RINGSPANN Brake HW 165 FHM Installation And Operating Instructions Manual Download

Page: 24 / 24

Installation and operating instructions for

Brake HW 165 FHM spring activated

–

hydraulically released

E 09.774e

Issue: 08.01.2021

Version: 1

Drawn: BAHS

Checked: EISF Pages: 24

Page: 24

Spare parts

Monitoring switches (Opening/wearing) Ref.: CONOUVREG-PIN-HW

Set of pads:



2 pads 11 " Dynamic " Ref: JG ST5 RINGSPANN 132

Hydraulic control parts comprising (Refer to assembly drawing):



1 Piston 12660-026



1 Rod seal JOITIG-090 105 Z



1 Piston seal JOIPIS-200 184 E



1 Static piston seal JOISTA-95.6-90-1



1 Cylinder 12660-005

In case of order, please specify:

Type, Nr. of the caliper and item Nr. of the part.

There is a type plate on the brake with a 16-digit article number. The exact design of the brake is
defined by this article number only.

Troubleshooting

NATURE

VERIFICATION

SOLUTION

Decrease in braking force

Check the pad gap

Proceed with pad gap
adjustment chapter 5.3

Check the condition of the pads
and the disc (wear or grease
particles).

Replace the pads and clean
the disc.

Check the pressure is zero

No more pressure

Abnormal overheating of
the disc during start-up.

Insufficient gap between the
pads and the disc in released
position.

Check that pressure is at 200
bars

Re-adjust the pads. chapter
5.3

Re-adjust pressure at 200
bars

The caliper releases and
closes slowly

Air may be in the circuit

Bleed according to chapter
2.4

Summary of Contents for Brake HW 165 FHM

Page 1: ...Schaberweg 30 38 Phone 49 6172 275 0 Fax 49 6172 275 275 www ringspann com info ringspann com 61348 Bad Homburg Germany Installation and operating instructions for Brake HW 165 FHM E 09 774e ...

Page 2: ...instructions should be kept in a safe place and should accompany the product if it is passed on to others either on its own or as part of a machine to make it accessible to the user Safety Notice Installation and operation of this product should only be carried out by skilled personnel Repairs may only be carried out by the manufacturer or accredited RINGSPANN agents If a malfunction is indicated ...

Page 3: ...Preparing the positioning area 2 2 Installing the disc 2 3 Installing the caliper 2 4 Initial start up 3 OPERATIONAL RUNNING 3 1 Caliper tightening 3 2 Caliper untightening 3 3 Caliper manual release 4 PERIODIC MAINTENANCE 5 MAINTENANCE 5 1 Manual release activation 5 2 Manual release deactivation 5 3 Adjustment of brake pad clearance pad wear take up 5 4 Replacement of worn brake pads 5 5 Opening...

Page 4: ... in the individual sections The Caliper is describe as manually readjusted This means that the pad wear must be compensated for by manual adjustment of the pad gap to avoid any loss of braking force The brakes have a manual release device mechanically holding the caliper open without any need for a hydraulic pressure This release is useful for installation and maintenance work when there is no hyd...

Page 5: ...is manual must be followed up to chapter 2 4 inclusive INITIAL START UP to ensure that the brake is operational When assembling operating and maintaining the brake it is to be ensured that the entire drive train is secured against being switched on unintentionally Moving parts can cause severe injury Rotating parts e g brake disc must be secured by the operator against unintentional touching Stron...

Page 6: ...ased E 09 774e Issue 08 01 2021 Version 1 Drawn BAHS Checked EISF Pages 24 Page 6 Fig 2 1 2 2 Installing the disc Make sure that the disc is accurately positioned and attach it to its hub Check that the disc is not buckled more than 0 3mm Check that the disc is 30mm thick Standard arrangement Disc ...

Page 7: ...asuring 50mm across flats caliper attachment 2 8mm AF spanner Flexible pipe inside Ø6mm Bleed 2 3 2 Brake handling Put the assembly in position on the disc raising it with two lifting rings Fig 2 1 Weight for 1 half caliper 215kg 2 3 3 Alignment procedure 1 Check the disc parallelism on its support 0 3mm max 2 Check the centering of the support with the disc 2mm 3 Place the first half caliper by h...

Page 8: ...Drawn BAHS Checked EISF Pages 24 Page 8 Fig 2 2 6 Tighten to the torque the 12 nuts V6 The tightening torque Cs which has to be applied on the two screw rows for each nut is Cs 1950Nm 5 with greased screws Important Check the tightening torque of the opposite nuts 7 Check after having tightened to torque that the whole part has not moved ...

Page 9: ...nnecting plug on bottom in a vertical plan 30 For more information please contact RINGSPANN 2 3 5 Hydraulic connection Important MAX PRESSURE 230bars For an ambient temperature range from 0 through 60 C recommended oil is ISO HM32 By instance RINGSPANN uses FUCHS RENOLIN EXTRA 32S Outside of the above temperature range the viscosity shall be between 12 and 100mm s with a possibility to extend this...

Page 10: ...ressure 230 bar max by threaded plug G 3 8 Fig 2 3 Do not use hemp mastic Teflon etc and use flexible hoses exclusively It is preferable to use liquid joints Clean the pipes and couplings while ensuring that they are perfectly clean soiling scale swarf etc Fig 2 3 2 3 6 Electrical connection Opening and wear contact Two poles fast action O F switch Mechanical contact output by cable 5 wire x 0 75m...

Page 11: ...he bleed screw 11271 17 to a 6mm ID flexible hose and put the end of the hose into a container Fig 2 5 2 Feed oil to the caliper from the power pack then from the hand pump 3 Loosen slightly the bleed screw 11271 17 4 When the oil pours out continuously and there are no more air bubbles at the end of the hose tighten the bleed screw 11271 17 5 Disconnect the flexible hose beware of any oil remaini...

Page 12: ...gs are screwed to the cover in holding position Manual release in place Manual release pending Fig 2 6 Refer to 5 2 for more information about the manual release mode Important The manual release must be deactivated to ensure a well running of the brake 2 4 3 Adjustments of pad gap Important Contact are factory set and do not need any adjustment If necesary follow the procedure 5 3 Fig 2 7 Beforeh...

Page 13: ...ning of the electric contacts Run the brake under no load with the disc turning 20 or so times to bed in the pads Information THE SYSTEM IS NOW OPERATIONNAL 3 Operational RUNNING 3 1 Caliper tightening The lack of hydraulic pressure allows the pads to be tightened on the disc The opening contact is not activated 3 2 Caliper untightening Apply a minimum pressure of 200bars to release the brake The ...

Page 14: ... refer to the power pack instructions Every five years Plan complete overhaul of the entire unit replace worn parts seals spring washers flexible hoses 5 Maintenance 5 1 Manual release activation 1 Supply the caliper with a pressure of 200bar and maintain the pressure until point 6 2 Remove the 2 retaining segments 14 by their 2 screws V03 on the cover 21 3 Remove the cover 21 via its 6 Allen scre...

Page 15: ...the 2 screws V03 into the unlock position to securely hold the retaining segments 7 Cut off the pressure 8 Remove the 2 screws V03 to put them on the cover 21 9 Replace the cover 21 and tighten the 6 screws V09 10 Re engage the connectors in the switches and lock with the flat screwdriver by a 1 4 of a turn clockwise Attention MOVEMENT IS STILL POSSIBLE AFTER CUTTING OFF THE PRESSURE Fig 5 2 04 V0...

Page 16: ...n it a 1 4 of a turn counter clockwise and then insert the screwdriver into the slot at the side to release the connector In ATEX execution it is not possible to remove the connector see Fig 5 11 3 Supply the caliper with a pressure of 200bar and maintain it throughout the operation Attention Retaining segments 14 can be fall Do not cutting off the pressure without removed these retaining segment ...

Page 17: ...force may occur Tools 19mm AF spanner 5mm Allen wrench Screwdriver Procedure This operation must be executed on both sides 2 half caliper 1 Apply a 200bar hydraulic pressure to the caliper and maintain the pressure throughout the entire procedure Attention DO NOT USE THE MANUAL RELEASE DEVICE 2 Remove the cover 21 by its 6 screws V09 Fig 5 2 3 Remove the 2 connectors of opening and wear contacts F...

Page 18: ...ng washer 15 on the flats of wear take up screw and lock it with its 2 screws V04 and 2 washers V14 8 Reinstall cover 21 and retighten 6 screws V09 9 Reengage connectors in the contacts and lock it using screwdriver turn it to 1 4 turn clockwise 10 Be careful to not inverted attribution of connectors on 2 contacts Attention Be careful to not inverted attribution of connectors on 2 contacts V04 V14...

Page 19: ...re 2 Cover being removed unscrew and remove 2 screws 6 V04 and 2 washers V14 Fig 5 4 see chapter 5 3 3 Remove the locking washer 15 to free the wear take up screw 06 Fig 5 5 see chapter 5 3 4 Screw or unscrew using a wrench or a 19mm socket on flats the wear take up screw 06 until the gap between the pad and the disc enables to put the new pad in position Fig 5 6 see chapter 5 3 5 Remove 1 reatini...

Page 20: ... 01 by pulling screw M10 9 Fit the new pad 11 in its housing If necessary use the screw M10 to helps 10 Replace the retaining plate 09 onto 01 with 4 screw V08 washer V17 Tightening torque Cs 470 N m 10 Loctite 243 Note Check that the 4 screws V08 located on the opposite side are correctly torqued to 470Nm 11 Remove the manual release chapter 5 2 and proceed with the adjustment of the pad gap chap...

Page 21: ...liper otherwise perform all the operations in chapter 5 3 Refer to the identification plate for the nominal clearance Tools 2 5mm Allen wrench 8mm AF spanner Fig 5 7 5 5 1 Adjustment of brake released switch This switch monitors the status of the brake closed or released It closes when the brake is released set under pressure Power the brake at 200bars Unscrew nut V11 8 mm on flats Check that the ...

Page 22: ...essure When the brake is close Check the contact state Position closed If this information is not obtained unscrew the screw HC V02 until change of state Power the brake at 200bars Check that state contact is Open Execute this operation till correct monitoring of the open closed status After an adjustment is finished do not forget to retighten nut V11 8mm on flats to the screw V02 Fig 5 8 ...

Page 23: ...sted otherwise proceed to adjustment Brake being open check that the connection pin 22 is in contact onto lever 42 Release pressure to close the brake Unscrew nut V11 8 mm on flats then adjust screw HC V02 2 5 mm Allen wrench to free it from the switch end adjust the screw skimming the lever Adjust the screw HC V02 until the switch triggers status worn pads When the pads will reach a 1 mm wear the...

Page 24: ...er and item Nr of the part There is a type plate on the brake with a 16 digit article number The exact design of the brake is defined by this article number only 7 Troubleshooting NATURE VERIFICATION SOLUTION Decrease in braking force Check the pad gap Proceed with pad gap adjustment chapter 5 3 Check the condition of the pads and the disc wear or grease particles Replace the pads and clean the di...

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