GALVI Shoe Brakes Brochure

INSTALLATION AND MAINTENANCE MANUAL
FOR NEW GALVI SHOE BRAKES DIN 15435

WITH HYDRO GALVI THRUSTERS
NEWCOMEN S.r.l.
Via della Betulla, 7 - 20035 Lissone (Milan) ITALY
Tel. +39 039 480891 - Fax +39 039 481289 - E-Mail info@galvi.com
1
INTRODUCTION
First of all we would like to thank you for choosing a new GALVI Shoe Brake with
electrohydraulic HYDRO GALVI Thruster.
Before installing your new GALVI Shoe Brake
it is necessary to read this Manual.
Not reading this Manual could cause malfunctioning of your new GALVI Shoe
Brake.
The Manufacturer is unconnected with any Civil or Penal liability for damages
ascribable to unskilfulness default and non-observance of the instructions of this
Manual.
All your comments and suggestions about this Manual will be carefully considered
in order to improve this document.
Our Technical Dept. is at your full disposal for any information about the new
GALVI Shoe Brakes and also for making their selection based on the data you will
supply.
We thank you for your kind attention and, looking forward to hearing from you
soon, we remain
Sincerely yours.
NEWCOMEN S.r.l.
a wholly owned Subsidiary of GALVI S.p.A.
2
TABLE OF CONTENTS
01 General information page 3

01.01 Packing of the new GALVI Shoe Brakes page 4
01.02 Handling of the new GALVI Shoe Brakes page 4
01.03 Drawings of the new GALVI Shoe Brakes page 4
01.04 Identification of the new GALVI Shoe Brakes page 5
02 Installation of the new GALVI Shoe Brakes page 6

02.01 Electrical connection of the new GALVI Shoe Brakes page 9
02.02 Adjusting of brake Shoes’ and Thruster’s opening strokes page 12
02.03 Adjusting of the Braking Torque page 14
02.04 Adjusting of the main levers’ balancing screws page 17
03 Optional items for the new GALVI Shoe Brakes page 18

03.01 Automatic linings’ wear adjustment (NV) page 18
03.02 Extra-wide brake Shoes (CL) page 19
03.03 Stainless steel pins (SS) page 20
03.04 Lubricators on main pins (GR) page 20
03.05 Open position microswitch (FIA) page 21
03.06 Linings’ wear microswitch (FIC) page 22
03.07 Manual opening and locking system (HAN) page 23
03.08 Black bituminous anti-salt paint (EPO) page 23
03.09 Supporting spheres for vertical brake axis (ORZ) page 24
04 Maintenance of the new GALVI Shoe Brakes page 25

04.01 Replacement of worn brake Shoes page 25
04.02 Replacement of main spring set page 27
04.03 HYDRO GALVI Thruster’s oil change page 28
04.04 Opening and closing HYDRO GALVI Thruster page 31
04.05 Replacement of HYDRO GALVI Thruster page 34
04.06 Lubrication of pins with lubricators (GR) page 35
04.07 Maintenance not provided for in this Manual page 35
05 Suggested spare parts for new GALVI Shoe Brakes page 35
06 List of components of the new GALVI Shoe Brakes page 36
07 Enclosed documents page 37

3
01 - GENERAL INFORMATION
The new GALVI Shoe Brakes are manufactured according to DIN 15435 Standard
and they are fail-safe, that is to say that they are spring applied and
electrohydraulically released by means of the HYDRO GALVI Thruster.
The new GALVI Shoe Brakes are the result of experience since 1962 in the
manufacturing of Industrial Brakes and they have the following standard features :
• HYDRO GALVI electrohydraulic Thruster (IP.65, class F) (HYD)

• Aluminium brake Shoes with steel bushings (CD)
• Asbestos free linings with friction coefficient µ = 0,42 (42)
• Standard galvanized pins (PS)
• Self lubricating bushes on main pins (AU)
• Galvanized tie rods, screws, nuts and small items (ZN)
• Epoxy paint final colour LIGHT GREY RAL 7001
• new square-shaped main spring fender with new universal Braking Torque
plate (with transparent film for repainting if necessary) i.e. unique for each
Brake diameter independently of the used HYDRO GALVI Thruster
• new universal main spring, i.e. just one spring for each Brake diameter
independently of the used HYDRO GALVI Thruster
• steel main levers pos. 02 and base pos. 01
The new GALVI Shoe Brakes can be fitted with the following optional items :
• Automatic linings’ wear adjustment (NV)

• Extra-wide brake Shoes (CL)
• Stainless steel pins (SS)
• Lubricators on main pins (GR)
• Explosion proof motor (EEx - d - II B - T4) (EX)
(only for GALVI Shoe Brakes with GALVI Thrusters type H50, H03, H04, H05
not provided for in this Manual)
• Open position microswitch (FIA)
• Linings’ wear microswitch (FIC)
• Manual opening and locking system (HAN)
• Black bituminous anti-salt paint (EPO)
• Supporting spheres for vertical brake axis (ORZ)
All GALVI Shoe Brakes are tested for four hours.
All HYDRO GALVI Thrusters are tested in horizontal position for four hours before
they are installed on the Brakes and they are tested again in vertical position
during the test of the GALVI Shoe Brakes.
4
01.01 - PACKING OF THE NEW GALVI SHOE BRAKES
The GALVI Shoe Brakes are always delivered carefully packed.
The type of packing depends on the type of transport, the distance, the net
weight and the Customer’s choices.
We normally use pallets with film for transport by land, wooden cases with tar
paper for sea freight and normal wooden cases for air freight.
01.02 - HANDLING OF THE NEW GALVI SHOE BRAKES
During the handling of the new GALVI Shoe Brakes any kind of impact must be
avoided, especially to the base pos. 01, the HYDRO GALVI Thruster pos. 75, the
main spring set pos. 7, 12, 14, 18 and the upper tie rod pos. 06 or 74.
In case of impact of any of the above mentioned components it is necessary to

check carefully the GALVI Shoe Brake and to replace any damaged component.
Not checking and replacing any damaged component
could cause malfunctioning and accidents.
01.03 - DRAWINGS OF THE NEW GALVI SHOE BRAKES
We think that it is better for the User to enclose to this Manual a drawing of each
model of GALVI Shoe Brake instead of a general data sheet only.
For this reason we enclose to this Manual 15 drawings of as many GALVI Shoe
Brakes from dia. 160 mm to dia. 500 mm included with HYDRO GALVI Thrusters.
The enclosed drawings show the Brakes in “NV” version with automatic linings’
wear adjustment pos. 74 and with no other optional item; they show the minimum
and maximum Braking Torque, the total mass and the Products’ code.
The enclosed drawings can also be sent by E-Mail or saved on CD in “dwg” and
“dxf” formats.
5
01.04 - IDENTIFICATION OF THE NEW GALVI SHOE BRAKES

All the new GALVI Shoe Brakes have an aluminium serial number plate pos. 21
fixed to the upper left lever pos. 03.
The following data are printed on the serial number plate pos. 21 :
• Type and diameter of GALVI Shoe Brake in the “Brake type” square
(N or NV.160, 200, 250, 315, 400, 500)
• Serial number and year of manufacturing in the “Serial Nr./Year” square
• Mass of the GALVI Shoe Brake in the “Mass kg” square
• “X” in the “AU” square (self lubricating bushes on main pins) and in the “ZN”
square (Galvanized pins, tie rods, screws, nuts and small items)
• “X” in the “CD” square (brake Shoes to DIN 15435 Standard)
x in the “CL” square (extra-wide brake Shoes)
• “X” in the “PS” square (standard pins)
or in the “SS” square (stainless steel pins)
• “X” in the “GR”, “FIA”, “FIC”, “HAN”, “EPO” squares if these optional items
are fitted
S.p.A. Brake type

Via della Betulla, 7
20035 - LISSONE - ITALIA
Serial Nr./Year Braking Torque Mass kg
SEE BR. TORQUE PLATE
Shoes CD CL Pins PS SS Bushes AU
Lubricators GR Switch FIA Wear Indic FIC
Locking HAN Paint EPO Zinc Plat. ZN
SHOE BRAKE’S SERIAL NUMBER PLATE
For a complete identification of the new GALVI Shoe Brakes it is necessary to read
also the HYDRO GALVI Thruster’s serial number plate.
The HYDRO GALVI Thruster’s serial number plate is fixed on the vertical upper part
of the Thruster and among its data it is necessary to read the following ones :
• model of HYDRO GALVI Thruster in the “HYDRO type” square
(HYD.023, 030, 050, 080, 121, 201, 301/06 or .../12
+ codes “IS”, “LI”, “LO” if these optional items are fitted)
• Voltage and frequency (Hz)
S.p.A. HYDRO type

Via della Betulla, 7
20035 - LISSONE - ITALIA
MOTOR 3 IEC34/1
Serial Nr./Year Lifting force N Stroke mm Mass kg
-1
kW Hz min Cos
IP 65 CL F TROP. Serv. S1-S3 c/h 2000
V A V A
HYDRO THRUSTER’S SERIAL NUMBER PLATE

6
In case the serial number plates are missing, the GALVI Shoe Brake can be
identified knowing the following data :
• Outer diameter of the brakedrum

• Width of the brake Shoes pos. 05
• With or without Automatic linings’ wear adjustment pos. 74
• Dimension “A” of the HYDRO GALVI Thruster, that is to say distance between
axis of upper pin pos. 29 and axis of lower pin pos. 30 with totally open
Thruster
02 - INSTALLATION OF THE NEW GALVI SHOE BRAKES

It is necessary to prepare a level surface on which the base pos. 01 of the GALVI
Shoe Brakes can lean totally.
The material of the level surface must have an ultimate tensile stress equal to or
higher than 430 N/mm2.
The level surface must be parallel to the brake axis and must be manufactured
according to following dimensions A, B, H and I.
The four holes which are necessary for fixing the GALVI Shoe Brake to the level
surface must be made according to the following dimensions H, I and M and the
perpendicularity between the main average plane of the Brake and the axis of
rotation of the brakedrum.
S.p .A .
B ra k e ty p e
Vi a de l la B e tu l
l a, 7
2 0035 - LISSO NE
- I TALIA
SrialNr./Year
e
B rakingTorque
SE E B R . TOR QU M
ass kg
Sh o e s CD E P LATE
Pi n s
Lu b r i ca to r s Bu sh e s
GR Sw i tc h AU
Lo c ki n g FI A We a r I nd i c
HA N Pa i n t FI C
EP O Zin c Pla t.
//
T A R 0 17 X X X 0 22
00 1.
XXX.
B RA KIN G TO RQ U E
00
5
A
XX X-H YD .XXX
XXX -H YD .XXX
XXX- H XX
XXX -H YD .XXX
XXX- H XX
Nm
M AX
N m
XX X
XXX
XXX
M AX
N m
XXX
XX X
M AX XXX
N m
B
XX X
XXX
XXX
XXX
XXX
H H BASE pos.01
4 Holes M
LEVEL SURFACE
I
7
Once the level surface has been manufactured according to dimensions A, B, H, I

and M it is possible to start installing the GALVI Shoe Brake.
The GALVI Shoe Brakes are supplied ready for installation, with Thruster full of oil
and with main spring pos. 14 set to the minimum value of Braking Torque.
It is necessary to remove the lower pin pos. 23 of the main lever pos. 02 opposite to
the Thruster pos. 75 after removing its two safety pins pos. 45.
After removing this pin, the main lever lever pos. 02 opposite to the Thruster pos. 75
can be lifted rotating itself on its upper pin pos. 23 which is fixed to the upper tie
rod pos. 06 or 74.
In this way the brake Shoe pos. 05 which is closer to the Thruster pos. 75 can be put
on the Brakedrum and the base pos. 01 of the GALVI Shoe Brake can be put under
the Brakedrum and can be fixed to the level surface.
During this operation it is important not to loose the disc pos. 19 and the balancing
spring pos. 15.
TIE ROD pos.06 (74) THRUSTER pos.75
S.p .A . B ra k e ty p e
Vi a de l l a B e tu
l l a, 7
2 0035 - LI SSO NE
- I TA LI A
SrialNr./Year
e
B rakingTorqu
e
Sh o e s SE E B R . TOR QU ass kg
M
CD E P LA TE
Pi n s
Lu b ri ca to rs Bu sh e s
GR Sw i tc h AU
HAN Pa i n t FI C
EP O Zin c Pl a t.
MAIN LEVER pos.02 BRAKE SHOE pos.05
SPLIT PIN pos.45

TA R X X X X X X 0 2 2
00 1.
XXX.
B RAKIN G TO RQ U E
00 5
XXX-H YD .XXX
XXX-H YD .XXX
PIN pos. 23
XXX-H XX
XXX-H YD .XXX
XXX-H XX
Nm
M AX
N m
XX X
XXX
XXX
M AX
N m
XXX
XX X
M AX XXX
N m
XX X
XXX
DISC pos.19 XXX
XXX
XXX
SPRING pos.15
BASE pos.01 MAIN SPRING pos.14
The base pos. 01 of the GALVI Shoe Brake must be fixed to the level surface by
means of four screws in the holes of the base itself and in the relevant holes of the
level surface according to dimensions H, I and M.
8
The features of the necessary screws and nuts are shown in the following drawing
and table :
2
Tensile strengt 800 N/mm UNI 5588-65 UNI 5589-65 UNI 6592-69
d
d
d1
d2
d
b min
k l+th.(level surface) s m s m1 s1 s2
Brake’s Tightening
Bolts b
dia. Torque d d1 d2 k l m m1 s s1 s2
q.ty min
mm Nm
160 4 50 M10 26 10,5 21 6,4 28 8 6 16 16 2

200 4 85 M12 30 13 24 7,5 33 10 7 18 18 2,5
250 4 210 M16 38 17 30 10 41 13 8 24 24 3
315 4 210 M16 38 17 30 10 41 13 8 24 24 3
400 4 410 M20 46 21 37 12,5 50 16 9 30 30 3
500 4 410 M20 46 21 37 12,5 50 16 9 30 30 3
Dimension “ l” should be increased by an omount equal to the thinness (th) of the

level surface.
Once the GALVI Shoe Brake has been fixed to the level surface it is possible to fix
to the base pos. 01 the lower part of the main lever pos. 02 opposite to the Thruster
pos. 75.
Thus it is necessary to put the lower part of the main lever pos. 02 opposite to the
Thruster pos. 75 into the Brake’s base pos. 01, to fix it again with its lower pin pos. 23
and to fix the pin using the two safety pins pos. 45.
After all these operations the GALVI Shoe Brake’s trim is the same one before
installation.
9
02.01 - ELECTRICAL CONNECTION OF THE NEW GALVI SHOE BRAKES
After installing the GALVI Shoe Brake following the instructions of section 02 of this
Manual it is necessary to make the electrical connection of the HYDRO GALVI
Thruster.
If not differently ordered, the HYDRO GALVI Thrusters are supplied with three phase
electric motor V. 230/400 - Hz 50, IP.65, insulation class F, whose direction of
rotation is unimportant.
All the data of the electric motor of the HYDRO GALVI Thruster are printed on the
serial number plate fixed on the vertical upper part of the Thruster itself, above the
terminal box.
We list the main electrical data of the HYDRO GALVI Thrusters V. 230/400 - Hz 50 :
HYDRO
kW Volt ∆ A∆ Volt Y AY rpm Cos. Φ Hz
Thruster
HYD.023/05 0,160 230 0,69 400 0,40 2790 0,76 50
HYD.030/05 0,195 230 0,85 400 0,49 2770 0,78 50
HYD.050/06(12) 0,210 230 1,00 400 0,58 2880 0,65 50
HYD.080/06(12) 0,320 230 1,31 400 0,76 2770 0,78 50
HYD.121/06(12) 0,320 230 1,64 400 0,95 2790 0,71 50
HYD.201/06(12) 0,450 230 1,87 400 1,08 2780 0,76 50
HYD.301/06(12) 0,560 230 2,20 400 1,30 2760 0,78 50
The electrical data of the HYDRO GALVI Thrusters with Voltage different from the
standard one will be informed if required by the Customer.
It is necessary to remove the terminal box cover by unscrewing its four screws.
The instructions for the electrical connection can be found inside the terminal box
cover; the Thruster can be star or delta connected as shown in the following
drawing.
The HYDRO GALVI Thrusters are supplied with star connection.

10
DATA PLATE FOR THRUSTER
S .p .A . H Y D R O ty p e
Vi a d el l a Be tu l al , 7
20 0 3 5 - LI SSON E - I TA LI A
SerialNr./Year fLitingforce N tSrokemm M
ass kg
MOTO R 3 I EC3 4 /1
kW mi n Co s
CL TR OP . Se rv . S1 -S3 c /h 20 00
XX XX
W2 U2 V2 W2 U2 V2
U1 V1 W1 U1 V1 W1
SCREW TERMINAL BOX COVER
The Thruster’s motor must be connected to the machine’s main motor as per
following electric scheme.
230 V
3
3 400 V
THRUSTOR
MAIN DRIVE MOTOR
MOTOR
SUGGESTED WIRING DIAGRAM

11
It is not suggested to make a series connection with the machine’s main motor
because, especially with high power motors, it is possible that the remanent
magnetism and the persistent movement of the machine’ motor’s rotor can cause
residual current which can exert an influence on the Thruster’s motor increasing its
closing time.
230 V
3
3 400 V
THRUSTOR
MAIN DRIVE MOTOR
MOTOR
NOT RECOMMENDABLE WIRING DIAGRAM

12
02.02 - ADJUSTING OF BRAKE SHOES’

AND THRUSTER’S OPENING STROKES
After installing the GALVI Shoe Brakes following the instructions of section 02 of this
Manual and after making the HYDRO GALVI Thruster’s electrical connection
following the instructions of section 02.01 of this Manual it is necessary to adjust the
brake Shoes’ and Thruster’s opening strokes.
With the Brake in closed position the upper tie rod pos. 06 must be rotated till the
HYDRO GALVI Thruster pos. 75 is totally open, without forcing over the normal
opening stroke.
Thus it is necessary to measure with Brake in open position the distance between
pin pos. 29 and base pos. 01.
TIE ROD pos.06 PIN pos.29 THRUSTER pos.75
S .p .A . B ra k e ty p e
Vi a de ll a B e tu l
20 0 3 5 - LISSON l a, 7
E - I TA LI A
SerialNr./Year
BrakingTorqu
e
SE E B R . TORQ U Mass kg
Sh o e s E P LA TE
CD CL Pi n s
Lu b ri c ato rs Bu sh e s
GR Swi tc h AU
Lo c ki n g FI A We a r nI d i c
HAN Pa i n t FI C
EPO Zin c Pl at.
BRAKE CLOSED AND ADJUSTED

"THRUSTER'S STROKE"
BRAKE OPEN
00 1.
XXX.
B R A K IN G T O R Q U E
5 00
XX X -H YD . X X X
XX X -H YD . X X X
XX X -H X X
XX X -H YD . X X X
XX X -H X X
N m
M A X
N m
XXX
XX X
XX X
M A X
N m
XX X
XXX
M A X XX X
N m
XXX
XX X
XX X
XX X
XX X
"BRAKE SHOE'S OPENING STROKE" BASE pos.01
Then the upper tie rod must be rotated in opposite direction till the HYDRO GALVI
Thruster’s hinge goes down in a measure equal to the “Thruster’s stroke” of the
following table, where “Thruster’s stroke” means Brake’s opening stroke at
Thruster’s axis.
Brake’s 160 mm 200 250 315 400 500

diameter not at DIN Standard mm mm mm mm mm
Thruster’s 30 30 38 38 42 48
Stroke mm mm mm mm mm mm
13
In the GALVI Shoe Brakes in “NV” version with automatic linings’ wear adjustment, it is
necessary to remove temporarily the “NV” device’s fork pos. 36 for rotating the upper tie
rod pos. 74 and it is necessary to put the fork pos. 36 back in its original position on upper
lever pos. 04 after setting the Thruster’s stroke, otherwise the automatic linings’ wear
adjustment will be disengaged.
UPPER LEVER NV pos.04 FORK pos. 36
TIE ROD pos.74 PIN pos.29 THRUSTER pos.75
Vi a de ll a B e tu l
l a, 7
2 0035 - LI SSO N E
- I TA LI A
SrialNr./Year
e
BrakingTorqu
e
Sh o e s SE E B R . TOR QU M
ass kg
CD E P LA TE
Pi n s
Lu b ri cato rs Bu sh e s
GR Sw i tc h AU
HAN Pa i n t FI C
EP O Zin c Pl at.
"THRUSTER'S STROKE"
BRAKE CLOSED ADJUSTING
BRAKE OPEN
00 1.
XXX.
5 00
XXX-H YD .XXX
XXX-H YD .XXX
XXX-H XX
XXX-H YD .XXX
XXX-H XX
Nm
M AX
N m
XX X
XXX
XXX
M AX
N m
XXX
XX X
M AX XXX
N m
XX X
XXX
XXX
XXX
XXX
"BRAKE SHOE'S OPENING STROKE" BASE pos.01
“NV” SHOE BRAKE WITH TEMPORARILY REMOVED FORK
Adjusting the HYDRO GALVI Thruster’s stroke in this way it is possible to adjust the brake
Shoe’s opening stroke as per DIN 15435 Standard, as per following table, where brake
Shoe’s opening stroke is the air gap between each lining and the brakedrum :
Brake’s 160 mm 200 250 315 400 500

brake
Shoe’s 0,80 1,00 1,25 1,25 1,60 1,60
opening mm mm mm mm mm mm
stroke
In the GALVI Shoe Brakes in “NV” version with automatic linings’ wear adjustment the
brake Shoes’ opening stroke is kept constant even in case of linings’ wear.
In the GALVI Shoe Brakes in “N” version without automatic linings’ wear adjustment the
brake Shoes’ opening stroke increases in a measure which is directly proportional to the
linings’ wear and for this reason it is necessary to rotate the Shoe Brake’s upper tie rod pos.
06 for adjusting the brake Shoes’ opening stroke as per above mentioned table.
This manual adjustment must be made every time the total wear of the linings reaches
0,40 mm.
14
02.03 - ADJUSTING OF THE BRAKING TORQUE
After following instructions of sections 02, 02.01 and 02.02 of this Manual it is
necessary to adjust the Braking Torque of the GALVI Shoe Brake.
The adjusting of the Braking Torque must be made with closed Brake that is to say
with brake Shoes pos. 05 closed on the Brakedrum.
The adjusting of the Braking Torque is made by compressing the GALVI Shoe
Brake’s main spring pos. 14 by clockwise rotation of the nut fixed at the top of the
main spring rod pos. 07.
For rotating this nut it is necessary to remove temporarily the safety pin pos. 52 from
its hole in the pin pos. 28 at the top of the main spring set.
It is necessary to keep the safety pin pos. 52 because once the Braking Torque is
adjusted it has the important function to prevent the nut from rotating.
A PIN pos.28
ELASTIC PIN pos.52
NUT OF TIE ROD pos.07
PIN pos.28
THRUSTER pos.75
S.p.A . B rake type
Via d e lla Be tulla
,7
20035 - L IS S O
NE - ITA LIA
Se ri a l N r. / Y e a
r
B rak i n g T o rq u
e
Sho e s SEE BR. TO RQ U E M a ss k g

CD PL A TE
CL P ins
PS SS
Lub r ica to rs Bushe s
GR S witch AU
Lo ck ing F IA We a r Ind ic
HAN Pa int F IC
EPO Zinc Pla t.
ZN
A
MAIN SPRING pos.14 Sect. A-A
Rotate the nut of tie rod pos. 07 clockwise until the index (the elastic pin pos. 18) in
the main spring fender reaches the wanted value of Braking Torque which can be
read on the Braking Torque plate pos. 22 fixed on the main spring fender.
15
TIE ROD pos.06 (74) A BRAKING TORQUE PLATE pos.22
ELASTIC PIN pos.52

S. p .A . B ra k e ty p e
Vi a de l l a B e tu l
l a, 7
2 0035 - LI SSO N E
- ITA LIA
Srial Nr./Year
e
B rakn
i gTorque
ass kg
CD E P LA TE

Pi n s
GR Sw i t c h AU
Lo c ki n g FIA We a r Ind i c
HAN Pa i n t FI C
EP O Zin c Pl a t .
PIN pos.28
A
THRUSTER pos.75
T A R 01 7X X X 022
00 1.
XXX.
00
5
XXX- H YD .XXX
XXX-H YD .XXX
XXX-H XX
XXX-H YD .XXX
XXX-H XX
Nm
M AX
N m
XX X
XXX
XXX
M AX
N m
XXX
XX X
Sect. A-A
M AX XXX
N m
XX X
XXX
XXX
XXX
ELASTIC PIN pos.18 (INDEX)

XXX
As it is possible to see in above drawing, the Braking Torque plate pos. 22 of the new
GALVI Shoe Brakes shows more than one value of maximum Braking Torque in function of
the type of HYDRO GALVI Thruster pos. 75.
More precisely, the Braking Torque plate pos. 22 of the new GALVI Shoe Brakes shows two
maximum values of Braking Torque for the Brake dia. 160 mm and three maximum values
of Braking Torque for the Brakes from dia. 200 mm to 500 mm included.
The following drawing shows the six Braking Torque plates pos. 22 for the Shoe Brakes from
dia. 160 mm to dia 500 mm included :
TAR017430022 TAR017540022
BRAKING TORQUE BRAKING TORQUE

TAR017320022
400-HYD.050 500-HYD.080
BRAKING TORQUE 400-H50 500-H03
315-HYD.030 400-HYD.080
500-HYD.121
315-H32 400-H03
500-H04
315-HYD.050 400-HYD.121
315-H50 400-H04 500-HYD.201
315-HYD.080 Nm Nm
315-H03
TAR017210022
TAR017100022 MAX
BRAKING TORQUE Nm
Nm MAX
2750 5500
BRAKING TORQUE 2670 Nm
MAX 5220
250-HYD.023
TAR017000022 200-HYD.015 Nm
1550 1600
250-HYD.030 2500 5000
BRAKING TORQUE 200-HYD.023 250-H32
160-HYD.015 200-HYD.030 250-HYD.050 1400 2250 4500

200-H32 250-H50
160-HYD.023
160-H32 Nm Nm 4000
2000
MAX 1200
Nm Nm MAX
MAX 400 Nm
400 720 MAX 3500
Nm
Nm 1750
250 700 MAX
250 1620
MAX 1000 Nm
MAX 350 2910 3000
Nm Nm
225 310 870 1500
600
200 300
800 2500
MAX 1250
175 Nm 500
MAX 250 440
Nm
140 150 MAX MAX 2000
MAX MAX 400 Nm 600 MAX Nm
Nm 200 Nm 520 Nm
1000
1600
125 170 330 860
1500
100 150 300
400 750
75 1000
100 200
50 500
200
50 100 500
25 350
29 95
43 250
16
Thus it is necessary to know the type of installed HYDRO GALVI Thruster pos. 75
for knowing the maximum Braking Torque.
In case the Braking Torque is not known by the User or by the Manufacturer it is
recommendable to contact GALVI Technical Dept. or to set the Brake at 150 % of
the main motor’s torque and to increase or decrease the Braking Torque in
function of the braking time and braking space obtained after an appropriate
period of adjustment of linings and brakedrum which must be perfectly clean.
Once the GALVI Shoe Brake’s Braking Torque has been adjusted it is necessary to
put the safety pin pos. 52 into its hole in the pin pos. 28 at the top of the main spring
so that the main spring rod pos. 07 cannot rotate counter clockwise and cause loss
of Braking Torque.
In the GALVI Shoe Brakes in “NV” version with automatic linings’ wear adjustment
the Braking torque is kept constant even in case of linings’ wear.
In the GALVI Shoe Brakes in “N” version without automatic linings’ wear adjustment
the Braking Torque decreases in a measure which is directly proportional to the
linings’ wear and to the increase of the brake Shoes’ opening stroke so that it is
necessary to adjust periodically the Brake’s upper tie rod pos. 06 for adjusting the
brake Shoes’ opening stroke.
17
02.04 - ADJUSTING OF THE MAIN LEVERS’ BALANCING SCREWS
After following instructions of sections 02, 02.01, 02.02 and 02.03 of this Manual it is
necessary to adjust the main levers’ balancing screws pos. 58.
It is necessary to adjust the main levers’ balancing screws pos. 58 in order to have
an equal opening of the two main levers pos. 02.
With the GALVI Shoe Brake in open position the balancing screws pos. 58 at the
base of the main levers pos. 02 must be adjusted till the two main levers pos. 02
can equally open.
MAIN LEVER pos.02
SCREW pos.58
NUT pos.38
DISC pos.19
SPRING pos.15
Once this last operation is made and the nut pos. 38 of the balancing screws pos.
58 is properly rotated, the GALVI Shoe Brake is ready for working.
18
03 - OPTIONAL ITEMS FOR NEW GALVI SHOE BRAKES
As written in section 01 of this Manual, the new GALVI Shoe Brakes with HYDRO GALVI
Thruster can be fitted with the following optional items described in the following setions :
• Automatic linings’ wear adjustment (NV)

• Extra-wide brake Shoes (CL)
• Stainless steel pins (SS)
• Lubricators on main pins (GR)
• Open position microswitch (FIA)
• Linings’ wear microswitch (FIC)
• Manual opening and locking system (HAN)
• Black bituminous anti-salt paint (EPO)
• Supporting spheres for vertical brake axis (ORZ)
In case other optional items not included in our standard range are needed we will be
glad to consider their manufacturing as per Customer’s requirement.
03.01 - AUTOMATIC LININGS’ WEAR ADJUSTMENT (NV)
The GALVI Shoe Brakes with Automatic linings’ wear adjustment are identified by the “NV”
code.
The Automatic linings’ wear adjustment is an optional item which is considered very useful
in any case and especially for all the GALVI Shoe Brakes used for intermittent service that is
to say for for main hoist drive, auxiliary hoist drive, boom hoist drive, grab opening and
closing.
The Automatic linings’ wear adjustment can be suggested in any case for any GALVI Shoe
Brake because, as already written in sections 02.02 and 02.03 of this Manual, it keeps
constant Braking Torque and brake Shoes’ opening stroke during linings’ wear.
The function of the Automatic linings’ wear adjustment is to adjust automatically the
upper tie rod pos. 74 during linings’ wear.
AUTOMATIC LINING'S WEAR ADJUSTMENT "NV"
TIE ROD pos.74

19
03.02 - EXTRA-WIDE BRAKE SHOES (CL)
The GALVI Shoe Brakes with extra-wide brake Shoes pos. 05 are identified by the
“CL” code.
The extra-wide brake Shoes pos. 05 are 1,5 times wider than the DIN Standard
brake Shoes are suggested for all GALVI Shoe Brakes for heavy duty.
In case the selection of the GALVI Shoe Brakes has been made by the
Manufacturer it is possible that the extra-wide brake Shoes pos. 05 are necessary
for satisfying the Customer’s need.
The extra-wide brake Shoes pos. 05 are in any case suggested because they allow
a better dissipation of thermal energy and a longer linings’ life.
The Extra-wide brake Shoes pos. 05 must be used with extra-wide Brakedrums or
extra-wide flexible Couplings called “PL” and “GL”.
The DIN Standard brake Shoes pos. 05 are called “RF2” while the extra-wide brake
Shoes pos. 05 are called “RF4”.
The widths of “RF2” and “RF4” brake Shoes pos. 05 are listed in the following table :
Brake’s 160 mm 200 250 315 400 500

Width of 55 70 90 110 140 180

RF2 Shoe mm mm mm mm mm mm
Width of 85 105 135 165 210 270

RF4 Shoe mm mm mm mm mm mm
20
03.03 - STAINLESS STEEL PINS (SS)
The GALVI Shoe Brakes with stainless steel pins are identified by the “SS” code.
The stainless steel pins are an optional item which is suggested for all GALVI Shoe
Brakes which are installed outdoors and, above all, in salty and very humid
environment.
03.04 - LUBRICATORS ON MAIN PINS (GR)
The GALVI Shoe Brakes with lubricators on main pins are identified by the “GR”
code.
The lubricators on main pins are an optional item which is suggested for all GALVI
Shoe Brakes which are installed outdoors and, above all, in salty and very humid
environment, just like the Stainless steel pins (SS).
The GALVI Shoe Brakes with lubricators on main pins need a periodical lubrication
with grease ESSO (EXXON) Beacon 2 with proper grease gun for lubricators
Tecalemit UNI 7662.
21
03.05 - OPEN POSITION MICROSWITCH (FIA)
The GALVI Shoe Brakes with open position microswitch are identified by the “FIA” code.
The open position microswitch is an optional item which is suggested for prevent for the
accidental functioning of the machine’s main motor before the GALVI Shoe Brake is open.
Even in case the “FIA” optional item is installed, it is necessary to make a periodical
inspection of the GALVI Shoe Brakes also for checking their linings’ condition.
The used microswitch is made by TELEMECANIQUE.
"FIA" "FIA"
l l a, 7
2 0035 - LI SSO N
E - I TA LI A
SrialNr./Year
e
B rakn
i gTorque
ass kg
CD E P LA TE
Pi n s
Lu b r i ca t o r s Bu sh e s
GR Sw i tc h AU
Lo c ki n g FI A We ar I ndi c
HAN Pa i n t FI C
EP O iZn c Pl a t.
T A R 0 1 7 2 10 0 22
00 1.2
01.0
05
250-H YD .023
25 0-H YD .0 30
250-H 3 2
250 -H YD .0 50
250 -H 50
Nm
M AX
N m
7 20
700
600
M AX
N m
500
4 40
M AX 400
N m
3 30
300
200
100
43
MICROSWITCH "FIA" - ELECTRICAL DATA

a.c. supply 50-60 Hz d.c. supply
Power broken in W
Inductive
5 for 5 million operating cycles
million of operating cycles
Voltage V 24 48 120
2
W 10 7 4
1
CONTACTS WORKING SWITH FOR "FIA"
110V
0.5 24V 1.8 4.5(P)
13 21 21-22
230/400V 13-14
21-22
13-14
0.2 48V 14 22
0 0.9 5.5
[mm]
0.1
0.5 1 2 5 10
Current in A
22
03.06 - LININGS’ WEAR MICROSWITCH (FIC)
The GALVI Shoe Brakes with linings’ wear microswitch are identified by the “FIC”
code.
The linings’ wear microswitch is an optional item which is suggested for checking
the linings’ wear in case it is possible to have a signal which shows the microswitch
contact, signal which is normally a led in the crane’s cabin.
The used microswitch is made by TELEMECANIQUE.
"FIC" "FIC"
100% 5 0% 0
S. p . A . Bra k e ty p e
l l a, 7
2 0035 - LI SSO N
E - I TA LI A
SrialNr./Year
e
B rakingTorqu
e
ass kg
CD E P LATE
Pi n s
Lu b r i ca to rs Bu sh e s
GR Sw i tc h AU
HA N Pa i n t FI C
EP O iZn c Pl a t.
00 1.X
XX .0
05
XXX- H YD .XXX
XXX- H YD .XXX
XXX-H XX
XXX- H YD .XXX
XXX-H XX
Nm
M AX
N m
XX X
XXX
XXX
M AX
N m
XXX
XX X
M AX XXX
N m
XX X
XXX
XXX
XXX
XXX
MICROSWITCH "FIC" - ELECTRICAL DATA

a.c. supply 50-60 Hz d.c. supply
Power broken in W
Inductive
5 for 5 million operating cycles
million of operating cycles
Voltage V 24 48 120
2
W 10 7 4
1
CONTACTS WORKING SWITH FOR "FIC"
110V
0.5 24V 1.8 4.5(P)
230/400V 13 21 21-22
13-14
21-22
13-14
0.2 48V 14 22
0 0.9 5.5
[mm]
0.1
0.5 1 2 5 10
Current in A
23
03.07 - MANUAL OPENING AND LOCKING SYSTEM (HAN)
The GALVI Shoe Brakes with manual opening and locking system are identified by
the “HAN” code.
The manual opening and locking system is an optional item which is suggested for
maintenance purpose or also for manual opening of the GALVI Shoe Brake in case
of black-out, obviously after lowering the load.
The system is made of a lever in vertical position with cam which can be turned
about 90° and opens the GALVI Shoe Brake and keeps it in open position.
For closing the Brake it is necessary to put the lever back in rest position and, for
safety reasons, in case the Brake is blocked in open position by the “HAN” optional
item and the HYDRO GALVI Thruster is feeded, the “HAN” system is automatically
disengaged, that is to say that the GALVI shoe Brake is automatically closed.
"HAN" LOCKING SCREW "HAN"
CAM
S .p .A . B ra k e ty p e
l l a, 7
0 0 3 5 - LI SSONE
- I TALI A
SerialNr./Year
B rakingTorque
Sh o e s SE E B R . TORQ Mass kg
CD U E P LA TE
CL Pi n s
Lu br i c at o r s Bu sh e s
GR Swi tc h AU
Lo c ki n g FI A We a r nI d i c
HA N Pa i n t FI C
EPO iZn c Pl a t.
VERTICAL LEVER
022
00 1.
XXX.
ORQUE
00
5
XX
XXX
X
.X X X
XX
N m
XX X
XX X
MA X
N m
XX X
XXX
MA X XX X
N m
XXX
XX X
XX X
XX X
XX X
03.08 - BLACK BITUMINOUS ANTI-SALT PAINT (EPO)
The GALVI Shoe Brakes with black bituminous anti-salt paint are identified by the
“EPO” code.
The black bituminous anti-salt paint is an optional item which is suggested for all
GALVI Shoe Brakes which are installed in salty and very humid environment, just like
the Stainless steel pins (SS) and the lubricators on main pins (GR).
24
03.09 - SUPPORTING SPHERES FOR VERTICAL BRAKE AXIS (ORZ)
The GALVI Shoe Brakes with supporting spheres for vertical brake axis are identified
by the “ORZ” code.
The supporting spheres for vertical brake axis are an optional item which is
necessary for any GALVI Shoe Brake which is installed in horizontal position, that is
to say with vertical brake axis.
The spheres support the GALVI Shoe Brake and they must roll on a horizontal level
surface under the Brake itself.
SUPPORTING LEVEL SURFACE
"ORZ"
"ORZ"
ass kg
FI C
AU
M
We a r I nd i c
Zin c Pl a t.
Bu sh e s
B ra k e ty p e
"ORZ"
P LA TE
BrakingTorque
SE E B R . TOR QU E
FI A
EP O
Sw i tc h
Pi n s
Pa i n t
S.p .A .
- I TA LI A
a, 7
Vi a de l l a B e tu l l
2 0035 - LI SSO N E
GR
HAN
SrialNr./Year
CD
e
Lu b ri ca to rs
Sh o e s
Lo c ki n g
X XX
X XX
X XX
X XX
X XX
X XX
X XX
X XX
N m
B R A KIN G T O R Q U E
X XX-H YD . XXX
X XX-H YD . XXX
X XX-H XX
X XX-H YD . XXX
X XX-H XX
M AX
M AX
M AX
N m
N m
N m
XX X
XX X
XX X
00 5
XXX.
00 1.
"ORZ"
25
04 - MAINTENANCE OF THE NEW GALVI SHOE BRAKES
As it is necessary to follow instructions of sections 02, 02.01, 02.03 and 02.04 of this
Manual for a good installation of the GALVI Shoe Brake, it is also very important to
follow the following instructions for a good maintenance.
A periodical good maintenance will guarantee the best functioning and the
longer life of the GALVI Shoe Brake.
For a good maintenance of the new GALVI Shoe Brake it is necessary to have the
suggested original GALVI spare parts listed in section 05 of this Manual.
04.01 - REPLACEMENT OF WORN BRAKE SHOES
All the brake Shoes pos. 05 of the new GALVI Shoe Brakes are made in aluminium
with steel bushings and with bonded asbestos free linings.
The lining is obviously subject to wear in function of the type of service of the GALVI
Shoe Brake and also in function of the type of environment.
It is necessary to control periodically the condition of the linings in order to be able

to replace the brake Shoes pos. 05 before the linings are totally worn.
If the linings are not periodically checked it is possible that the brake Shoes’
aluminium castings can touch directly the Brakedrum damaging it and causing
loss of Braking Torque.
Both DIN Standard “RF2” brake Shoes pos. 05 and extra-wide “RF4” brake shoes
pos. 05 can be easily replaced without disassembling the GALVI Shoe Brake.
In fact for replacing the worn brake Shoes pos. 05 it is necessary to open the Brake,
to remove the two safety pins pos. 45 of their pin pos. 24, to remove the pin pos. 24
in order to separate them from the main lever pos. 02 and to rotate them upwards
by rotating them on the Brakedrum, as shown in the following drawing.
26
MAIN LEVER pos.02
BRAKE SHOE pos.05 PIN pos.24
S.p . A . B r a k e ty p e
l l a, 7
2 0035 - LI SSO N
E - I TA LI A
SrialNr. /Year
e
B rakn
i gTorque
SE E B R . TOR QU ass kg
M
Sh o e s E P LA TE
CD
Pi n s
Lu b r i ca t o rs Bu sh e s
GR Sw i t c h AU
Lo c ki n g FI A We ar I nd i c
HAN Pa i n t FI C
EP O Zi n c Pl a t.
00 1.
XXX.
00 5
XXX-H Y D .XXX
XXX-H Y D .XXX
XXX-H XX
XXX-H Y D .XXX
XXX-H XX
Nm
M AX
N m
XX X
XXX
XXX
M AX
N m
XXX
XX X
M AX XXX
N m
XX X
300
XXX
XXX
XXX
PIN pos.24 SPLIT PIN pos.45
In every drawing enclosed to this Manual the “Rmin” dimension shows the minimum
distance between the GALVI Shoe Brake’s vertical axis and a lateral
encumbrance for extracting the pin POS. 24 which fixes the brake Shoe POS. 05 to
the main lever pos. 02.
R min
l l a, 7
2 0035 - LI SSO N
E - ITA LIA
SrialNr./Year
e
Brakn
i gTorque
Sh o e s SE E B R . TOR QU E ass kg
M
CD P LA TE
Pi n s
Lu b r i ca t o rs Bu sh e s
GR Sw i tc h AU
Lo c ki n g FIA We a r I nd i c
H AN Pa i n t FIC
EP O Zin c Pl a t .
00 1.
XXX.
00 5
XXX-H YD .XXX
XXX-H YD .XXX
XXX-H XX
XXX- H YD .XXX
XXX- H XX
Nm
M AX
N m
XX X
XXX
XXX
M AX
N m
XXX
XX X
M AX XXX
N m
XX X
XXX
XXX
XXX
XXX
MINIMUM DISTANCE FROM LATERAL ENCUMBRANCE

FOR EXTRACTING THE BRAKE SHOE’S PIN POS. 24
27
The brake Shoes pos. 05 with worn lining can be replaced with new brake Shoes
and they can also be reconditioned, that is to say that they can be sent to the
Manufacturer who will remove the worn linings and bond the new ones.
The GALVI brake Shoes linings are never riveted because the used bonding system
creates a cohesion between lining and aluminium support which is higher than the
one obtained with rivets.
We advise against the reconditioning of the GALVI brake Shoes made by the User
or by User’s Suppliers.
We recommend to use only original GALVI brake Shoes or GALVI brake

Shoes reconditioned by the Brake’s Manufacturer.
04.02 - REPLACEMENT OF THE MAIN SPRING SET

The main spring set’s function is to close the GALVI Shoe Brake and its replacement
is suggested only in case it is damaged or inefficient for any reason.
Whichever the reason of its replacement is, the main spring set must be totally
replaced, that is to say that it must be replaced without disassembling it and it
must be replaced with a new original one supplied already assembled and
complete of every component.
Thus the main spring set must be removed and replaced and it never must be
disassembled because, in case of unskilfulness or non-compliance during its
assembling, its disassembling would make possible a wrong functioning of the
main spring which could cause the non-closing of the GALVI Shoe Brake.
MAIN SPRING SET
Vi a de l l a B e tu l
2 0035 - LI SSO N E l a, 7
- I TA LI A
SrialNr./Year
e
BrakingTorqu
e
SE E B R . TOR QU M
ass kg
Sh o e s CD E P LA TE
Pi n s
GR Sw i tc h AU
HAN Pa i n t FI C
EP O Zin c Pl a t.
TA R X X X X X X 0 2 2 TA R X X X X X X 0 2 2
00 1.
XXX.
B RA KIN G TO RQ U E B RA KIN G TO RQ U E
00
5
XXX-H YD .XXX XXX-H YD .XXX

XXX-H XX XXX-H XX

XXX-H XX XXX-H XX
Nm Nm
M AX M AX
N m N m
XX X XX X
XXX XXX
XXX XXX
M AX M AX
N m
XXX N m
XXX
XX X XX X
M AX XXX M AX XXX
N m N m
XX X XX X
XXX XXX
XXX XXX
XXX XXX
XXX XXX
28
04.03 - HYDRO GALVI THRUSTER’S OIL CHANGE
HYDRO GALVI Thrusters’ oil must be changed every 1000 hours of functioning or
every 12 months of functioning, whichever comes first.
After unscrewing the Thruster’s upper cap it is necessary to empty completely the
oil from the Thruster itself and to flush it using the same type of oil used for refilling.
At least three flushings must be carried out : the first one with 60% of the quantity
specified for filling, the second one and third one with 30%.
It is advisable not to use the oil used for flushing for the final filling, or that used for
the first filling for the second and third flushing.
If, however, the same oil is used for the three flushes make sure that it is filtered
properly after every flushing.
The type of oil finally used needs not necessarily to be the same as that used for
the previous filling; however, it must have the same technical characteristics.
All HYDRO GALVI Thrusters are delivered with oil
ESSO (EXXON) Invarol EP.22
Oil must be poured always in the upper hole of the HYDRO GALVI Thruster.
Due to the air bubble that forms in the lower parts, it is necessary to carry out filling
in at least three phases, pouring in the quantity of oil indicated in the table below.
After pouring in the quantity shown for the first phase, tighten the cap with a low
torque, turn the HYDRO GALVI Thruster upside down and in that position, pull out
the piston by hand and push it back in again at least three times.
Slowly bring the HYDRO GALVI Thruster back into a vertical position, then proceed
with the second filling (2nd Phase), once again turning the HYDRO GALVI Thruster
upside down as in the 1st Phase, then complete the filling (3rd Phase) again turning
the HYDRO GALVI Thruster upside down.
Once filling has been completed, the oil level, measured from the cap’s support
plane, must be equal to the value indicated in the table in the “Level” column.
Remember that if the level is too low, it may mean that the HYDRO GALVI Thruster
cannot operate properly if installed in horizontal position.
The cap must be definitively tightened with a tightening torque of 25 N·m.

29
1st Phase 2nd Phase 3rd Phase Total ± 3% Level

HYDRO Thruster
litres litres litres litres mm
HYD.023/05 1.500 0.150 0.100 1.750 17
HYD.030/05 2.000 0.500 0.200 2.700 20
HYD.050/06 & 080/06 4.400 0.550 0.200 5.150 22
HYD.050/12 & 080/12 6.700 0.600 0.200 7.500 23
HYD.121/06 & 201/06 6.900 0.700 0.200 7.800 28
HYD.301/06 6.900 0.700 0.200 7.800 27
HYD.121/12 & 201/12 6.800 0.700 0.200 7.700 28
HYD.301/12 6.800 0.700 0.200 7.700 27
CAP
LO LI
CAP
30
When the HYDRO is fitted with optional internal springs (IS) and/or with optional
lifting and lowering valves (LI-LO), the volume of oil must be reduced depending
on the volume of the relative optional items.
The following table shows the quantities of oil that must be subtracted from those
indicated above, bearing in mind that the reduction must be made on the
quantities of the 1st Phase and on the total quantities :
WITH INTERNAL SPRINGS (IS) WITH LIFTING AND/OR

HYDRO LOWERING VALVES (LI-LO)
Thruster litres to be subtracted from litres to be subtracted from
1st Phase’s and total q.ty 1st Phase’s and total q.ty
HYD.023 0.025 0.080
HYD.030 0.045 0.085
HYD.050 0.100 0.160
HYD.080 0.190 0.160
HYD.121 0.250 0.220
HYD.201 0.400 0.220
HYD.301 0.650 0.220

Calculating the above quantities is the responsibility of the user, but it is an
extremely simple matter.
31
04.04 - OPENING AND CLOSING HYDRO GALVI THRUSTER
The HYDRO GALVI Thruster is basically a maintenance free Product.

The only required maintenance is the periodical oil change described in section
04.03 of this Manual.
HYDRO GALVI Thrusters must never be disassembled for normal maintenance if

they have no functioning problems.
In case the HYDRO GALVI Thruster has any functioning problem it is warmly
suggested to consult the Manufacturer for any operation.
In case the HYDRO GALVI Thruster has been disassembled for any reason it is
absolutely necessary to follow the following instructions for closing the Thruster
itself, that is to say for joining the lower part called motor housing to the upper part
called reservoir.
Before joining the motor housing to the reservoir it is necessary that the contact
surfaces of the two components are perfectly clean.
Thus it is necessary to check the gap between the two components, joining them
without gasket pos. 36, using screws pos. 69 and tightening them with a tightening
torque of 5 N·m.
The correct gap is between 0.5 and 0.75 mm.
A gap larger than 0.75 mm would mean a risk of not ensuring an appropriate
pressure on gasket pos. 36 once it has been inserted while a gap smaller than 0.55
mm would result in deforming the internal parts during final tightening.
Once this check has been completed, the two components must be separated,
prior to joining them definitively.
Put a band of KKSEAL5831 liquid gasketing to each of the two contact surfaces.
The width of the band of gasketing applied must be about 3 - 4 mm.
Distribute the gasketing uniformly on both surfaces, making sure that the four holes
are surrounded by gasketing.
There is no point in applying gasketing to surfaces that are not going to be in

contact with gasket pos. 36.
Insert the two plugs pos. 83 in the holes provided in the tank, then position seals
pos. 36 and insert them on the plugs pos. 83.
32
This operation must be carried out with great care, to prevent the gasket from
breaking, as it is quite fragile.
Join the tank and the motor housing, taking care that the two plugs are
adequately inserted in the holes of the component concerned.
Insert the four screws pos. 69 after having applied three drops of KKSEAL5403
thread locking to the initial threaded part, and then tighten them without
completely joining the two parts.
Definitively tighten the screws in three phases in accordance with the torque
values indicated below.
HYDRO Thruster 1st Phase 2nd Phase 3rd Phase
HYD.023 & 030 Screws 1,3,2,4 10 Nm Screws 4,2,3,1 17 Nm Screws 2,4,1,3 25 Nm
HYD.050 & 080 Screws 1,3,2,4 12 Nm Screws 4,2,3,1 20 Nm Screws 2,4,1,3 30 Nm
HYD.121, 201 & 301 Screws 1,3,2,4 20 Nm Screws 4,2,3,1 35 Nm Screws 2,4,1,3 50 Nm
75 minutes after the completion of the above operation, the HYDRO GALVI
Thruster can be filled, in accordance with the procedures described in section
04.03 of this Manual.
KKSEAL5831
WITH GASKET pos. 36 AND KKSEAL5831
RESERVOIR KKRES.....09
GAP 0,5 - 0,75 mm
WITHOUT GASKET pos. 36
SPI233804X10
GASKET KKGAS.....36
PARALLEL PIN pos. 83
TIGHTENING TORQUE AS PER TABLE TIGHTENING TORQUE 5 N m

KKSEAL5831
MOTOR HOUSING KKHOU.....02

33
34
04.05 - REPLACEMENT OF HYDRO GALVI THRUSTER

In case the HYDRO GALVI Thruster pos. 75 must be replaced first of all it is necessary
to disconnect it from the electric line, obviously after creating all the necessary
safety conditions.
Afterwards it is necessary to take note of the Braking Torque the GALVI Shoe Brake
has been set to because it is necessary to unset the Brake for replacing the Thruster
pos. 75.
For unsetting the GALVI Shoe Brake it is necessary to remove temporarily the safety
pin pos. 52 from its hole in the pin pos. 28 at the top of the main spring and to
rotate the nut of tie rod pos. 07 counter clockwise until the index (elastic pin pos.
18) in the main spring fender reaches the minimum value of Braking Torque
indicated on the Braking Torque plate pos. 22 fixed on the main spring fender.
A SPLIT PIN pos.46 PIN pos.29

ELASTIC PIN pos.52
Vi a de l l a B e
tu l l a, 7
2 0035 - LI SSO
N E - I TA LI A
SrialNr. /Year
e
B rakn
i gTorque
ass kg
CD E P LA TE
Pi n s
Lu br i cat o rs Bu sh e s
GR Sw i tc h AU
HAN Pa i n t FI C
EP O Zi n c Pl a t .
PIN pos.28
THRUSTER pos.75
A
T A R 017X X X 022
00 1.
XXX.
B RA KING TO RQ U E
5 00
X XX-H YD .X XX
X XX-H YD .XX X
X XX-H XX
X XX-H YD .XX X
X XX-H XX
Nm
M AX
N m
XX X
XXX
Sect. A-A
XXX
ELASTIC PIN pos.18 (INDEX)

M AX
N m
XXX
XX X
M AX XXX
N m
XX X
XXX
SPLIT PIN pos.47

XXX
XXX
XXX
PIN pos.30
BRAKING TORQUE PLATE pos.22
It is necessary to keep the safety pin pos. 52 because once the Braking Torque is
adjusted it has the important function to prevent the nut of tie rod pos. 07 from
rotating.
Thus it is possible to remove the four safety pins pos. 46 and 47 of the upper and
lower pins pos. 29 and 30 of the HYDRO GALVI Thruster pos. 75, to remove the two
pins and to free the Thruster from the Brake.
Once the HYDRO GALVI Thruster pos. 75 has been replaced with a new one of the
same model, it is necessary to fit in the upper and lower pins pos. 29 and 30, to fit in
their safety pins pos. 46 and 47 and to make the electrical connection following
the instructions of section 02.01 of this Manual.
Once the GALVI Shoe Brake’s Braking Torque has been set to the value it was set
to before changing the HYDRO GALVI Thruster pos. 75 by following the instructions
of section 02.03 of this Manual, it is necessary to put the safety pin pos. 52 into its
hole in the pin pos. 28 at the top of the main spring so that the main spring rod pos.
07 cannot rotate counter clockwise and cause loss of Braking Torque.
35
04.06 - LUBRICATION OF PINS WITH LUBRICATOR (GR)

The GALVI Shoe Brakes with optional pins with lubricators (GR) need their main
joints to be periodically lubricated by injection of grease ESSO (EXXON) Beacon 2
with proper grease gun for lubricators Tecalemit UNI 7662.
04.07 - MAINTENANCE NOT PROVIDED FOR IN THIS MANUAL

For any maintenance intervention not provided for in this Manual the User is invited
to consult the Manufacturer of the Dealer for asking the necessary information and
instructions.
05 - SUGGESTED SPARE PARTS FOR NEW GALVI SHOE BRAKES

As already written in section 04 of this Manual, for a good maintenance of the new
GALVI Shoe Brakes it is suggested to have the genuine GALVI Spare Parts listed in
this section.
For each GALVI Shoe Brake it is suggested to keep in stock the following genuine
GALVI Spare Parts in the below mentioned minimum quantities :
• four “RF2” brake Shoes pos. 05 for “CD” Brakes
or
• four “RF4” brake Shoes pos. 05 for “CL” Brakes
• one HYDRO GALVI Thruster pos. 75
• one “TIR” upper tie-rod pos. 06 for “N” Brakes
or
• one “RIP” upper tie-rod pos. 74 for “NV” Brakes
• one “SPR” main spring set pos. 07, 12, 14, 18
It is suggested to order the Spare Parts together with the GALVI Shoe Brake in order
not to be out of stock in moment they are necessary.
The availability of the above mentioned strategic Spare Parts will protect the User
from almost every unforeseen event; it is in any case suggested to have a
complete spare Brake.
Even if the above mentioned Spare Parts are normally available, in case they are
not ordered together with the GALVI Shoe Brake, their prompt delivery is not
assured.
In case the GALVI Shoe Brake is installed on a GALVI flexible Coupling type “GD” or
“GL” it is suggested to keep in stock minimum two sets of “RG2” Rubber Bushes
and one set of “RG1, 2, 3, 4” complete driving pins.
06 - LIST OF COMPONENTS OF THE NEW GALVI SHOE BRAKES

Please find herewith enclosed a numbered list of the main components of the new
GALVI Shoe Brakes so that any necessary component can be easily identified.
36
74 04 36 61 54 78 69 45 33 26 27 33 45 69 78 03 52 28 33 45 78 21 77
78
45
33
25 20
02 Vi a de l l a B e tu
2 0035 - LI SSO NE
Srial Nr. /Year
e
S.p .A .
l l a, 7
- I TA LI A
B ra k e ty p e 29
BrakingTor que
SE E B R . TOR QU M
ass kg
Sh o e s CD E P LATE
Pi n s
Lu b ri ca to r s Bu sh e s
GR Sw i tc h AU
05 34
H AN Pa i n t FI C
EP O iZn c Pl a t.
78 46
45 78
33 TA R X X X X X X 0 2 2
75
00 1.
XXX.0
05
24
XXX- H YD .XXX
XXX- H YD .XXX
XXX-H XX
XXX- H YD .XXX
78
XXX-H XX
Nm
16 51
M AX
N m
XX X
XXX
XXX
58 47
M AX
N m
XXX
XX X
M AX XXX
N m
XX X
XXX
78 XXX
XXX
30
XXX
38 11
15 53
19 60
78
01 78 69 45 33 23 07 12 14 18 78 31 35 48 78 10 22
06 55 43 40
* = VALID ONLY FOR "N" BRAKES
POS. CODE ITEMS Q.TY' POS. CODE ITEMS Q.TY'

01 BAS001XXX001 BASE NR 1 35 ROS001XXX035 SPECIAL WASHER NR 2
02 LEV001XXX002 MAIN LEVER NR 2 36 ** FOR001XXX036 FORK NR 1
03 LEV001XXX003 UPPER LEVER NR 2 38 DAD5589MXX-6 NUT NR 2
04 LEV002XXX004 UPPER LEVER NV NR 1 40 * DAD5593MXX-6 NUT NR 1
05 RFX.XXX BRAKE SHOE NR 2 43 * MODXXXXXXXXX DISC SPRING NR 12
06 * TIR001XXX006 TIE ROD NR 1 45 COF36UXXXXX SPLIT PIN NR 16
07 TIR001XXX007 TIE ROD NR 1 46 COF36UXXXXX SPLIT PIN NR 2
10 CON001XXX010 SPRING FENDER NR 1 47 COF36UXXXXX SPLIT PIN NR 2
11 CRN017XXX011 HINGE NR 1 48 COF36UXXXXX SPLIT PIN NR 2
12 FON001XXX012 BOTTOM NR 1 51 ROS001XXX033 SPECIAL WASHER NR 4
14 MOL017XXX014 MAIN SPRING NR 1 52 SPI6873XXXXX ELASTIC PIN NR 1
15 MOL017XXX015 SPRING NR 2 53 VAR.LOC.XXXX LOCTITE ML 1,5
16 MOL0XXXXX016 HOLDER SPRING NR 2 54 ** ROS1751AXX ELASTIC WASHER NR 2
18 SPI6873XXXXX ELASTIC PIN NR 1 55 * SPI6873XXXXX ELASTIC PIN NR 1
19 DIS001XXX019 DISC NR 2 58 VIT25GXXXXXX SCREW NR 2
20 ROSXXXXXX020 WASHER NR X 60 VIT84GXXXXXX SCREW NR 2
21 TAR001XXX021 DATA PLATE FOR SHOE BRAKES NR 1 61 ** VIT84GXXXXXX SCREW NR 2
22 TAR017XXX022 BRAKING TORQUE PLATE NR 1 69 BOC.KUXXXXXX SELF LUBRIFICATING BUSH NR 8
23 PER001XXX023 PIN NR 2 70 BOC.KUXXXXXX SELF LUBRIFICATING BUSH NR 2
24 PER001XXX024 PIN NR 2 74 ** RIP002XXX100 AUTOMATIC WEAR ADJUSTING DEVICE NR 1
25 PER001XXX025 PIN NR 1 75 HYDXXXXXXX HYDRO GALVI THRUSTER NR 1
26 PER001XXX026 PIN NR 1 77 VARBOS.5242C BOSTIK -
27 PER001XXX027 PIN NR 1 78 VARGRA.BEA2 GREASE -
28 PER001XXX028 PIN NR 1
29 PER001XXX029 PIN NR 1 OPTIONAL ITEMS (see relevant sections)
30 PER0XXXXX030 PIN NR 1 - EXFCFAXXXXXX OPEN POSITION MICROSWITCH "FIA"
31 PER001XXX031 PIN NR 1 - EXFCFCXXXXXX LINING'S WEAR MICROSWITCH "FIC"
33 ROS001XXX033 SPECIAL WASHER NR 18 - EXFCHAXXXXXX MANUAL OPENING AND LOCKING SYSTEM "HAN"
34 ROS001XXX034 SPECIAL WASHER NR 2 - EXFCORXXXXXX SUPPORTING SPHERES FOR VERTICAL BRAKE AXIS "ORZ"
* = VALID ONLY FOR "N" BRAKES
** = VALID ONLY FOR "NV" BRAKES
N.B. The letter "X" which appears in the code numbers replaces any other letter or number mentioned only in the specific lists.
37
07 - ENCLOSED DOCUMENTS
Please find herewith enclosed a collection of 15 drawings of the new GALVI Shoe
Brakes to DIN 15435 Standard with HYDRO GALVI Thruster.
38
530 max
132 max 398 max 84 min
e
Brake typ
S.p.A. NV-160 Mass [kg]
,7
Torqu e
Betulla
Via della
NE - ITALY Brakin g
20035 LISSO TORQUE
PLATE AU
ar SEE BR. Bushe s
Serial Nr./Ye SS FIC
PS Wear Indic
Pins
CL FIA ZN
Shoe s
CD Switc h Zinc Plat.
GR EPO
Lubricators Paint
HAN
Locking
383 max
TAR017000022
BRAKING TORQUE
160-HYD.015
160-HYD.023
160-H32
001 Nm
.00 MAX
1.0 Nm
05 250
250
16
225
0
200
175
MAX
Nm
55
140 150
125
100
5
75
130
50
10
25
140 348
488
120 120
4 Holes 12
100
55
160
BRAKING TORQUE = 25 - 250 N m

MASS: BRAKE 14 kg + THRUSTER "HYDRO" 11 kg = 25 kg
CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKABQBMZUXX
Unita 'di
Posiz. misura Quantita ' Materiale Massa unit. Massa totale
Denominazione - Description
Unit of Note
Item Quantity Material Unit mass Total mass
measurem
Lavorazione Generale 12,5 3,2 0,8 0,2
Standard machining
PROGETTISTA DISEGNATORE CONTROLLO
A termini di legge la Galvi S.p.A. si riserva la proprieta' DESIGNER DRAUGHTSMAN CHECK
del presente disegno che non potra' pertanto essere ne'

FIRMA
riprodotto ne' usato a qualsivoglia titolo senza espressa N° MODIFICHE - AMENDMENTS DATA - DATE
SIGNATURE
preventiva autorizzazione.
In accordance with the law Galvi S.p.A. holds the property

rights of this drawing which may not therefore be reproduced
or used in anyway without explicit prior permission.
MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
SUBJECT: SHOE BRAKES NV-160-HYD.023/05-CD-42-PS-AU-ZN
S.p.A. TOLLERANZA GENER.
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKABQBMZUXX

39
588 max
161 max 427 max 106 min
S.p.A.
Via della
20035 LISSONE
Betulla, 7 Brake type
- ITALY
Serial Nr./Yea
r NV-200
Braking Torque
Shoes
CD SEE BR. TORQU Mass [kg]
CL E PLATE
Pins
Lubricators PS SS
GR Switch Bushes
Locking FIA AU
HAN Wear Indic
Paint FIC
EPO
Zinc Plat.
ZN
402 max
TAR017100022
BRAKING TORQUE
200-HYD.015
200-HYD.023
001
.10
200-HYD.030
20
1.00
200-H32
5
Nm
0
MAX
Nm
400
400
MAX 350
Nm
310
300
MAX
Nm
250
200
70
5
170
160
150
100
10
50
29
170 376
546
145 145
4 Holes 14
100
55
160

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKBBQBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKBBQBMZUXX

40
588 max
161 max 427 max 106 min
Brake type
S.p.A.
7
NV-200
Via della Betulla,
- ITALY Mass [kg]
20035 LISSONE Braking Torque
Serial Nr./Year PLATE
SEE BR. TORQUE AU
Bushes
PS SS
CL Pins FIC
Shoes CD FIA
Wear Indic
GR Switch ZN
Lubricators Zinc Plat.
Paint
EPO
HAN
Locking
467 max
TAR017100022
BRAKING TORQUE
200-HYD.015
200-HYD.023
001
.10
200-HYD.030
1.00
20
200-H32
5
Nm
0
MAX
Nm
400
400
MAX 350
Nm
310
300
MAX
Nm
250
200
70
5
170
160
150
100
10
50
29
170 376
546
145 145
4 Holes 14
100
55
160
BRAKING TORQUE = 29 - 400 N*m

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKBBRBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKBBRBMZUXX

41
671 max
197 max 474 max 127 min
S.p.A.
Via della Betulla,
7
Brake type
20035 LISSONE
S erial Nr./Year
- ITALY NV-250
Braking Torque
S EE BR. TORQUE Mass [kg]
Shoes CD PLATE
CL Pins PS SS
Lubricators Bushes
GR Switch AU
Locking
FIA Wear Indic
HAN Paint
FIC
EPO Zinc Plat.
ZN
481 max
TAR017210022
001.
20 1.
BRAKING TORQUE
005
250
250-HYD.023
250-HYD.030
250-H32
250-HYD.050
250-H50
Nm
MAX
Nm
720
700
600
MAX 500
Nm
90
440
3
190
MAX 400
Nm
330
300
200
12
100
43
200 430
630
180 180
4 Holes 18
100
65
160

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKCBQBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKCBQBMZUXX

42
670 max
197 max 473 max 127 min
S.p.A.
Via della Betulla,
7
Brake type
20035 LISSONE
S erial Nr./Year
- ITALY NV-250
Braking Torque
S EE BR. TORQUE Mass [kg]
Shoes CD PLATE
CL Pins PS SS
Lubricators Bushes
GR Switch AU
Locking
FIA Wear Indic
HAN Paint
FIC
EPO Zinc Plat.
ZN
481 max
TAR017210022
001.
20 1.
BRAKING TORQUE
25
005
250-HYD.023
250-HYD.030
0
250-H32
250-HYD.050
250-H50
Nm
MAX
Nm
720
700
MAX
Nm
440
600
500
90
3
190
MAX 400
Nm
330
300
200
12
100
43
200 430
630
180 180
4 Holes 18
100
65
160

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKCBRBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKCBRBMZUXX

699 max
43
197 max 502 max 127 min
Brake type
S.p.A.
7 NV-250
Via della Betulla,
- ITALY Mass [kg]
20035 LISSONE Braking Torque
S erial Nr./Year S EE BR. TORQUE
PLATE
AU
SS Bushes
Pins PS
CD CL Wear Indic
FIC
Shoes FIA
GR Switch ZN
Lubricators Zinc Plat.
Paint
EPO
Locking
HAN
552 max
TAR017210022
001.
20 1.
BRAKING TORQUE
25
005
250-HYD.023
250-HYD.030
0
250-H32
250-HYD.050
250-H50
Nm
MAX
Nm
720
700
MAX
Nm
440
600
500
90
3
190
MAX 400
Nm
330
300
200
12
100
43
200 430
630
180 180
4 Holes 18
100
65
190

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKCBSBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKCBSBMZUXX

44
784 max
244 max 540 max 153 min
S.p.A. Brake type

V ia della Betu lla , 7
20035 LISSO NE - ITALY NV-315
Serial Nr./Year Braking Torque Mass [kg]
S EE BR. TORQUE PLATE
Lubricators GR S witch FIA Wear Indic FIC
595 max
TAR017320022
BRAKING TORQUE
00
1.3
315-HYD.030
315-H32
01
31
.00
315-HYD.050
5
315-H50
315-HYD.080
5
315-H03
Nm
MAX
Nm
1550 1600
1400
1200
1000
110
5.5
MAX
Nm
870
800
230
MAX
Nm 600
520
400
12
200
95
240 490
730
220 220
4 Holes 18
110
80
160

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKDBRBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKDBRBMZUXX

45
812 max
244 max 568 max 153 min
S.p.A. Brake type

595 max
TAR017320022
BRAKING TORQUE
00
1.3
315-HYD.030
315-H32
01
31
.00
315-HYD.050
5
315-H50
315-HYD.080
5
315-H03
Nm
MAX
Nm
1550 1600
1400
1200
1000
110
5.5
MAX
Nm
870
800
230
MAX
Nm 600
520
400
12
200
95
240 490
730
220 220
4 Holes 18
110
80
190

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKDBSBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKDBSBMZUXX

46
812 max
244 max 568 max 153 min
S.p.A. Brake type

595 max
TAR017320022
BRAKING TORQUE
00
1.3
315-HYD.030
315-H32
01
31
.00
315-HYD.050
5
315-H50
315-HYD.080
5
315-H03
Nm
MAX
Nm
1550 1600
1400
1200
1000
110
5.5
MAX
Nm
870
800
230
MAX
Nm 600
520
400
12
200
95
240 490
730
220 220
4 Holes 18
110
80
190

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKDBTBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKDBTBMZUXX

47
939 max
297 max 642 max 188 min
S.p.A. Brake type

V ia d e lla Be tu lla , 7
2 0 03 5 LISSO N E - ITA LY
NV-400
S erial N r./Y ear Braking Torque Mass [kg]
S EE BR. TO RQ UE P LA TE
S h oes CD CL P in s PS SS B u sh es AU
Lubricators GR Sw itch FIA Wear Indic FIC
L ockin g HAN Pa in t E PO Zin c P la t. ZN
731 max
00
1.4
01
.00
5
40
TAR017430022
BRAKING TORQUE
400-HYD.050
400-H50
0
400-HYD.080
400-H03
400-HYD.121
400-H04
Nm
MAX
Nm 2750
140
2670
2500
2250
2000
MAX
Nm 1750
280
1620
1500
5
1250
MAX 1000
Nm
860
15
750
500
250
295 563
858
270 270
4 Holes 22
140
100
190

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKEBSBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKEBSBMZUXX

48
939 max
297 max 642 max 188 min
S.p.A. Brake type

NV-400
731 max
00
1.4
01
.00
5
40
TAR017430022
BRAKING TORQUE
400-HYD.050
400-H50
0
400-HYD.080
400-H03
400-HYD.121
400-H04
Nm
MAX
Nm 2750
140
2670
2500
2250
2000
MAX
Nm 1750
280
1620
1500
5
1250
MAX 1000
Nm
860
15
750
500
250
295 563
858
270 270
4 Holes 22
140
100
190

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKEBTBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKEBTBMZUXX

49
938 max
297 max 641 max 188 min
S.p.A. Brake type

NV-400
772 max
00
1.4
01
.00
5
40
TAR017430022
BRAKING TORQUE
400-HYD.050
400-H50
0
400-HYD.080
400-H03
400-HYD.121
400-H04
Nm
MAX
Nm
2670 2750
2500
140
2250
2000
MAX
Nm 1750
1620
280
1500
5
1250
MAX 1000
Nm
860
15
750
500
250
295 563
858
270 270
4 Holes 22
140
100
240

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKEBUBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 07/12/2000 FCKEBUBMZUXX

50
1081 max
362 max 719 max 236 min
S.p.A. Brake type

V ia del la Bet ulla, 7
20 0 3 5 L IS S O N E - I T A L Y
N V-500
Seria l Nr./Year Brakin g Torqu e Mass [kg]
S hoes CD CL P in s PS SS Bushes AU
Lu b rica to rs GR S w itc h FIA W e a r Ind ic FIC
L o c k in g HAN P a in t EPO Z in c P la t. ZN
811 max
00 1.
50 1.
00 5
50
0
T AR017540022
BRAKING TORQUE
500-HYD.080
500-H03
500-HYD.121
500-H04
500-HYD.201
Nm
180
M AX
Nm 5500
5220
5000
4500
4000
340
3500
M AX
5
Nm
2910 3000
2500
M AX 2000
Nm
15
1600
1500
1000
500
350
360 690
1050
325 325
4 Holes 22
180
130
190

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKFBTBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 16/01/2001 FCKFBTBMZUXX

51
1080 max
362 max 718 max 236 min
S.p.A. Brake type

20 0 3 5 L IS S O N E - I T A L Y
N V-500
811 max
00 1.
50 1.
00 5
50
0
T AR017540022
BRAKING TORQUE
500-HYD.080
500-H03
500-HYD.121
500-H04
500-HYD.201
Nm
180
M AX
Nm 5500
5220
5000
4500
4000
340
3500
M AX
5
Nm
2910 3000
2500
M AX 2000
Nm
15
1600
1500
1000
500
350
360 690
1050
325 325
4 Holes 22
180
130
240

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKFBUBMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 16/01/2001 FCKFBUBMZUXX

52
1080 max
362 max 718 max 236 min
S.p.A. Brake type

20 0 3 5 L IS S O N E - I T A L Y
N V-500
811 max
00 1.
50 1.
00 5
50
0
T AR017540022
BRAKING TORQUE
500-HYD.080
500-H03
500-HYD.121
500-H04
500-HYD.201
Nm
180
M AX
Nm 5500
5220
5000
4500
4000
340
3500
M AX
5
Nm
2910 3000
2500
M AX 2000
Nm
15
1600
1500
1000
500
350
360 690
1050
325 325
4 Holes 22
180
130
240

CODE OF BRAKE WITHOUT THRUSTER "HYDRO": FCKFB1BMZUXX
Unita 'di
Unit of Note
measurem
Standard machining

FIRMA
SIGNATURE

MATERIALE:
MATERIAL:
TRATTAMENTI:
TREATMENTS:
OGGETTO:
STANDARD TOLERANCE
SCALA
SCALE
DATA
DATE
N. DISEGNO o CODICE
DRAWING N° or CODE
20035 LISSONE - ITALIA / / 16/01/2001 FCKFB1BMZUXX

GALVI Shoe Brakes Brochure

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INSTALLATION AND MAINTENANCE MANUAL

FOR NEW GALVI SHOE BRAKES DIN 15435

Before installing your new GALVI Shoe Brake

it is necessary to read this Manual.

01 General information page 3

02 Installation of the new GALVI Shoe Brakes page 6

03 Optional items for the new GALVI Shoe Brakes page 18

04 Maintenance of the new GALVI Shoe Brakes page 25

05 Suggested spare parts for new GALVI Shoe Brakes page 35

06 List of components of the new GALVI Shoe Brakes page 36

07 Enclosed documents page 37

• HYDRO GALVI electrohydraulic Thruster (IP.65, class F) (HYD)

• Automatic linings’ wear adjustment (NV)

All GALVI Shoe Brakes are tested for four hours.

01.01 - PACKING OF THE NEW GALVI SHOE BRAKES

The GALVI Shoe Brakes are always delivered carefully packed.

01.02 - HANDLING OF THE NEW GALVI SHOE BRAKES

In case of impact of any of the above mentioned components it is necessary to

Not checking and replacing any damaged component

could cause malfunctioning and accidents.

01.03 - DRAWINGS OF THE NEW GALVI SHOE BRAKES

01.04 - IDENTIFICATION OF THE NEW GALVI SHOE BRAKES

S.p.A. Brake type

SHOE BRAKE’S SERIAL NUMBER PLATE

S.p.A. HYDRO type

Serial Nr./Year Lifting force N Stroke mm Mass kg

HYDRO THRUSTER’S SERIAL NUMBER PLATE

• Outer diameter of the brakedrum

02 - INSTALLATION OF THE NEW GALVI SHOE BRAKES

Once the level surface has been manufactured according to dimensions A, B, H, I

TIE ROD pos.06 (74) THRUSTER pos.75

MAIN LEVER pos.02 BRAKE SHOE pos.05

SPLIT PIN pos.45

DISC pos.19 XXX

BASE pos.01 MAIN SPRING pos.14

160 4 50 M10 26 10,5 21 6,4 28 8 6 16 16 2

Dimension “ l” should be increased by an omount equal to the thinness (th) of the

02.01 - ELECTRICAL CONNECTION OF THE NEW GALVI SHOE BRAKES

HYD.023/05 0,160 230 0,69 400 0,40 2790 0,76 50

HYD.030/05 0,195 230 0,85 400 0,49 2770 0,78 50

HYD.050/06(12) 0,210 230 1,00 400 0,58 2880 0,65 50

HYD.080/06(12) 0,320 230 1,31 400 0,76 2770 0,78 50

HYD.121/06(12) 0,320 230 1,64 400 0,95 2790 0,71 50

HYD.201/06(12) 0,450 230 1,87 400 1,08 2780 0,76 50

HYD.301/06(12) 0,560 230 2,20 400 1,30 2760 0,78 50

The HYDRO GALVI Thrusters are supplied with star connection.

DATA PLATE FOR THRUSTER

SCREW TERMINAL BOX COVER

SUGGESTED WIRING DIAGRAM

NOT RECOMMENDABLE WIRING DIAGRAM

02.02 - ADJUSTING OF BRAKE SHOES’

TIE ROD pos.06 PIN pos.29 THRUSTER pos.75

BRAKE CLOSED AND ADJUSTED

"BRAKE SHOE'S OPENING STROKE" BASE pos.01

Brake’s 160 mm 200 250 315 400 500

UPPER LEVER NV pos.04 FORK pos. 36

TIE ROD pos.74 PIN pos.29 THRUSTER pos.75

BRAKE CLOSED ADJUSTING