和操纵阀组等。其液压原理参见图三。
3.2.1 油箱组件

5
液控液压盘式刹车装置用户手册 工作原理及结构特征

油箱组件包括油箱、吸油阀、放油阀、液位温度计、冷却器等元
器件，其中，吸油阀门的作用是在维修油泵时，关闭该阀，使油箱与
油泵吸油口断开，防止液压油外泄。正常工作时，处于开启状态。放
油阀门是为了更换液压油而设，正常工作时，处于关闭状态。液位温
度计供观察油箱液面高低及油箱油温。冷却器为列管式水冷冷却器，
用来平衡整个系统的发热。
3.2.2 泵组
泵组为液压系统的心脏。系统配备两台同样的柱塞泵，分别由防
爆电机驱动，一台工作，另一台备用。
3.2.3 控制块总成
主要由：油路块、蓄能器、截止阀、单向阀、安全阀和高压滤油
器等元器件组成。
蓄能器可降低液压回路的压力脉动，并在泵无法正常工作时提供
一定的储存能量，保证开式钳仍能正常制动 4～6 次。
截止阀是用来释放蓄能器油压的，在正常工作时，截止阀一定要
关严。否则，系统压力将建立不起来。
单向阀的作用是把两台泵的出油口隔开、保持蓄能器的油液不回
流，同时形成三个相互独立而又相互联系的油路。
安全阀是一个溢流阀，起安全保护作用。
高压滤油器过滤系统高压油，保证液压系统的清洁。
3.2.4 加油组件
加油组件由一台手摇泵、一台过滤器组成。油箱加油时，必须通
过加油泵组完成，以保证油液的清洁度。
3.2.5 电控柜
液压动力源的电控柜主要用来控制电机和加热器的起、停，电控
柜采用隔爆处理。
3.2.6 操纵阀组
操纵阀组包括工作刹车阀组件，驻刹车阀组件，紧急刹车阀组和

6
液控液压盘式刹车装置用户手册 工作原理及结构特征

压力表等。
工作刹车阀组件包括一个电磁比例减压阀，用来调节工作刹车油
路压力。
驻刹车阀组件包括一个电磁换向阀，用以控制闭式钳给压或泄压。
紧急刹车阀组包括一个电磁换向气阀、一个气控换向阀、一个气
控液换向阀和一个液控换向阀。通过操纵电磁换向气阀来实现断电紧
急刹车，也可通过操纵气控换向阀来实现断气紧急刹车。
液压动力源主油路块上有三个压力表接口，分别连接用来显示系
统压力、闭式钳压力、开式钳压力。液压动力源辅助油路块上安装有
三个压力传感器（4~20mA）,向控制系统传输三个压力信号：系统压
力、闭式钳压力、开式钳压力。

3.3 操纵单元
操纵单元包括电子刹把、驻刹车开关、紧急刹车按钮和防爆电控
箱。电控箱内包括空气开关、电源、放大器等电器元件。

7
液控液压盘式刹车装置用户手册 工作原理及结构特征

1.加油软管 2.手摇泵 3.加油过滤器 4.回油滤油器 5.风冷却器

6.风冷电机 7.温度控制器 8.加热器 9.液位温度计 10.空气滤清器
11.高压球阀 12.高压胶管总成 13.主电机 14.联轴器 15.泵架
16.柱塞泵 17.高压胶管总成 18.插装式单向阀 19.高压球阀 20.溢流阀
21.高压滤油器 22.蓄能器 23.测压接头 24.测压软管 25.压力表
26.板式高压球阀 27.电控箱 28.液控换向阀 29.快速接头 30.电磁换向阀
31.气控液换向阀 32.气体压力开关 33.气体压力传感器 34.电磁气阀 35.气控换向阀
36.电磁比例减压阀 37.液控单向阀

图三 液压系统原理图

8
液控液压盘式刹车装置用户手册 工作原理及结构特征

3.4 工作原理
3.4.1 工作刹车
电子刹把在原始位置时，开式钳油缸压力最大，为系统压力，开
式钳处于刹车状态。拉动电子刹把，控制电磁比例阀（36），电磁比
例阀（36）输出相应压力值的液压油进入左右路开式钳，实现工作松
刹。随着刹把的角度增大，开式钳的刹车力也相应减小，当刹把角度
最大时，开式钳的制动力为零，复位弹簧拉动开式钳复位，开式钳处
于完全松刹状态。
3.4.2 驻刹车
驻刹车开关是一个转换开关，控制驻刹车电磁换向阀（30）得电
或失电。转换开关到“刹”位为失电，闭式钳刹车；转换开关到“松”
位为得电，闭式钳松刹。控制的基本原则是失电刹车。解除驻车制动
时，必须让“电子刹把”先刹住载荷，然后将转换开关转到“松”的
位置，松开闭式钳。
3.4.3 紧急刹车
紧急刹车操纵件为一个按钮式转换按钮，控制电磁换向气阀（34）
得电、失电。按下按钮，电磁换向气阀失电，系统处于紧急刹车状态；
旋转提起按钮，电磁换向气阀得电，解除紧急制动状态。控制的基本
原则是失电刹车。解除紧急刹车时，必须让“电子刹把”先刹住载荷，
然后才可旋转提起按钮，才能解除紧急制动。
3.4.4 过卷/防碰保护
当大钩提升重物上升到某位置，由于操作失误或其它原因，应该
工作刹车而未实施刹车时，天车附近处安装的气动行程阀（或绞车上
安装的过卷阀）由于外力碰撞而动作，使气路接通，由过卷/防碰阀输
出的气信号控制气控换向气阀换向，切断气源，实现紧急制动。

9
液控液压盘式刹车装置用户手册 安装

四、安装
4.1 安装刹车盘
4.1.1 刹车盘的工作表面对滚筒轴的跳动不大于0.3mm。
4.1.2 刹车盘清理干净，摩擦面严禁沾染任何油污。
4.1.3 对于水冷式刹车盘，还需连接进、出水管。

4.2 安装刹车钳、钳架
4.2.1 将上、下过渡板紧固于钳架上。
4.2.2 将刹车钳安装于钳架上，应转动灵活、无卡阻、无别劲现象。安
装刹车钳时，需用放油阀给调节油缸放油，使两个刹车块之间的距离
最大，以便钳体的安装。
4.2.3 整体安装到绞车。
安装找正要求：
(1) 刹车盘外圆与钳架内圆之间的间隙应均匀（5±1mm），不允许与
钳架有干涉现象。
(2) 钳架与刹车盘应平行、对中，偏差为±1mm。
(3) 刹车块应包容在刹车盘之内。
(4) 所有刹车块应平行、完整的贴合刹车盘，贴合面不少于75%。
(5) 调整找正后，分别将上、下过渡板焊接在绞车底座和横梁的设计位
置。

4.3 安装液压动力源
将液压动力源安装于设计位置，该位置应方便对液压动力源的操
作、检查和维护。

4.4 安装操纵单元
将操纵单元安装于设计位置，电子刹把及各刹车按钮应安装在方
便操作的位置。

10
液控液压盘式刹车装置用户手册 安装

4.5 连接液压管路
液压管路主要由高压软管、快速接头、管夹等组成。液压管路的
连接就是用高压软管将液压动力源和刹车执行单元连接成一个完整的
液压系统。在需要拆开运移的地方，设有快速接头，以方便拆卸。管
线连接见示意图四。

图四 液压管线连接示意图

(1) 安装前要注意所使用管线内洁净，金属管道内无锈蚀，管接头要安
装密封件，应严格按照油口标记连接液压管线。

！警告！
刹车执行单元到液压动力源间的管线请严格按照油口标记连接，
如管线连接错误，将会导致盘刹无法正常刹车，可能造成重大安全事
故！
(2) 保证快速接头在工作状态不受外力及重力的作用，不得带压插拔，
拔下后须用护帽封堵；插接时，注意清洁，不得虚接。
(3) 液压管路间隔1.5～2米应有管夹固定。
(4) 管路布置应位于安全地带，避免损伤。

11
液控液压盘式刹车装置用户手册 安装

4.6 连接气路管线
气路管线的连接就是将过卷阀的气信号与液压动力源内的气动接
口连接好。

4.7 电路的连接
液压动力源电控柜的接线请参照液压动力源电控原理图五接线。
接线的插头或插座应符合相关技术标准和安全防爆规范。

12
液控液压盘式刹车装置用户手册 安装

图五 液压动力源电控原理图

13
液控液压盘式刹车装置用户手册 调试

五、调试
5.1 调试前的准备工作
(1) 检查管汇的连接，确保无误。
(2) 检查油箱液面。
(3) 检测蓄能器充氮压力，确保充氮压力为4MPa。
(4) 开启吸油口截止阀、柱塞泵泄油口截止阀；关闭蓄能器组截止阀。
若使用场合不需冷却器工作，则将冷却器旁路截止阀开启；若需要
冷却器工作，则将冷却器旁路截止阀关闭。
(5) 点动电机，检查旋转方向是否正确（柱塞泵旋向为顺时针，即按泵
上红色箭头方向）。

5.2 调试
(1) 启动电机。
(2) 调定系统额定压力、最大压力
调节步骤如下：
A. 启动一台泵电机组。
B. 松开安全阀螺帽并按顺时针方向旋转，调节至大约3/4的位置。
C. 拆下泵的调压阀保护帽，松开泵的调压阀螺帽。用内六方扳手
顺时针转动螺钉以增大压力。观察系统压力表读数，到12MPa
时为止。如果调节的同时，压力停止上升，则转动安全阀少许。
交替调节安全阀和柱塞泵调压阀，直到压力表显示为12MPa。
D. 向下调节安全阀，到压力表读数为11.5MPa时拧紧安全阀螺帽。
E. 重新向下调节泵的调压螺钉，系统压力表读数保持额定压力值
为止。拧紧螺帽，装上保护帽并拧紧。

注意：液压动力源出厂前，最大压力已调节好，无特殊情况，严
禁调节。

(3) 观察液压动力源上的压力表，是否稳定在调定值。
(4) 排气：把排气管线接在油缸上的排气用的测压接头上，轻拉制动刹

14
液控液压盘式刹车装置用户手册 调试

把，使开式钳油缸稍微上压，工作钳工作压力在2MPa左右，排气。
等排气管线的另一端排出的油液不再含有气沫，松开刹把，拆下排
气管线，排气工作完成。用上述方法逐个给开式钳油缸排气。在油
缸有压时，按同样方法给闭式钳油缸排气。
(5) 电子刹把不动时，左右工作钳压力到达最大值，旋起紧急刹车按钮，
驻车手柄旋至“松”位，这时所有压力表都是系统压力值，然后关闭
液压动力源的电机，保压10分钟，压降小于0.2MPa；观测除液压
动力源系统压力表外其他任何压力表，若压力表值不变，则系统正
常；若压力表值减小，说明系统有渗漏，应及时解决。
(6) 调节刹车钳刹车间隙：开式钳油缸的油压为零而闭式钳油缸的油压
为最大的情况下，刹车块与刹车盘之间的距离，称为刹车间隙。开
式钳的正常刹车间隙(单边)值为1至2毫米；闭式钳的正常刹车间隙
（单边）值为0.5至1毫米。超过正常刹车间隙时，需要进行调节。

刹车间隙的调节步骤如下：
注意：在刹车钳间隙调节前，确保大钩勾载妥善处理。

开式钳刹车间隙调节
开式钳自动调节间隙，无需手动调整，恒定保持单边间隙 1~2mm。
闭式钳刹车间隙调节
保证工作钳在刹车状态，安全钳处在松刹状态，确保勾载妥善处理。
A．拧下调节螺柱的定位螺丝。
B．用间隙调节工具调节闭式调节螺柱，旋转调节柱塞使刹车块完
全贴合刹车盘面，反方向旋转调节螺柱 1/4 圈（此时刹车盘与刹车
块的单边间隙约为 0.5mm），最后拧紧定位螺丝。
C. 按照以上两个步骤依次给每个安全钳调节刹车间隙。

注意：开式钳调节刹车间隙前，确保开式钳油缸油压为零，闭式钳
在刹车状态。闭式钳调节刹车间隙前，确保工作刹车在刹车状态，
闭式钳油缸油压为最大，处于松刹状态！

15
液控液压盘式刹车装置用户手册 调试

（7）缓缓拉动“电子刹把”，检查左、右路压力是否平稳下降，开式钳
动作是否灵敏、响应是否迅速。反复操作几次，确保性能可靠。
（8）贴磨刹车块。旋转刹车盘，缓缓拉动“电子刹把”，使刹车块对刹
车盘贴磨，反复多次。
（9）新刹车块须贴磨到接触面积达75%以上才能使用。贴磨时应注意
控制刹车油压，一般在3MPa下磨合。
（10）检查防碰装置；
（11）现场安装调试完成后，正常使用前，必须使油泵运行10～30分
钟，并反复操作“刹把”几次。同时检查液位、油路等系统各处是否正常，
特别是油箱液位，应保持在最高和最低液面标志之间。
（12）一切正常后，才可以使用。

16
电控液压盘式刹车装置用户手册 操作规程

六、操作规程
6.1 开机前，准备工作
(1) 检查所有外围电源接线是否正确（电源、电子刹把、电磁比例阀
（11）、电磁换向气阀（12）、电磁换向阀（15）、紧急刹车按
钮、驻刹车转换开关及过卷防碰气信号）是否正确；
(2) 检查各管路连接是否正确；
(3) 开启吸油口阀门、柱塞泵泄油口阀门；
(4) 关闭蓄能器组回油阀门；
(5) 闭合电控箱空气开关QM1；
(6) 接通外部电源；
(7) 开启气源。

！警告！
开机前，必须确保柱塞泵吸油口和泄油口的截止阀都已经打开，
否则将造成柱塞泵的严重损坏。

6.2 操作规程
(1) 将电子刹把、紧急刹车按钮、驻刹车手柄复位，即：电子刹把处于
“松”位，紧急刹车按钮处于“刹”位，驻刹车开关处于“刹”位；
(2) 启动电机，此时系统处于紧急制动状态。
(3) 解锁：先保证电子刹把处于原位，使其处于“刹”位以刹住载荷；然
后旋转驻刹车开关，旋起紧急刹车按钮，使其均处于“松”位。
(4) 工作制动：电子刹把处于原位时，为刹车状态，拉动“电子刹把”即
可缓慢松刹。下钻时，要使刹车块轻触刹车盘。以便减少制动响应
时间，避免溜钻现象。

！注意！
下放钻具，特别在下放较重的钻具时，需要辅助刹车配合使用。
即，必须利用盘式刹车和辅助刹车的组合能力来安全下放钻柱和套管。
任何时候都不允许将钻具自由下降。刹停制动前，必须先连续减速，

17
电控液压盘式刹车装置用户手册 操作规程

以保证操作的安全性，减少制动动负荷，提高刹车系统和整个钻机设
备的使用可靠性和使用寿命。

！警告！
起下钻时，要自始至终保持辅助刹车与绞车相连。否则，可能会
减少盘式刹车的使用寿命，或由于速度太快引起动载过大，造成财产
损坏、人身伤害甚至死亡！
(5) 驻刹车：拨动驻刹车手柄至“刹”位，实现驻刹车。转换到工作刹车
时，必须保证电子刹把处于原始位置，使其处于“刹”位以刹住载荷，
再拨动驻刹车开关至“松”位，解除驻刹车，然后进行工作刹车的正
常操作。

！注意！

驻刹车只有闭式钳参与刹车。为了确保闭式钳油缸内大刚度碟簧
有足够的弹力来实施制动，必须每12个月至少更换一次碟簧组。

！警告！

司钻离开司钻位置时，必须应用驻刹车悬停住钻具。当需长时间
悬停重载钻具时，必须使用卡瓦，严禁运用盘式刹车长时间悬持重负
载。
(6) 紧急刹车：按下紧急刹车按钮，实现紧急刹车。转换到工作刹车时，
必须保证电子刹把处于原始位置，使其处于“刹”位以刹住载荷，再
提起紧急刹车按钮，解除紧急刹车，然后进行工作刹车的正常操作。

！警告！

正常起下钻过程中，特别在快速起下钻过程中，严禁操作驻刹车
手柄、紧急刹车按钮。否则将造成钻机设备的严重损害。

18
电控液压盘式刹车装置用户手册 维护与保养

七、维护与保养
由于盘式刹车装置应用了液压系统，使得它比传统的带刹车要复
杂得多。特别是对污染物敏感的液压泵、液压阀及液压油缸等高性能
元器件的引入，使得盘式刹车装置比带刹车需要更精心地维护。盘式
刹车装置维护的重点在液压回路和刹车钳油缸上。下面所提到的项目
以及保养计划所列的内容，在使用中均应进行例行保养。

7.1 液面
必须经常检查液面并及时补油。当系统中的液面减少到最低液面
以下时，可能引起温升、不溶解空气积聚、泵因气穴而失效、电加热
器外露而引起局部温度升高，使油液分解变质，从而引起系统故障。
液面下降，说明有渗油或漏油的地方，要及时检查，及时维修。

7.2 油温
液压油的工作温度，允许最高值为70℃，因为更高温度会加快油
液的老化，并缩短密封件和软管的寿命。必须经常监测油箱中的油液
温度。油温逐渐升高，表明液压油可能被污染或形成胶质，或柱塞泵
磨损。油温突然升高是报警信号，应立即停机检查。

7.3 压力表
经常观测液压动力源上压力表的压力值，特别是系统压力表，压
力应当稳定于设定值。

7.4 滤油器
回油滤油器带有目测式堵塞指示器，指针在绿区时，滤芯正常；
黄区时，轻微堵塞；红区时，严重堵塞，必须清洗滤油器壳体并更换
滤芯。每天在工作温度达到正常值时，至少进行一次检查。或者每当
交接班时，下一班司钻检查一次。高压滤油器带有目测式堵塞指示器，
红色柱塞顶出时表示已堵塞，必须清洗滤油器壳体并更换滤芯。每天
在工作温度达到正常值时，至少进行一次检查，或者每当交接班时，

19
电控液压盘式刹车装置用户手册 维护与保养

下一班司钻检查一次。但在温度上升期间可能因为流动阻力较大而使
红柱塞顶出，要注意区别。
空气滤清器只用于当油箱液面升降时过滤进出油箱的空气。每隔
一至三个月检查并清洗或更换一次滤芯。

7.5 蓄能器
必须经常检测蓄能器的充气压力。检测时，停机并卸掉蓄能器内的油
压，拆下外护帽及内护帽，连好充氮工具，轻拧旋钮，测量压力。若
压力不足4MPa 时，把该接头连到氮气瓶上，拧下旋钮即可充气。卸
压时，打开所有的截止阀，即能释放蓄能器的油压。蓄能器阀块组示
意图见图六。

图六 蓄能器阀块组

7.6 泵组
检测泵组，必须保持两台泵组都处于良好的工作状态。

7.7 防碰天车系统
过卷/防碰阀应经常检测，确保其性能可靠。特别在冬季，压缩空

20
电控液压盘式刹车装置用户手册 维护与保养

气里可能含有水分，气路因天气寒冷而发生结冰堵塞现象，引起防碰
失灵。防碰系统需每天试用一次，确保能够正常工作。

7.8 开式钳
在交接班时需检测刹车块的厚度以及油缸的密封性能。随着刹车
块的磨损，需及时调节刹车间隙，当刹车块厚度仅剩12mm(磨损10mm)
时，必须更换。

7.9 闭式钳
需经常检测松刹间隙（至少一周一次）、刹车块的厚度以及油缸
的密封性能。如果刹车盘与刹车块之间的间隙大于1mm，必须调整到
松刹间隙为0.5mm左右；当施行紧急刹车操作后，也必须重新检查调
整松刹间隙。当刹车块厚度磨损到只有12mm(磨损10mm)时，必须更
换。

！注意！

请及时调整闭式钳的松刹间隙，否则，可能发生紧急制动或者驻
车制动失灵事故。

！注意！

为了确保闭式钳的使用可靠性，油缸内碟簧组每12个月至少更换
一次。

7.10 快速接头、液压管线
每天检查所有快速接头二次，确保连接良好。特别移动管线或意
外碰到管线后，严格检查液压管线是否损坏，快速接头是否虚接，确
保液压管线无损伤、快速接头连接良好。

7.11 电缆插头、控制电缆
每天检查所有电缆插头二次，确保连接良好。特别在移动电缆或
意外碰到电缆后，严格检查控制电缆是否损坏，插头是否虚接，确保

21
电控液压盘式刹车装置用户手册 维护与保养

控制电缆无损伤、插头连接良好。

7.12 结构件
对于结构件的检查保养主要是指制动钳的杠杆钳臂、销轴、油缸、
钳架、刹车盘、接头以及所有紧固件，应检查这些零件是否损坏、变
形、裂纹、松动和其它可能存在的问题。
 检查所有紧固件是否松动，并及时紧固。
 刹车盘的保养检查要点是：
(1) 磨损：刹车盘允许的最大磨损量为10mm（单边5mm）。应定期检
查测量每个刹车盘工作面的厚度。
(2) 热疲劳龟裂：刹车盘在制动过程中因滑动摩擦而产生大量热量使盘
面膨胀，而冷却时又趋于收缩，这样冷热交替容易产生无规则疲劳
应力裂纹——龟裂属正常现象。随着使用时间的延长，如果最初的
微小应力裂纹扩展较大时，应引起足够重视，并采取修补措施。例
如可以用工具沿裂纹处磨掉一些，以便检查裂纹深度，对裂纹进行
焊接修补，最后用砂轮打磨平整。
(3) 油污：工作盘面上不允许沾染或溅上油污，以免降低摩擦系数，降
低刹车力，以致造成溜钻事故。但滚筒在运动过程中，钢丝绳上的
油有时难免会飞溅到刹车盘的工作面上，因此要经常检查清除。
 检查焊接件，特别是钳架、背板的焊缝是否有裂纹、腐蚀等问题，
如有必要则要维修或更换。半年至少检查一次。
 检查活动部件是否有粘连现象，特别是钳臂销轴处。

！注意！

应避免防锈油浸入背板-刹车块贴合缝隙，刹车块-刹车盘贴合面，
否则将造成摩擦系数降低的危险！

刷涂时，须佩戴护目镜和手套！刷涂后，残留油脂和包装物应妥
善处理！

22
电控液压盘式刹车装置用户手册 维护与保养

保养计划表
序号 检查内容 要 求 保养周期
最高液面以下，最低液面以上。加油
1 液位 时，须从手摇泵加油口加 L-HM46 抗磨
液压油或 L-HV32 低温抗磨液压油
2 温度 油温不高于 60℃
每班
3 系统压力 参考参数表
4 滤油器 堵塞指示器的指针应在绿色区域
5 泵组运转声音、温度 无异常噪音、高温
6 防碰天车系统 触动防碰阀并确保刹车设置正确
7 油缸密封性 应无滴漏
工作钳：1～2mm
8 刹车块间隙
安全钳：0.5～1mm
9 刹车块厚度 最小厚度 12mm 每天
10 各管线及接头 密封良好无渗漏、无损坏
11 快速接头 无渗漏、损坏、虚接
12 钳缸及外露销轴 表面保持干燥
各销轴是否粘连 无载下推、拉、转各销轴并确认移动
13
自由无粘连 每周
14 蓄能器预充压 充氮压力应为 4MPa
15 所有固定螺栓 检查并紧固所有固定螺栓、螺钉
1 个月
16 钳缸及外露销轴 清理污垢，干燥表面，涂防锈油
17 拆检清洗杠杆和销轴 清洗刹车粉尘更换损坏零件
允许最大磨损厚度 10mm，热疲劳裂纹
18 刹车盘磨损、龟裂
不得影响强度和漏水，否则应更换 6 个月
19 钳架焊缝 检查焊缝是否有裂纹及固定螺栓
20 结构检查 检查刹车系统中所有结构部件
21 安全缸碟簧 更换全部碟簧 12 个月

23
电控液压盘式刹车装置用户手册 故障检修

八、故障检修
下表给出了一些潜在的故障现象和可能引起的故障原因，供检修
时参考。

现象 原因 处理措施
柱塞泵、系统溢流阀设置不正确 重新设置
柱塞泵、系统溢流阀工作不正常 检查、维修或更换
系统压力
油箱液位太低 补油
或工作压
油路中有空气 排气
力不正常
油滤被堵塞 清洗或更换滤芯
压力表指示不正确 检查、调整、更换
系统溢流阀溢流 重新设置
系统溢流阀 检查、维修或更换
油温过高
油箱液位太低 补油
环境温度过高 暂停工作或降温
油箱液位太低、油温低 补油、加温
由于吸入和回油箱接头松动而使泵系统有 拧紧接头、排气
噪音过大
气
柱塞泵与电机连接松动或有缺陷 检查、修理
或振动
柱塞泵与电机轴不对中 检查、修理
柱塞泵与电机底座松动 紧固
检查柱塞泵、系统溢流阀、
系统压力、工作压力过低
减压阀的设置及状况
油滤被堵塞 清洗、更换
刹车钳刹
蓄能器充氮气压力过低或漏失 维修、重新充氮气
车力不足
司钻阀堵塞或出现故障 清洗、修理或更换
调节刹车间隙的注油系统有气或密封不严 排气、解决密封问题
液压油漏失 检查、修理并补油
销轴润滑不良 检查、修复或更换轴瓦
刹车钳臂
刹车粉尘在销钉和销孔堆积 清洗
运动不灵
销轴过度腐蚀 更换
活
相关部件损坏 更换
开 式 刹 车 回油管路阻流 检查、疏通回油管路
钳 释 放 缓 回位弹簧失效 更换
慢

24
电控液压盘式刹车装置用户手册 关键元器件的拆装与更换

九、关键元器件的拆装与更换
！注意 ！
 在维修液压动力源或管线之前，一定要先停泵，卸掉蓄能器的压力，
否则，可能会造成人身伤害！
 维修液压系统时，必须特别注意保持清洁，因为污染物是液压系统
发生故障的重要因素。松开螺纹之前要先把其外面清理干净。用清
洁的护盖把通入系统内部的所有开口封好，以防污染物进入系统。
在工作中应十分注意不要污染液控系统。

9.1 回油滤油器滤芯
先把回油滤油器上盖按逆时针松开。再拆下整个滤油器，取出后，
拆下上盖，取出旧滤芯。用煤油清洗滤油器内部，晾干。放入新滤芯，
拧上上盖，再装好整个滤油器。

9.2 管路过滤器滤芯
把管路过滤器下部按逆时针拆下，换上新的滤芯。

9.3 高压滤油器滤芯
把高压滤油器拆下，用扳手把上盖打开，取出旧滤芯，用煤油清
理干净壳体内部，晾干。装上新滤芯，装上上盖，再把整个滤油器按
原样装好。

！注意！
滤油器的滤芯只能更换新滤芯，严禁旧滤芯清洗后再用！

9.4 油泵
更换一台泵时，另一台泵可以正常工作，蓄能器可以不卸压。关
闭泵的吸油、回油管路上的截止阀，防止油箱里的油流出。拆下出油
管线及接头、吸油管线及接头、回油管线及接头。拆下联接泵与电机
的两个螺钉，把泵取出。检查联轴器是否失效，若能用，把泵上的联
轴器拆下，装到新泵上；若不能用，需把包括电机一端的一套连轴器

25
电控液压盘式刹车装置用户手册 关键元器件的拆装与更换

都换下。然后把新泵安装好，把吸油管线及接头、出油管线及接头连
好。把内泄回油管接口对住泵的内泄回油口，打开截止阀，给泵的壳
体充满油，再把管线接好。打开吸油管路上的截止阀。检查无误，进
行泵压调试。

！注意！
 连接管线、接头时，必须把 O 型密封圈、组合垫圈按技术要求安
装好，否则，将引起渗漏油。
 安装泵的联轴器时，严禁用锤子敲击。应当在轴与孔、键与键槽对
正后，稍微用力推进即可。否则，将引起泵的损坏。
 泵启动前，必须给泵的壳体充满油，把吸油、回油管路上的截止阀
打开，否则，将引起泵的严重损坏。

9.5 闭式缸的碟簧、密封件
碟簧的使用寿命为一年。使用一年后，必须更换，碟簧应成组更
换，不允许只更换其中几片。在检修时应注意每片碟簧的装配次序，
不能混乱或与其它组碟簧相调换。油缸有漏油现象，说明密封圈已失
效应更换。
碟簧和密封件的更换方法及步骤如下：
(1) 在有压状态下，调整调节柱塞使刹车钳开口最大，然后转换到无压
状态，拔掉快速接头；再拆下油缸两端的销轴，将油缸整体取下，
用煤油把外部清洗干净；
(2) 按图七所示步骤拆下油缸的各零件；

26
电控液压盘式刹车装置用户手册 关键元器件的拆装与更换

1、闭式缸螺栓 2、弹簧垫圈 3、轴套 4、闭式缸盖 5、轴套

6、碟簧 7、闭式活塞 8、B7型密封圈 9、闭式缸体 10、F3型导向带
11、B3型密封圈 12、A5型防尘圈 13、组合垫圈14 14、铰接体 15、排气测压接头
16、铰接螺丝 17、限位螺钉 18、闭式调节螺柱 19、内六角圆柱头定位螺丝
20、转换柱塞

图七 闭式缸的拆装

(3) 用煤油洗净每一片新碟簧，并晾干，再用充足的润滑油脂均匀地涂
抹在每一片碟簧上。等清洗后的油缸、油缸盖、活塞、导向套等晾
干后开始安装。
(4) 安装好缸体内新的防尘圈、密封圈、导向带；
(5) 安装好活塞上的新的导向带、密封圈；
(6) 严格按照规定的碟簧装配关系把新碟簧组装好：第一片大口向下，
第二片大口向上，第三片大口向下，第四片大口向上，第五片大口
向下，第六片大口向上，然后装上缸盖；
(7) 安装活塞时，注意导向带。先加一些液压油，一人按住活塞，另一
人用铜棒轻击活塞，把活塞装到位。
(8) 安装油缸盖，把螺栓对称均匀地拧紧，用扭力扳手上紧螺栓，均匀
上紧（100～120 N·m）。
(9) 把油缸总成安装到原位。连好管路，然后调整刹车间隙。

！注意！
装配过程中注意保持清洁，防止将密封圈刮伤或碰坏。

9.6 开式缸的密封件
(1) 卸掉油缸内油压，调节柱塞的油液至刹车间隙最大，活塞回位后，

27
电控液压盘式刹车装置用户手册 关键元器件的拆装与更换

拔下快速接头、回位拉簧，拆下弹簧卡圈，把销轴拆下，取下油缸
总成；
(2) 把油缸总成用煤油清理干净；
(3) 按图八所示步骤拆下油缸的各零件；

1、六角螺栓 2、弹簧垫圈 8 3、缸盖 4、导向带 5、轴套

6、短活塞 7、排气测压接头 8、丝堵 9、组合垫圈 10、缸体
11、间隙调节阀 12、Y型密封圈 13、导向带 14、长活塞 15、防尘圈 16、呼吸过滤消声器

图八 开式缸的拆装

(4) 先拆下油缸的放气螺塞，拔出活塞和调节柱塞；
(5) 取下油缸内的旧导向带、密封圈和防尘圈；
(6) 用煤油清洗活塞及缸筒等，清洗干净并晾干；
(7) 把导向带及新密封圈、导向带、防尘圈装在缸筒内；
(8) 在油缸内壁上均匀涂一些液压油，把调节柱塞和活塞装进去 (注意
导向带勿掉下来)；
(9) 把油缸总成按原样装回原处，连好油路，调整好间隙。

9.7 刹车块
刹车块由于磨损或其他原因失效时，必须更换。否则，容易发生
溜钻、顿钻事故。
更换刹车块的准备工作：
 闭式钳：必须在给压状态下，调节调节柱塞使刹车间隙开到最大，
然后卸掉油缸内压力；
 开式钳：必须在无压的状态下，使活塞复位，用放油阀放掉调节柱
塞内的油，使调节柱塞完全回位。
28
电控液压盘式刹车装置用户手册 关键元器件的拆装与更换

把连接刹车块的6个螺栓拧下后，即可将旧刹车块取下。依次把需
更换的旧刹车块全部拆下。取下刹车块时，先取最上部或最下部刹车
钳的刹车块，沿圆周方向把刹车块依次取出。再依次按反方向把新刹
车块装上连接好。

！注意！
新刹车块更换好后需重新调整刹车间隙。
更换新刹车块必须成套更换。
更换新刹车块后必须对刹车块进行贴磨，达到75％贴磨面。

29
电控液压盘式刹车装置用户手册 易损件

十、易损件
易损件明细表如下：

序号 名称 规格（代号） 备注
1 刹车盘 根据盘刹编号
2 刹车块 BQ-C-08
3 B7 型密封圈 BG-L-15 图七-8
4 B3 型密封圈 BG-L-13 图七-11
5 F3 型导向带 BG-C-14 图七-10
6 碟簧 BG-C-09 图七-6
7 A5 型防尘圈 BG-C-12 图七-12
8 导向带 KG-LS-07 图八-4
9 Y 型密封圈 KG-LS-05 图八-12
10 导向带 KG-LS-06 图八-13
11 防尘圈 KG-LS-08 图八-15
12 高压滤油器滤芯 104050311
13 管路过滤器滤芯 104050511
14 回油滤油器滤芯 104050211
15 复位弹簧 KQ-C1-01

30
电控液压盘式刹车装置用户手册 公司信息

附 录

公司售后服务信息：
公司名称：北京普世科石油机械新技术有限公司
通讯地址：北京市海淀区学清路 18 号（北京机电研究所）1 栋 10 层 1009 室
邮政编码：100083
服务电话：010－82755979
销售电话：010－82755989
传真电话：010－82413899
公司网址：www.psk.com.cn
公司邮箱：[email protected]

31
 Document Number TC-DLS1D5T-01
Date 2024.9

Hydraulic Disc Brake

Parts list

Beijing PSK New Technology of Petroleum Machinery Co.,Ltd

 Foreword

In the Parts List of PSK hydraulic disc brake system, its structure is
introduced.

Due to design improvements or special order, the products delivered may

have slight difference with the Parts List, these differences won’t affect the
understanding of the product’s structure, performance and application. Please
contact with us if having any questions.

Beijing PSK New Technology of Petroleum Machinery Co., Ltd

Address：10F9, Building of Jidian, No.18 Xueqing Road, Haidian District, Beijing

Post Code： 100083

Service Tel.： 010－82755979
Sale Tel.： 010－82310588
Fax No.： 010－82319581
Website： www.psk.com.cn
E-mail： [email protected]
 目录 Contents
1.Brake Execute Unit.................................................................................................1

1.1 Caliper Support Arm.......................................................................................... 2

1.2 Disk Ring Assembly........................................................................................... 3

1.2.1 Disc....................................................................................................................3

1.2.2 Connecting Ring..............................................................................................4

1.3 Service Caliper Assembly.................................................................................5

1.3.1 Service Caliper Assembly.......................................................................... 5

1.3.2 Service Caliper Cylinder.............................................................................6

1.4 Safety Caliper Assembly...................................................................................7

1.4.1 Safety Caliper Assembly............................................................................ 7

1.4.2 Safety Caliper Cylinder...............................................................................8

2.HPU............................................................................................................................. 9

2.1Schematic Diagram of HPU...............................................................................9

2.2Assembly Drawing of HPU.............................................................................. 11

 Picture for reference only

5 H180X26-05 Connecting Ring 2

4 P180X26-04 Disc 2

3 BQ-L-00 Safety Caliper Assembly 2

2 KQ-LS-00 Service Caliper Assembly 2

1 J180X26-03 Caliper Support Arm 2

The configuration above is for reference only, the specific configuration depends on the actual situation

No. Code Name Quantity

Name Brake Execute Unit Beijing PSK New Technology of Petroleum Machinery Co.,Ltd

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-1-
 5 J180X26-0305 Bush 4

4 J180X26-0301 Curbed Beam 1

3 J180X26-0303 Bolt 6

2 J180X26-0304 Washer 6

1 J180X26-0302 Lower Bridge Piece 1

No. Code Name Quantity

Name Caliper Support Arm

Beijing PSK New Technology of Petroleum Machinery Co.,Ltd
Code J180X26-03

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-2-
 Name Disc
Beijing PSK New Technology Of Petroleum Machinery Co.,Ltd
Code P180X26-04

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-3-
 Name Connecting Ring
Beijing PSK New Technology Of Petroleum Machinery Co.,Ltd
Code H180X26-05

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-4-
 29 JB982-14 Combined Seal Washer 14 3
28 BQ-C-13 Pressure joints 1
27 BQ-C-12 Bolt of Articulated Body 1
26 PPT-3 Pressure joints M14X1.5 2
25 BQ-L-04 Pin, Emergency Support 2
24 GB/T894.1-30 Elastic Collar 30 4
23 KQ-LS-01 Pin, Cylinder 2
22 BQ-C-19 Bush 28x32x29 4
21 BQ-L-11 Cover Plate 4
20 GB/T 819.1-M5 Bolt of Cover Plate M5X8 8
19 BQ-L-10 Pin, Caliper Pivot 2
18 BQ-L-18 Bush 40x44x44 8
17 BQ-L-06 Pin, Brake Pad 2
16 BQ-L-15 Bush 35x39x47 4
15 BQ-L-07 Plate Assembly, Brake Pad 2
14 BQ-L-16 Bush35x39x34 4
13 BQ-C-09 Bolt of Brake Block M10X26 16
12 GB/T93-10 Bush 10 16
11 BQ-L-05 Plate, Lower Pin Retainer 4
10 BQ-C-08 Brake Block 2
9 BQ-L-17 Bush 40x44x30 4
8 GB/T93-5 Washer 5 16
7 BQ-C-11 Cap Screw 16
6 BQ-C-03 Plate, Pivot Pin Retainer 4
5 BQ-C-14 Bush 70x75x69 2
4 BQ-L-12 Spacer 4
3 BQ-L-02 Lever Assembly, Emergency 2
2 KQ-LS-02 Spring, Caliper Return 2
1 KG-LS-00 1Service Caliper Cylinder 1
No. Code Name Quantity
Service Caliper
Name
Assembly Beijing PSK New Technology of Petroleum Machinery Co.,Ltd
Code KQ-LS-00
公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581
-5-
 16 KG-S1-07 Respiration filter G1/8 6
15 KG-LS-08 Dust-Proof Ring 60X68X5 2
14 KG-LS-01 Oil cylinder long piston 1
13 KG-LS-06 Guide band 9.7x2.5x302mm 2
12 KG-LS-05 Y Seal Ring 2
11 KG-S1-05 Automatic valve 1
10 KG-LS-02 Cylinder block 1
9 JB982-14 Combined Seal Washer 5
8 KG-S1-09 Outside hexagonal plug M14X1.5 2
7 106050211 Pressure Joints 2
6 KG-LS-04 Oil cylinder short piston 1
5 BG-L-11 Bush30X34X34 2
4 KG-LS-07 Guide band 9.7x2.5x193mm 2
3 KG-LS-03 Cap 2
2 KG-S1-03 Washer 8 16
1 KG-S1-02 Bolt M8X23 16
No. Code Name Quantity
Service Caliper
Name
Cylinder Beijing PSK New Technology of Petroleum Machinery Co.,Ltd
Code KG-LS-00

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-6-
 23 BQ-C-08 Brake Block 2
22 BQ-L-05 Plate, Lower Pin Retainer 4
21 BQ-L-06 Pin, Brake Pad 2
20 BQ-L-16 Bush 4
19 BQ-L-15 Bush 4
18 BQ-L-07 Plate Assembly, Brake Pad 2
17 GB/T93-12 Washer 16
16 BQ-L-09 Bolt of Brake Block 16
15 GB/T819.1-M5 Bolt of Cover Plate 8
14 BQ-L-11 Cover Plate 4
13 BQ-L-18 Bush 8
12 BQ-L-17 Bush 4
11 BQ-C-11 Cap Screw 16
10 GB/T93-5 Washer 16
9 BQ-L-03 Plate, Pivot Pin Retainer 4
8 BQ-L-10 Pin, Caliper Pivot 4
7 GB/T894.1-30 Elastic Collar 4
6 BQ-L-01 Pin, Cylinder 2
5 BQ-L-19 Bush 4
4 BQ-L-02 Lever Assembly, Emergency 2
3 BQ-L-04 Pin, Emergency Support 2
2 BQ-L-12 Spacer 4
1 BG-L-00 Safety Cylinder Assembly 1
No. Code Name Quantity
Safety Caliper
Name
Assembly Beijing PSK New Technology of Petroleum Machinery Co.,Ltd
Code BQ-L-00

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-7-
 20 BG-L-08 Conversion Plunger 1
19 GB/T70.1-M6 Locating Screw 1
18 BG-L-07 Conversion Thread Insert 1
17 BG-C1-03 Inner Hexagon Screw 1
16 BQ-C-12 Hinged Bolt 1
15 PPT-3 Pressure Joints 1
14 BQ-C-13 Hinged Joint 1
13 JB982-14 Combined Seal Washer 3
12 BG-C-12 A5 Dust-Proof Ring 1
11 BG-L-13 B3 Seal Ring 1
10 BG-C-14 F3 Guide band 1
9 BG-L1-04 Body,Cylinder 1
8 BG-L-15 B7 Seal Ring 1
7 BG-L-05 Working Plunger 1
6 BG-C-09 Disk Spring 6
5 BG-L-10 Bush 1
4 BG-L-01 Cap 1
3 BG-L-11 Bush 2
2 GB/T93-10 Washer 16
1 BG-L-02 Bolt of Emergency Cylinder 16
No. Code Name Quantity
Safety Caliper
Name
Cylinder Beijing PSK New Technology of Petroleum Machinery Co.,Ltd
Code BG-L-00

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-8-
 Schematic
Name
Diagram of HPU
Beijing PSK New Technology of Petroleum Machinery Co.,Ltd
Code P1D5T

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-9-
No. Code Name Quantity
1 106020421 Refueling hose 1
2 101030121 Hand Pump 1
3 104050421 Rotary Pressure Pipeline Oil Filter （Core） 1
4 104050121 Return Oil Filter （Core） 1
5 104110121 Explosion-proof Air Cooler 1
6 105162021 Explosive-proof Motor 0.12kW 1
7 105240121 Temperature Controller 1
8 104030121 Explosion-proof electric heater 1kW 1
9 104070121 Level Thermometer 1
10 104040121 Air Filter 1
11 102062521 High Pressure Globe Valve 3
12 High-pressure Rubber Hose 2
13 105162321 Explosive-proof Motor 3kW 2
14 104080321 Elastic Coupling 2
15 104090121 Pump Rack 2
16 101010111 Constant Pressure Plunger Pump 2
17 High-pressure Rubber Hose 2
18 102100221 Plug in one-way valve 4
19 102062621 High Pressure Globe Valve 2
20 102030121 Direct-acting Overflow Valve 1
21 104050621 Flip Type Pressure Pipeline Oil Filter (Core) 1
22 104020121 Accumulator （Capsule） 2
23 106050121 Pressure Testing Adapter 3
24 106040921 Pressure Hosepipe 3
25 104060111 Pressure Gang 3
26 102060921 High Pressure Globe Valve, Plate Type 2
27 Explosive-proof Electric Cabinet 1
28 102010111 Hydraulic control directional valve 1
29 106030211 Quick Coupling 2
30 102040311 Explosion-proof solenoid valve 1
31 102020411 Pneumatic hydraulic directional valve 1
32 105060111 Explosion-proof pressure switch 2
33 1100（0~2MPa） Explosion-proof gas pressure transmitter 1
34 102110111 Electromagnetic air valve 1
35 102050311 Pneumatic Operated Directional Valve 1
Explosion proof electromagnetic proportional pressure
36 102120611 1
reducing valve
37 102071121 Hydraulic control one-way valve 1
38 MPM489（0～16MPa） Explosion-proof liquid pressure transmitter 3
Name Schematic Diagram of HPU
Beijing PSK New Technology of Petroleum Machinery Co.,Ltd
Code P1D4T

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

- 10 -
Name Assembly Drawing of HPU
Beijing PSK New Technology of Petroleum Machinery Co.,Ltd

Code P1D5T

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

- 11 -
 文件编号 TC-DLS1D5T-01
日期 2024.9

液 压 盘 式 刹 车

图 册

北京普世科石油机械新技术有限公司
 图册说明
本图册为 PSK 公司液压盘式刹车装置零部件结构图册。
由于产品的不断改进或特殊订货要求，本图册中个别内容可能与实际不一
致，这些内容不会影响顾客对产品结构和性能的理解，也不会影响顾客的使用。
如有疑问，请与我们联系。

北京普世科石油机械新技术有限公司

地址：北京市海淀区学清路18号1栋10层1009室

邮编： 100083
服务电话： 010－82755979
销售电话： 010－82310588
传真： 010－82319581
网址： www.psk.com.cn
邮箱： [email protected]
 目录
1.盘刹执行机构............................................................................................................. 1

1.1 钳架...................................................................................................................... 2

1.2 盘环总成..............................................................................................................3

1.2.1 刹车盘................................................................................................................3

1.2.2 连接环................................................................................................................4

1.3 开式钳总成..........................................................................................................5

1.3.1 开式钳总成................................................................................................... 5

1.3.2 工作钳油缸总成........................................................................................... 6

1.4 闭式钳总成..........................................................................................................7

1.4.1 闭式钳总成................................................................................................... 7

1.4.2 闭式缸总成................................................................................................... 8

2.液压站......................................................................................................................... 9

2.1 液压站原理图.......................................................................................................9

2.2 液压站装配图.....................................................................................................11
 注：图片仅供参考

5 H180X26-05 连接环 2

4 P180X26-04 刹车盘 2

3 BQ-L-00 闭式钳 2

2 KQ-LS-00 开式钳 2

1 J180X26-03 钳架 2

以上配置仅供参考，具体配置依实际情况而定。

序号 代码 名称 数量

名称 盘刹执行机构 北京普世科石油机械新技术有限公司

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-1-
 5 J180X26-0305 轴套 4

4 J180X26-0301 弯梁 1

3 J180X26-0303 螺栓 6

2 J180X26-0304 弹簧垫 6

1 J180X26-0302 下连接板 1

序号 代码 名称 数量

名称 钳架
北京普世科石油机械新技术有限公司
编码 J180X26-03

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-2-
 名称 刹车盘
北京普世科石油机械新技术有限公司
编码 P180X26-04

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-3-
 名称 连接环
北京普世科石油机械新技术有限公司
编码 H180X26-05

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-4-
 29 JB982-14 组合垫圈 14 3
28 BQ-C-13 铰接接头 1
27 BQ-C-12 铰接螺栓 1
26 PPT-3 测压接头 M14X1.5 2
25 BQ-L-04 闭式钳支承轴 2
24 GB/T894.1-30 弹性挡圈 30 4
23 KQ-LS-01 LS 开式钳上销轴 2
22 BQ-C-19 轴套 28x32x29 4
21 BQ-L-11 盖板 4
20 GB/T 819.1-M5 十字沉头螺钉 M5X8 8
19 BQ-L-10 中销轴 2
18 BQ-L-18 轴套 40x44x44 8
17 BQ-L-06 下销轴 2
16 BQ-L-15 轴套 35x39x47 4
15 BQ-L-07 背板 2
14 BQ-L-16 轴套 35x39x34 4
13 BQ-C-09 刹车块螺栓 M10X26 16
12 GB/T93-10 弹簧垫圈 10 16
11 BQ-L-05 下销轴挡板 4
10 BQ-C-08 刹车块 2
9 BQ-L-17 轴套 40x44x30 4
8 GB/T93-5 弹簧垫圈 5 16
7 BQ-C-11 挡板螺栓 16
6 BQ-C-03 中销轴挡板 4
5 BQ-C-14 轴套 70x75x69 2
4 BQ-L-12 支承轴挡圈 4
3 BQ-L-02 闭式钳钳臂 2
2 KQ-LS-02 复位弹簧 2
1 KG-LS-00 100S 开式缸 1
序号 代码 名称 数量

名称 开式钳总成
北京普世科石油机械新技术有限公司
编码 KQ-LS-00
公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581
-5-
 16 KG-S1-07 呼吸过滤消声器 G1/8 6
15 KG-LS-08 防尘圈 60X68X5 2
14 KG-LS-01 长活塞 1
13 KG-LS-06 导向带 9.7x2.5x302mm 2
12 KG-LS-05 Y 型密封圈 2
11 KG-S1-05 间隙调节阀 1
10 KG-LS-02 缸体 1
9 JB982-14 组合垫圈 5
8 KG-S1-09 外六角丝堵 M14X1.5 2
7 106050211 排气测压接头 2
6 KG-LS-04 短活塞 1
5 BG-L-11 轴套 30X34X34 2
4 KG-LS-07 导向带 9.7x2.5x193mm 2
3 KG-LS-03 缸盖 2
2 KG-S1-03 弹簧垫圈 8 16
1 KG-S1-02 六角头全螺纹螺栓 M8X23 8.8 级 16
序号 代码 名称 数量

名称 开式缸总成
北京普世科石油机械新技术有限公司
编码 KG-LS-00

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-6-
 23 BQ-C-08 刹车块 2
22 BQ-L-05 下销轴挡板 4
21 BQ-L-06 下销轴 2
20 BQ-L-16 轴套 4
19 BQ-L-15 轴套 4
18 BQ-L-07 背板 2
17 GB/T93-12 弹簧垫圈 16
16 BQ-L-09 刹车块螺栓 16
15 GB/T819.1-M5 十字沉头螺钉 8
14 BQ-L-11 盖板 4
13 BQ-L-18 轴套 8
12 BQ-L-17 轴套 4
11 BQ-C-11 挡板螺栓 16
10 GB/T93-5 弹簧垫圈 16
9 BQ-L-03 中销轴挡板 4
8 BQ-L-10 中销轴 4
7 GB/T894.1-30 弹性挡圈 4
6 BQ-L-01 闭式上销轴 2
5 BQ-L-19 轴套 4
4 BQ-L-02 闭式钳臂 2
3 BQ-L-04 闭式支承轴 2
2 BQ-L-12 支承轴挡圈 4
1 BG-L-00 闭式缸总成 1
序号 代码 名称 数量

名称 闭式钳总成
北京普世科石油机械新技术有限公司
编码 BQ-L-00

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-7-
 20 BG-L-08 转换柱塞 1
19 GB/T70.1-M6 内六角圆柱头定位螺丝 1
18 BG-L-07 闭式调节螺柱 1
17 BG-C1-03 限位螺钉 1
16 BQ-C-12 铰接螺栓 1
15 PPT-3 测压接头 1
14 BQ-C-13 铰接接头 1
13 JB982-14 组合垫圈 3
12 BG-C-12 A5 防尘圈 1
11 BG-L-13 B3 密封圈 1
10 BG-C-14 F3 导向带 1
9 BG-L1-04 闭式缸体 1
8 BG-L-15 B7 密封圈 1
7 BG-L-05 闭式活塞 1
6 BG-C-09 碟簧 6
5 BG-L-10 轴套 1
4 BG-L-01 闭式缸盖 1
3 BG-L-11 轴套 2
2 GB/T93-10 弹簧垫圈 16
1 BG-L-02 闭式缸螺栓 16
序号 代码/Code 名称 数量

名称 闭式缸总成
北京普世科石油机械新技术有限公司
编码 BG-L-00

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-8-
 名称 液压站原理图
北京普世科石油机械新技术有限公司
编码 P1D5T

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

-9-
序号 代码 名称 数量
1 106020421 加油软管 1
2 101030121 手摇泵 1
3 104050421 旋转式管路滤油器（滤芯） 1
4 104050121 直回式回油过滤器（滤芯） 1
5 104110121 风冷却器 1
6 105162021 隔爆电动机 0.12kW 1
7 105240121 防爆温度控制器 1
8 104030121 隔爆电加热器 1kW 1
9 104070121 液位温度计 1
10 104040121 空气滤清器 1
11 102062521 高压球芯截止阀 3
12 高压胶管总成 2
13 105162321 隔爆电动机 3kW 2
14 104080321 弹性联轴器 2
15 104090121 泵架 2
16 101010111 恒压柱塞泵 2
17 高压胶管总成 2
18 102100221 插装式单向阀 4
19 102062621 高压球芯截止阀 2
20 102030121 插装式直动溢流阀 1
21 104050621 倒装式压力管路滤油器(滤芯) 1
22 104020121 蓄能器（胶囊） 2
23 106050121 测压接头 3
24 106040921 测压软管 3
25 104060111 耐震压力表 3
26 102060921 板式高压球芯截止阀 2
27 隔爆电控箱 1
28 102010111 液控换向阀 1
29 106030211 快速接头 2
30 102040311 防爆电磁阀 1
31 102020411 气控液换向阀 1
32 105060111 防爆压力开关 2
33 1100（0~2MPa） 防爆气压力变送器 1
34 102110111 电磁气阀 1
35 102050311 气控换向阀（防碰） 1
36 102120611 防爆电磁比例减压阀 1
37 102071121 液控单向阀 1
38 MPM489（0～16MPa） 防爆液体压力变送器 3
名称 液压站原理图
北京普世科石油机械新技术有限公司
编码 P1D5T

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

- 10 -
 名称 液压站装配图
北京普世科石油机械新技术有限公司

编码 P1D5T

公司网址：www.psk.com.cn 公司邮箱：[email protected] 销售电话：010-82310588 传真：010-82319581

- 11 -
 Packing List of Attachment Tools and Spare Parts for Hydraulic Disc Brakes （L Type Calipers）

No. Code Name Qty Unit Remarks

1 J-01 Tool Box 1 pc

2 J-02 200N.m Dial Torque Wrench 1 pc

3 J-04 Solid Wrench 17-19 1 pc

4 J-05 Solid Wrench 22-24 1 pc

5 J-06 Solid Wrench 24-27 1 pc

Attachmen 6 J-07 Adjustable Spanner 1 pc

t Tools 7 J-13 Gas Charging Tool 1 suit

8 J-14 Allen Wrench(10 pcs) 1 suit

9 J-16 3、150mm Cabinet Screwdriver 1 pc

10 J-29 Clearance adjustment tool 1 pc

11 J-36 Exhaust Pipeline 1 pc

12 J-17 5CP American Circlip Pliers 1 pc

1 BQ-L-09 Bolt of Brake Block 12 pc

2 BQ-C-08 Brake block 8 blocks

3 BG-C-02 Bolt of Emergency Cylinder 8 pcs

4 KQ-LS-02 Spring, Caliper Return 2 pcs

5 H3 Quick-acting Coupling 1 suit

6 H2 Quick-acting Coupling 1 suit

7 Y-83 O-ring16×2.4 20 pcs

8 Y-82 O-ring11×1.9 10 pcs

随 机 9 Y-81 O-ring8×1.9 10 pcs
备 件
Attachmen 10 JB982-14 Combined Washer 14 10 pcs
t Spare 11 GB/T93-10 Spring Washer 10 8 pcs
Parts
12 GB/T894.1-30 Circlip for shaft 30 4 pcs

13 104050211 Filter element 1 pcs

14 PPT-3 Pressure Joint 1 pcs

15 BG-C-09 Disc spring 4 pcs

16 KX-LS-00 Service caliper repair kit 1 suit

17 BX-L-00 Emergency caliper repair kit 1 suit

18 N-06 Operation Placard 1 pcs

19 N-07 Operation Procedure Card, Brake Disc 1 pcs

 盘刹随机工具及备件清单 （L型钳子 KQ-LS-00/BQ-L-00)）
序号 代号 名称 数量 单位 备注
No. Code Name Qty Unit Remarks
1 J-01 工具箱 1 件

2 J-02 扭力扳手 1 件

3 J-04 死扳手17-19 1 件

4 J-05 死扳手22-24 1 件

5 J-06 死扳手24-27 1 件

随 机 6 J-07 活扳手300mm 1 件
工 具 7 J-13 充气工具 1 套

8 J-14 内六方扳手（10件） 1 套

9 J-16 小螺丝刀3、150mm 1 件

10 J-29 间隙调节工具 1 件

11 J-36 排气管线 1 件

12 J-17 5CP美式卡簧钳 5CP 1 个

1 BQ-L-09 刹车块螺栓 12 个

2 BQ-C-08 刹车块 8 块

3 BG-C-02 闭式缸螺栓 8 个

4 KQ-LS-02 复位弹簧 2 个

5 H3 快速接头 3/8〞 1 套

6 H2 快速接头 1/4〞 1 套

7 Y-83 O型圈16×2.4 20 个

8 Y-82 O型圈11×1.9 10 个

9 Y-81 O型圈8×1.9 10 个
随 机
10 JB982-14 组合密封垫14 10 个
备 件
11 GB/T93-10 弹簧垫圈10 8 个

12 GB/T894.1-30 轴用弹性挡圈30 4 个

13 104050211 回油滤油器滤芯 1 个

14 PPT-3 测压接头 1 个

15 BG-C-09 碟簧 4 片

16 KX-LS-00 工作钳修理包 1 套

17 BX-L-00 安全钳修理包 1 套

18 N-06 操作警示牌 1 个
19 N-07 盘刹操作规程牌 1 个
 Packing List of Spare Parts for Model PS75/1800D Hydraulic Disc Brakes

(For One Years-Use)

No. Code Name Class Unit Qty

一 Brake Execute Unit

1 KG-LS-00 Main Service Caliper Cylinder Assembly B pcs 1

2 BG-L-00 Emergency Caliper Cylinder Assembly B pcs 1

3 KM-LS-00 Seal, Service Cylinder A suit 2

4 BM-L-00 Seal, Emergency Cylinder A suit 2

5 BQ-C-08 Pad Assembly A block 48

6 KQ-LS-02 Spring, Caliper Return A pcs 8

7 BG-C-09 Spring A pcs 12

8 KX-LS-00 Service Kit, Service Caliper A suit 2

9 BX-L-00 Service Kit, Emergency Caliper A suit 2

10 BQ-L-09 Bolt of Brake Block B pcs 24

11 BG-L-02 Bolt of Emergency Cylinder B pcs 16

12 J-17 5CP External Pliers B pcs 1

13 J-36 Pressure Pipe B pcs 1

14 J-32 Gap Adjustment Tool B pcs 1

15 KG-S1-05 Automatic valve A pcs 2

1/2
 二 Hydraulic Power Unit

1 106030211 Quick-acting Coupling B suits 6

2 106030311 Quick-acting Coupling B suits 2

3 104020211 Accumulator Capsule B pcs 4

4 104060111 Pressure Gang B pcs 6

5 104070121 Level Thermometer C pcs 1

6 104050211 Filter Core A pcs 4

7 104050511 Filter Core B pcs 2

8 104050311 Filter Core B pcs 2

9 101010111 Variables Constant Pressure Pump A pcs 2

10 101030121 Hand Pump B pcs 1

11 102020111 Pneumatic Control Reversing Valve C pcs 1

12 102120611 Proportional Reducing Valve B pcs 2

13 102010111 Hydraulic Control Reversing Valve B pcs 1

14 105080511 Amplifier B pcs 2

15 102040111 Electromagnetic Directional Valve B pcs 1

16 102110111 Electromagnetic Directional Valve B pcs 1

Remark：Class A: necessary;
Class B: ordinary;
Class C: propositional

2/2
 PS75/1800D 型液压盘式刹车推荐一年备件清单

序号 编码 名 称 级别 单位 数量

一 执行机构部分

1 KG-LS-00 开式钳钳缸总成 B 个 1

2 BG-L-00 闭式钳钳缸总成 B 个 1

3 KM-LS-00 开缸密封 A 套 2

4 BM-L-00 闭缸密封 A 套 2

5 BQ-C-08 刹车块 A 块 48

6 KQ-LS-02 复位弹簧 A 个 8

7 BG-C-09 碟簧 A 个 12

8 KX-LS-00 开式钳修理包 A 套 2

9 BX-L-00 闭式钳修理包 A 套 2

10 BQ-L-09 刹车块螺栓 B 个 24

11 BG-L-02 闭式缸螺栓 B 个 16

12 J-17 5CP 美式卡簧钳 B 把 1

13 J-36 排气管线 B 根 1

14 J-32 间隙调节工具 B 把 1

15 KG-S1-05 间隙调节阀 A 个 2

1/2
 二 液压站部分（电控）

1 106030211 快速接头(3/8″) B 套 6

2 106030311 快速接头(1/4″) B 套 2

3 104020211 蓄能器胶囊 B 个 4

4 104060111 耐震压力表 B 个 6

5 104070121 液位温度计 C 个 1

6 104050211 回油过滤器滤芯 A 个 4

7 104050511 旋转式管路过滤器滤芯 B 个 2

8 104050311 倒状板式过滤器滤芯 B 个 2

9 101010111 恒压柱塞泵 A 台 2

10 101030121 手摇泵 B 台 1

11 102020111 气控液换向阀 C 个 1

12 102120611 防爆比例减压阀 B 个 2

13 102010111 液控方向阀 B 个 1

14 105080511 放大器 B 个 2

15 102040111 电磁换向阀（液阀） B 个 1

16 102110111 电磁换向阀（气阀） B 个 1

注：等级 A：必要备件，等级最高；
等级 B：常备备件，等级次之；
等级 C：建议备件，等级最低。

2/2