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Installation and operating instructions for

Brake HS 165 FHM spring activated

–

hydraulically released

E 09.778e

Issue: 27.05.2021

Version: 3

Drawn: BAHS

Checked: EISF Pages: 28

Page: 5

Life-threatening danger!

Disc must be absolutely degreased before all contact with the brakes
linings.

In case of lining pollution with grease, the nominal brake force is not
guaranteed.

Calipers are fail safe components.
All setting and repairs must be performed by skilled operators.

BE CAREFUL: The caliper is delivered in " manual release" position and
the holding force is adjusted in the factory.
Instructions in this 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.

Strongly pre-loaded pressure springs are installed in the springed
thrusters of the brake. The spring thruster may only be disassembled by
the factory.

2

Installation

2.1 Preparing the positioning area

Ensure that the positioning surface is clean and dry.
Make sure that there is sufficient space around the brake.
Check that the mounting holes are in conformity (center distances, sizes and numbers).

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Содержание Brake HS 165 FHM

Страница 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 HS 165 FHM E 09 778e ...

Страница 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 ...

Страница 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...

Страница 4: ... brake at www ringspann com and the drawings 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 installati...

Страница 5: ...his 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 Stro...

Страница 6: ...perating instructions for Brake HS 165 FHM spring activated hydraulically released E 09 778e Issue 27 05 2021 Version 3 Drawn BAHS Checked EISF Pages 28 Page 6 Brake HS 165 FHM 420 L H Thrustor mounted left shown Fig 2 1 ...

Страница 7: ...ages 28 Page 7 Brake HS 165 FHM 420 R V Fig 2 2 8 Brake off monitoring switch 9 Pad gap monitoring switch 19 Manual release and adjustment screw 30 Lifting eyes 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 ...

Страница 8: ...aliper 2 3 1 List of tools 1 1200Nm torque wrench socket measuring 46mm across flats for brake attachment 2 AF spanner Flexible pipe inside Ø6mm Bleed 2 3 2 Brake handling Put the assembly in position on the disc raising it with lifting eyes Fig 2 1 and Fig 2 2 Weight for one caliper HS 165 FHM ___ H 625kg HS 165 FHM ___ R V 528kg 2 3 3 Alignment procedure 1 Brake HS 165 FHM 420 R V Check the disc...

Страница 9: ... crowbar can be used in the area shown by the arrow 2a and 2b to slide the caliper from one side to the other Fig 2 3 Check that disc deflection in relation to the support does not exceed 0 3mm Check parallelism of the fixed pad 3 Fig 2 4 in relation to the disc using a set of laminated shims in compliance with the following spacing Transversal spacing 0 2mm maxi over pad width ...

Страница 10: ... spring activated hydraulically released E 09 778e Issue 27 05 2021 Version 3 Drawn BAHS Checked EISF Pages 28 Page 10 Fig 2 4 Longitudinal spacing 0 3mm max over pad length If necessary set the support using foil 4 located close to the attachment screws Fig 2 4 ...

Страница 11: ...iston heads If the caliper stands on a horizontal support the orientation of the piston heads is not important For other positions the piston heads must be oriented Bleed screw 11271 17 on top Fig 2 5 and connecting plug on bottom in a vertical plan 30 For more information please contact RINGSPANN 2 3 5 Hydraulic connection Important Opening pressure 230bar MAX PRESSURE 250bar For an ambient tempe...

Страница 12: ...draulic pressure 250bar max by threaded plug G 3 8 Fig 2 5 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 5 2 3 6 Electrical connection Opening and wear contact Bipolar switch Mechanical contact output by cable 5 wire x 0 75mm Standard...

Страница 13: ...d screw 11271 17 to a 6mm ID flexible hose and put the end of the hose into a container Fig 2 7 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 remaining in t...

Страница 14: ...rewed to the cover in holding position Manual release in place Manual release pending Fig 2 8 Refer to chapter 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 chapter 5 3 Fig 2 9 ...

Страница 15: ... well running 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 OPERATIONAL 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 opening pressure to open the brake The opening ...

Страница 16: ...k 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 opening pressure 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 screw...

Страница 17: ...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...

Страница 18: ...t 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 1 3 Supply the caliper with opening pressure and maintain it throughout the operation Attention Retaining segments 14 can be fall Do not cutting off the pressure without removed these retaining segment 4 Remove the 2 retaining segments 14 Fig 5 2 and install t...

Страница 19: ...nly original RINGSPANN brake pads may be used Tools AF spanner Allen wrench screwdriver Procedure 1 Apply opening 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 Fig 5 1 4 Unscrew and remove the 2 screws V04 and 2 ...

Страница 20: ...es 28 Page 20 Fig 5 4 7 Reposition the lock washer 15 each side and secure with screws V04 and washers V14 8 Replace the cover 21 with the 6 screws V09 and the connectors of switches 9 Be careful not to reverse the assignment of the connectors on the two switches Attention Be careful not to reverse the assignment of the connectors on the two switches V04 V14 15 06 ...

Страница 21: ...ing removed unscrew and remove the allen screws V04 and 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 4 see chapter 5 3 4 Screw or unscrew using a 19mm wrench or socket 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 5 see chapter 5 3 5 Screw a M10x40 min screw in the reta...

Страница 22: ...commended length 60 mm 9 Remove pad 11 from its pad holder 01 by pulling screw M10 10 Fit the new pad 11 in its housing If necessary use the screw M10 to helps 11 Loosen the screw M10 V30 12 Reinstall retaining plate 09 onto 01 with 4 screw V08 and washer V17 13 Loosen the screw M10 into the retaining plate 09 Tightening torque Cs 470Nm 10 Loctite 243 Note Check that the 4 screws V18 located on th...

Страница 23: ...back spring 5 Remove pad 11 from its pad holder 02 by pulling screw M10 6 Fit the new pad 11 in its housing If necessary use the screw M10 7 Loosen the screw M10 V30 8 Put back in place the screw V10 including its spring and tighten it up fully on the pad 9 Reinstall retaining plate 10 onto 02 with 4 screws V08 and Washer V17 10 Loosen the screw M10 into the stop plate 10 11 After the pads replace...

Страница 24: ...Installation and operating instructions for Brake HS 165 FHM spring activated hydraulically released E 09 778e Issue 27 05 2021 Version 3 Drawn BAHS Checked EISF Pages 28 Page 24 Fig 5 7 ...

Страница 25: ...dentification plate for the nominal clearance PG Pad Gap Tools Allen wrench 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 opening pressure Unscrew nut V11 AF spanner Check that the axle 22 is in contact onto lever 41 Adjust the screw V02 until the a...

Страница 26: ...778e Issue 27 05 2021 Version 3 Drawn BAHS Checked EISF Pages 28 Page 26 Power the brake with opening pressure 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 to the screw V02 Fig 5 8 ...

Страница 27: ...pening pressure Check that the pads clearance is correctly adjusted otherwise proceed to adjustment Brake being open check that the connection pin 22 is in contact onto lever 42 Cut off pressure to close the brake Unscrew nut V11 then adjust screw HC V02 to free it from the switch end adjust the screw skimming the lever Adjust the screw V02 until the switch triggers status worn pads When the pads ...

Страница 28: ... 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 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 ...

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