WE KNOW BRAKES

Our Disc brakes

Johnson designs and manufactures a range of disc brakes in our factories.  The disc brakes come in various configurations, either hydraulic, pneumatic, electric, or manual models depending on customer preference and the application.  The brake systems come in power applied and spring applied fail safe versions.  The two mounting styles available for most models are side or foot mounted.  Johnson also produces brakes with custom engineered mounting designs as required by the customer.  There are direct spring acting, free floating designs and lever brakes as well.  Our free floating brake designs will compensate for various amounts of axial run-out in power transmission equipment.  Johnson has a standard range of control systems for all of the styles of brakes, and custom engineered brake control systems are also available.

Johnson disc brakes are in service around the world on mining conveyors, oil field, nuclear, steel industry, crane hoists and other material handling or power transmission equipment.

Scroll down to see all the types of industrial brake systems we manufacture which include, hydraulic, pneumatic, electrical and manual versions.

  • DS (Direct Spring Acting) Hydraulic Disc Brakes

    01

    Model: DS1050D Opposing Piston, Floating Assembly

    Dual Actuators, US Navy Whip Hoist

    02

    Model: DS3040A, Direct Acting and Free Floating, Spring / Hydraulic Disc Brakes

    Base style “A”, US Navy Portal Crane Hoists

    03

    Model: DS3040B

    Base Style “B”, Mine Hoist Application

    04

    Model: DS2040C, Direct Acting and Free Floating, Spring / Hydraulic Disc Brakes

    Base Style “C”, Ship Loader Hoist Brake

    Direct Acting Spring Disc Brakes

    - Applications include:

    - Hoist and Conveyor systems

    DS Brake Features include:

    • Spring set, hydraulic pressure release
    • Self-contained removable actuators
    • Many spring stack options
    • Stroke / wear adjustment
    • Spring caging feature
    • Hydraulic pressure isolated from disc
    • Actuator manual release / retraction
    • Fixed assemblies with opposing actuators
    • Floating assemblies with low friction float bearings
    • Floating assemblies with single or opposing actuators
    • Narrow profile with actuators on one side
    • Single and multiple actuator assemblies
    • Optional bases for fixed and floating assemblies
    • Optional release and wear proximity – switches
    • Flow through actuators – better oil filtering

    Direct Acting Brake Caliper Selection:

    The brake size must be chosen to give required braking torque and to dissipate the energy during stopping without over heating the disc. Brake torque is often related to drive motor torque by an arbitrary service factor typically 75% -100% full load torque for crane travel and similar inertial loads which tend to be self stopping or 150% -200% for crane hoists and other overhauling loads. If a precise stop time or distance is specified, then the brake torque must be calculated.
    MODEL
    Swept Face “F”
    in(mm)
    MIN. DISC DIA. “D”
    in(mm)
    MIN. Dynamic TORQUE
    Lb.ft(Nm)
    APPLIED FORCE
    lb(n)
    DS1025-08
    8 (200) 30 (762) 27000 (36700) 59200 (263300)
    DS2025-08
    8 (200) 40 (1016) 79000 (107500) 119000 (529000)
    DS3025-08
    8 (200) 60 (1524) 192800 (261400) 178000 (792000)
    DS1040-09
    9 (229) 35 (889) 45500 (61600) 84000 (373000)
    DS2040-09
    9 (229) 50 (1270) 142600 (193400) 167000 (743000)
    DS3040-09
    9 (229) 70 (1778) 318900 (432400) 251000 (1117000)
    DS1050-10
    10 (254) 40 (1016) 64300 (87200) 103000 (458000)
    DS2050-10
    10 (254) 55 (1397) 192100 (260500) 205000 (912000)
    DS3070-10
    10 (254) 80 (2032) 449100 (608900) 308000 (1370000)
    DS1070-12
    12 (305) 50 (1270) 113200 (153400) 143000 (636000)
    DS2070-12
    12 (305) 70 (1778) 346700 (470100) 287000 (1277000)
    DS3070-12
    12 (305) 100 (2540) 788300 (1068800) 430000 (1913000)
  • Magnetic Disc Brakes

    03

    Type CU, DC Magnetic Disc Brakes

    (Nuclear Industry)

    01

    CX Series DC Magnet Disc Brakes

    02

    CX Series DC Magnet Disc Brake

    Spring Set DC Magnet Released Disc Brakes

    - Service Duty (Type CU) and Emergency Stop Duty (Type CX) DC Magnet Disc Brakes

    Dimensions:

    • Metric, foot mounted

    Construction:

    • Fabricated steel mechanism
    • All pins ground stainless steel
    • Friction linings, high temperature non asbestos

    Options:

    • Service brake self adjusting device
      (compensates for brake lining wear)
    • Limit switches to monitor release / set or wear
    • Special materials, tests and finishes as required;
    • High integrity requirements such as the nuclear industry

    Electrical:

    • Separate enclosed control units for DC or AC supplies
    • Economy circuits available
    • Shunt or series magnets available

    Applications:

    • Mechanical handling equipment, cranes, winches,conveyors and mills etc.
    • Emergency stop brakes often installed on flange of crane winding drum

    Engineering:

    • Design and selection assistance available
    BRAKE
    MODEL
    DISC
    DIA. “D” (1)
    APPLIED
    FORCE “AF”
    EFFECTIVE
    FACE “F”
    WEIGHT
    mm(in) kN(Lb) mm(in) kg(lb)
    CU01 250-400(9.8-15.7) 3.6(809) 50(2) 30(66)
    CU1 315-500(12.4-19.7) 6.1(1370) 60(2.36) 50(110)
    CU2 400-710(15.7-27.9) 16.4(3690) 86(3.4) 142(313)
    CU3 500-800(19.7-31.5) 37.9(8520) 120(4.7) 230(507)
    CU4 630-800(24.8-31.5) 54.0(12100) 120(4.7) 292(644)
    CX10 380-600(15-23.6) 25(5620) 60(2.36) 89(196)
    CX20 450-710(17.7-27.9) 50(11200) 75(2.95) 102(225)
    CX40 500-800(19.7-31.5) 100(22500) 90(3.5) 157(346)
    CX60 600-960(23.6-37.8) 150(33700) 114(4.5) 280(617)
    CX90 960-1500(37.8-59) 225(50600) 134(5.27) 440(970)
    CX135 - details on application

    Magnetic Actuator:

    Short stroke DC tractive type with encapsulated coil and screw-off release nut with optional switch. All fabricated steel construction.
    • Resin encapsulated coil with Class F insulation
    • Optional replaceable coil arrangement for CX range
    • 100% continuously rated up to +40°C ambient
    • Air gap dust and drip protected by neoprene gaiter
    • Terminal box IP55 enclosure

    Characteristics:

    All DC magnets tend to inherently slow response due to build up and decay of the magnetic field. The actual times are dependent on size and vary with excitation voltage, coil temperature and spring loading (torque) and also the magnet stroke which increases as brake linings wear.

    Coil Forcing:

    (Shunt Wound Voltage Operated)
    All CU & CX Range brakes are forced open by electric current creating a magnetic field. Brake release and set times are reduced by a separate brake control unit to apply increased power magnetic force during a short preset start period . Control units are enclosed ventilated drip proof IP22 for DC supplies or totally enclosed IP55 with rectifier for 1 or 3 phase AC supplies.
  • Thruster Disc Brakes

    01

    CL Series Thruster Disc Brake (Port Industry, Steel Industry)

    02

    MB Series Motor Mounted Thruster Disc Brake (Lumber Industry)

    04

    CL Series Thruster Disc Brake (Port Industry, Steel Industry)

    Spring Set 3 Phase Thruster Released Disc Brakes

    Dimensions:

    • All metric in-line and compact type

    Construction:

    • Fabricated steel mechanism
    • Major pivots non-ferrous bushed
    • All pins ground stainless steel
    • Friction linings high temperature non asbestos
    • Optional sintered metallic linings

    Thrusters:

    • Standard Eltma Elhy EB series IP56 enclosed

    Special Options -Self adjusting mechanism :

    • Mechanical release lever
    • Limit switches to monitor release/ set or wear
    • Electronic modulated torque by remote pedal

    Applications:

    • Mechanical handling equipment, cranes, winches, stacker reclaimers and conveyors etc.

    Engineering:

    • Design and selection assistance available
    BRAKE
    MODEL
    DISC
    DIA. “D” (1)
    THRUSTER
    MODEL
    APPLIED
    FORCE “AF”
    SWEPT
    FACE “F”
    WEIGHT
    mm (in) kN (Lb) mm (in) kg (lb)
    CL11 250-500
    (9.8-19.7)
    EB220 5250
    (1180)
    55 (2.2) 56 (123)
      EB300 7125
    (1600)
    CL10 315-630
    (12.4-24.8)
    EB20 4980
    (1120)
    80 (3.15) 95 (209)
    EB300 7910
    (1780)
    95 (209)
    EB50 12483
    (2806)
    99 (218)
    EB80 21386
    (4808)
    105 (232)
    CL20 400-710
    (15.7-27.9)
    EB50 14690
    (3300)
    120 (4.7) 157 (346)
      EB80 23519
    (5287)
    163 (359)
    EB150 38000
    (8546)
    163 (359)
    CL30 630-800
    (24.8-31.5)
    EB150 38990
    (8766)
    130 (5.1) 255 (562)
    EB250 62780
    (14110)
    268 (591)
    EB320 95160
    (21390)
    275 (606)
    CL25 450-1000
    (17.7-39.3)
    EB1250 38300
    (8620)
    120 (4.7) 230 (507)
    EB2000 62300
    (14015)
    275 (606)

    Thruster data:

    • Standard EB Series
    • Fluid; transformer oil BS148 typical Shell diala ‘B’
    • Approximate operating times: brake release 0.1 seconds
    • Brake set 0.25 -0.5 seconds depending on size and brake spring load.
    • Optional features
    • High temperature viton seals.
    • Internal preset hydraulic delay valve(s)
    • Dust protecting hood
    • Internal return c-spring
    • Converter unit to operate from DC supply 220-440V
    • Explosion proof design EExd Group I and II

    Alternative Thrusters:

    • Johnson/Eldro/Elhy/Elco to din 15430.
    • Johnson DC Custom
    • Thrusters Also type KT/TKF can be supplied.
    • Flame proof available
  • Hydraulic Disc Brakes

    28hhh

    28HHH Hydraulic Disc Brakes

    Small Conveyor System for a gold mine

    58HHH

    58HHH High Duty Cycle Hydraulic Disc Brakes

    Log Handling Crane, Lumber Industry

    01

    74HHH High Duty Cycle, Spring Applied / Hydraulic Disc Brake

    Ship Loader Boom Hoist, Coal Industry

    02

    3836HX Hydraulic Applied Disc Brake

    Winch Hoist Cable Tensioner, Electrical Industry

    03

    DS1040-08 Direct Acting and Free Floating, Spring / Hydraulic Disc Brakes

    Mounted on a Pinion Drive for a Mine Hoist

    04

    7600 Series Spring Applied / Hydraulic Release Disc Brake

    SMARF Facility NASA, Emergency Rocket Hoist Brakes, Tandem Brake Discs

    LEVER ACTUATED DISC BRAKE CALIPERS:

    - Spring Set / Hydraulic Released Disc Brakes

    - Hydraulic set / Spring Released Disc Brakes

    Dynamic and Static Application
    Disc Brakes for:

    • Industrial
    • Ski Lifts
    • Offshore / Onshore Oil Industry
    • Marine
    • Mining
    • Logging

    Features:

    • MECHANISM – free-floating when set and self-centering when released
    • ACTUATION – spring set / hydraulic released, hydraulic set / spring released – spring compensated
    • MOUNTING – foot-mount or side-mount, actuators either handing
    • CONSTRUCTION – steel and ductile iron, or aluminum shoes, stainless steel pins standard
    • CONFIGURATION – single or double actuator,offset to either side of brake disc
    • LININGS – non-asbestos compositions to suit application requirements
    • DISCS – solid or ventilated, carbon or stainless steel, cast iron or non-ferrous
    • OPTIONS – special alloys, coatings, controls and custom mountings
    • APPLICATIONS -hoists / winches, conveyors, drives, processing machines
    • ENGINEERING -application and selection assistance available
    Brake Model Data – 800 to 4000X Series Caliper Disc Brakes

    CALIPER
    SERIES
    DISC
    THICK.
    MIN.
    DIA. “D”
    MAX.
    DIA. “D”
    SWEPT
    FACE “F”
    APPLIED FORCE
    “AF”
    TORQUE DYNAMIC
    MIN. DISC DIA.
    TORQUE STATIC
    MIN. DISC DIA.
    TORQUE DYNAMIC
    60″/1524mm DIA.
    TORQUE STATIC
    60″/1524mm DIA.
    WEIGHT
    in
    (mm)
    in
    (mm)
    in
    (mm)
    in
    (mm)
    lb
    (N)
    lb.ft
    (Nm)
    lb.ft
    (Nm)
    lb.ft
    (Nm)
    lb.ft
    (Nm)
    lb
    (kg)
    800
    1000
    0.75
    (19)
    15
    (380)
    75
    (1905)
    2.56
    (65)
    8530
    (38000)
    2210
    (3000)
    1270
    (1720)
    10208
    (13860)
    5868
    (7960)
    73
    (33)
    1800
    2000
    1.25
    (32)
    25
    (635)
    85
    (2159)
    3.38
    (87)
    19200
    (85400)
    8650
    (11700)
    4612
    (6200)
    22650
    (30700)
    12080
    (16400)
    130
    (59)
    1800X
    2000X
    1.25
    (32)
    25
    (635)
    85
    (2159)
    3.38
    (87)
    29400
    (131100)
    13250
    (18000)
    10600
    (14370)
    34680
    (47020)
    27750
    (37620)
    130
    (59)
    2800
    3000
    1.75
    (44)
    30
    (760)
    90
    (2290)
    5.00
    (127)
    26650
    (119000)
    13900
    (18800)
    8000
    (10800)
    30500
    (41500)
    17600
    (23860)
    230
    (105)
    2800X
    3000X
    1.0
    (25)
    30
    (760)
    90
    (2290)
    5.00
    (127)
    28800
    (128000)
    15000
    (20300)
    12000
    (16200)
    33000
    (44700)
    26400
    (35760)
    230
    (105)
    3800
    4000
    2.0
    (50)
    35
    (890)
    95
    (2413)
    6.13
    (156)
    53300
    (237000)
    32000
    (43500)
    18500
    (25100)
    61800
    (81000)
    34500
    (46800)
    427
    (194)
    3800X
    4000X
    1.0
    (25)
    35
    (890)
    95
    (2413)
    6.13
    (156)
    57600
    (256000)
    34600
    (46900)
    27700
    (37500)
    64600
    (87500)
    51700
    (70000)
    427
    (194)
    Brake Model Data – 4800 to 7600 Series Caliper Disc Brakes

    CALIPER
    SERIES
    DISC
    THICK.
    MIN.
    DIA. “D”
    MAX.
    DIA. “D”
    SWEPT
    FACE “F”
    APPLIED FORCE
    “AF”
    TORQUE DYNAMIC
    MIN. DISC DIA.
    TORQUE STATIC
    MIN. DISC DIA.
    TORQUE DYNAMIC
    100″/2540mm DIA.
    TORQUE STATIC
    100″/2540mm DIA.
    WEIGHT
    in
    (mm)
    in
    (mm)
    in
    (mm)
    in
    (mm)
    lb
    (N)
    lb.ft
    (Nm)
    lb.ft
    (Nm)
    lb.ft
    (Nm)
    lb.ft
    (Nm)
    lb
    (kg)
    4800
    5000
    1.0
    (25)
    30
    (762)
    100
    (2540)
    6.00
    (152)
    39100
    (174000)
    19600
    (265000)
    15600
    (21200)
    75700
    (103900)
    61300
    (83100)
    332
    (151)
    5800
    6000
    1.0
    (25)
    40
    (1016)
    100
    (2540)
    7.13
    (181)
    78300
    (348300)
    53600
    (72700)
    42900
    (58200)
    151500
    (205400)
    121200
    (164300)
    764
    (347)
    T5800 1.0
    (25)
    40
    (1016)
    100
    (2540)
    7.13
    (181)
    157000
    (698400)
    107500
    (145800)
    86000
    (116300)
    303800
    (410800)
    243000
    (329500)
    1395
    (634)
    7200
    7400
    1.25
    (32)
    60
    (1524)
    100
    (2540)
    8.5
    (216)
    117600
    (523100)
    126200
    (171100)
    101000
    (136800)
    224200
    (303900)
    179300
    (243100)
    1680
    (764)
    7600 1.25
    (32)
    60
    (1524)
    100
    (2540)
    8.50
    (216)
    235200
    (1046200)
    252300
    (342100)
    202000
    (273700)
    448300
    (607800)
    358700
    (486300)
    2580
    (1173)
  • Air Operated Disc Brakes

    01

    58HBA Pneumatic (Air) Disc Brake

    1750 HP Drives on Mining Shaft

    02

    816FA Pneumatic Disc Brake

    Mounted on a Log Loading Machine for Forest Industry

    03

    816A Pneumatic Disc Brake

    Air Applied / Spring Released

    78HBA Series Spring Applied / Pneumatic Release

    Dual Mode, Service and Parking Brake, mounted on a mobile Oil Rig

    Lever Actuated Disc Brake Calipers:

    - Spring Set / Air Pressure Released Disc Brakes

    - Air set / Spring Released Disc Brakes

    Dynamic and Static Application Disc Brakes for:

    • INDUSTRIAL
    • OFFSHORE / ONSHORE OIL INDUSTRY
    • MARINE
    • MINING
    • LOGGING

    Features:

    • MECHANISM – free-floating when set and self-centering when released
    • ACTUATION – spring set / air released, air set / spring released – spring compensated
    • MOUNTING – foot-mount or side-mount, actuators either handing
    • CONSTRUCTION – steel and ductile iron, or aluminum shoes, stainless steel pins standard
    • CONFIGURATION – single or double actuator, offset to either side of brake disc
    • LININGS – non-asbestos compositions to suit application requirements
    • DISCS – solid or ventilated, carbon or stainless steel, cast iron or non-ferrous
    • OPTIONS – special alloys, coatings, controls and custom mountings
    • APPLICATIONS -hoists / winches, conveyors, drives, processing machines
    • ENGINEERING -application and selection assistance available
    Pneumatic / Air Brake Model Data – 800 to T5800 Series Caliper Disc Brakes

    CALIPER
    SERIES
    DISC
    THICK.
    MIN.
    DIA. “D”
    MAX.
    DIA. “D”
    SWEPT
    FACE “F”
    MAX. APPLIED
    FORCE “AF”
    TORQUE DYNAMIC
    MIN. DISC DIA.
    TORQUE DYNAMIC
    MAX. DISC DIA.
    MAX. WEIGHT
    in
    (mm)
    in
    (mm)
    in
    (mm)
    in
    (mm)
    lb
    (N)
    lb.ft
    (Nm)
    lb.ft
    (Nm)
    lb
    (kg)
    800
    1000
    0.75
    (19)
    15
    (380)
    75
    (1905)
    2.56
    (65)
    6400
    (28500)
    1670
    (2260)
    9670
    (13100)
    47
    (21)
    1800
    2000
    1.25
    (32)
    25
    (635)
    85
    (2160)
    3.38
    (87)
    19600
    (87200)
    5770
    (7820)
    21800
    (29500)
    106
    (48)
    1800X
    2000X
    1.25
    (32)
    25
    (635)
    85
    (2160)
    3.38
    (87)
    29400
    (131100)
    5770
    (7820)
    21800
    (29500)
    106
    (48)
    2800
    3000
    1.75
    (44)
    30
    (760)
    90
    (2286)
    5.00
    (127)
    19200
    (85400)
    10000
    (13600)
    34000
    (46100)
    225
    (102)
    2800X
    3000X
    1.0
    (25)
    30
    (760)
    90
    (2286)
    5.00
    (127)
    28800
    (128000)
    15000
    (20300)
    51000
    (69200)
    225
    (102)
    3800
    4000
    2.0
    (50)
    35
    (890)
    95
    (2413)
    6.13
    (156)
    38400
    (171000)
    23200
    (31200)
    71200
    (96500)
    494
    (225)
    3800X
    4000X
    1.0
    (25)
    35
    (890)
    95
    (2413)
    6.13
    (156)
    57600
    (256000)
    34800
    (46800)
    107000
    (145000)
    494
    (225)
    4800
    5000
    1.0
    (25)
    30
    (762)
    90
    (2286)
    6.00
    (152)
    39100
    (174000)
    19600
    (26500)
    68500
    (92900)
    327
    (149)
    5800
    6000
    1.0
    (25)
    40
    (1016)
    100
    (2540)
    7.13
    (181)
    78300
    (348000)
    53600
    (72700)
    151000
    (205000)
    754
    (343)
    T5800 1.0
    (25)
    40
    (1016)
    100
    (2540)
    7.13
    (181)
    157000
    (698400)
    108000
    (145000)
    303000
    (411000)
    1375
    (625)
  • TL Series Grinding Mill High Torque Caliper Disc Brakes

    01

    Three TL800 Series Caliper Brakes

    Leaving the Main Manufacturing Facility on Transport. Used with SAG, AG, and BALL mills

    02

    Two model 4-TL250 Series Toggle Lever Caliper Disc Brakes

    Used with SAG, AG, and BALL mills

    03

    Caliper levers incorporate a unique toggle mechanism to compensate for spring force resulting in constant braking torque

    04

    4-TL250 HIGH TORQUE Toggle Lever disc brakes

    Perspective Image of the Massive 4-TL250 Brake Calipers, Application for Mining SAG Mill

    TL SERIES TOGGLE LEVER CALIPER BRAKES

    • TL SERIES TOGGLE LEVER CALIPER BRAKES are the largest known spring applied, hydraulic released caliper brakes in the world. Features include a stackable design allowing 1 to 4 calipers to be mounted in a common frame and spring force compensation by toggle mechanism resulting in constant braking torque. The TL series brake is particularly well-suited to accommodate very high braking torque requirements in the harshest environments.
    • TL series brakes are ideally suited for use with equipment such as SAG mills and rock crushers.
    • TL series brakes are well suited for use with conveyors requiring high torque braking.

    Design Features:

    • Caliper shoes are attached with stainless steel shoe pins. These pins Incorporate countersunk lubricating holes, tapped pin-pulling holes, and a pin retention groove.
    • Caliper levers incorporate a unique toggle mechanism to compensate for spring force. This ensures constant braking torque.
    • The system is powered by a hydraulic power unit incorporating a manifold fitted with two 010 valves (shown in blue) to accommodate brake set, creeping and inching modes.
    MODEL APPLIED FORCE
    lb (kN)
    Disc DIA.
    in (mm)
    DYNAMIC TORQUE
    Lb.ft (kNm)
    TL075 75000(334) 80 (2032) 112,500 (152)
    TL150 150000(668) 144 (3658) 421,800 (571)
    TL250 250000(1112) 588 (14935) 3,000,000 (4,085)
    TL375 375000(1668) 600 (15240) 3,689,000 (5,000)
    TL550 550000(2446) 600 (15240) 5,410,000 (7,335)
    TL800 800000(3558) 600 (15240) 7,853,000 (10647)

    Brake Selection::

    Note: All of the above TL brake calipers can be made in stacks of up to four individual brake units. Depending on the stackup the TL brake calipers can provide a torque of up to four times what is shown in this table.

    The brake size must be chosen to give required braking torque and to dissipate the energy during stopping without over heating the disc. Brake torque is often related to drive motor torque by an arbitrary service factor typically 75% -100% full load torque for crane travel and similar inertial loads which tend to be self stopping or 150% -200% for crane hoists and other overhauling loads. If a precise stop time or distance is specified, then the brake torque must be calculated.

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