Ortlinghaus TPI 1240 EN Operation manual

Ortlinghaus-Werke GmbH
Postfach 50 14 40
42907 Wermelskirchen
Kenkhauser Str. 125
42929 Wermelskirchen
Germany
Tel. [phone]
Fax [phone]
Email [email protected]
Website www.ortlinghaus.com
Version: 11.2011
0128-...-..-...100 / -...150 / -...200 /
-...250 series
Keep for future use
Translation of
original operating manual
Technical product information
TPI 1240 EN
Hydraulically released brake

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
2 11.2011
Table of contents
1. Notes regarding use of the operating manual 3
1.1. Who are the operating instructions aimed at? 3
1.2. What can be found in the operating instructions? 4
1.3. Use of these instructions 4
1.4. Notes on the symbols used in the text 4
1.4.1. Personal injury 4
1.4.2. Product / machinery / plant system damage 5
1.5. Personnel qualifications and training 5
1.6. The Ortlinghaus numbering system 5
2. Technical data / intended purpose 6
2.1. Intended Use 6
2.2. Appropriate use 6
2.3. Improper use 7
2.4. Functional description 8
2.4.1. Brakes 8
2.4.2. Release brake 8
2.5. Variants 9
2.5.1. Type key for variants 9
2.5.2. Rotatable brake (0128-...-..-....50) 10
2.5.3. Brake with inner lubrication (0128-..2/3-..-......)10
2.5.4. Brake with backup actuation (0128-. 5 to 8
.-..-......) 11
3. Transport, packaging 12
3.1. Hazard notes on transport, packaging 12
3.2. Condition on delivery 12
3.3. Transport 13
4. Installation and assembly instructions 14
4.1. Installation conditions 14
4.2. Fundamental installation variants 14
4.3. Installation 15
5. Commissioning 18
5.1. Hazard notes on commissioning 18
5.2. Function test 20
5.2.1. Test run of brake 20
6. Operation 21
6.1. Hazard notes for operation 21
6.2. Inspection while the machine is in operation 23
6.3. Recommended oils 23
7. Troubleshooting 24
8. Maintenance 25
8.1. Hazard notes on maintenance 25
8.2. Status check 26
8.3. Air measurement 26
8.4. Maintenance intervals 27
8.4.1. Oil change 27
8.4.2. Changing the seals (elastomer) 27
8.4.3. Changing the springs 27
8.5. Care 28
9. Servicing and repair, modification 29
9.1. Hazard notes on servicing and repairs 29
9.2. Disassembly 30
9.2.1. Removal of the actuator unit 30
9.2.2. Assembly of the actuator unit 30
9.2.3. Removal/assembly housing, plates and hub 30
9.3. Size and tightening torque of the screws 31
9.4. Hazard notes on modifi
cation 32
10. Spare parts 33
10.1. Parts list 34
10.2. Cutaway 35
11. Storage, de-commissioning 36
11.1. Hazard notes on storage, de-commissioning 36
11.2. Storage 37
11.3. De-commissioning 37
12. Disposal 38
12.1. Hazard notes on disposal 38
13. Annex 39
13.1. Declaration of Conformity 39
Table 1: List of amendments
Amendment Edition date
BA rev. no.1240.007 11.2011

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
11.2011 3
1. Notes regarding use of the operating manual
These operating instructions, hereafter referred to as OI, are part of the
product and contain important information on how to safely and correctly
operate our product in machinery and plant systems as well as maintain,
repair, convert, store, decommission and dispose of the product.
In addition to these OI please also refer to the technical descriptions and
information provided in the product drawing as well as the application-
specific design data, e.g. design calculations. If these should not be
contained within the scope of documentation then please request these
immediately from Ortlinghaus.
Without the product drawing these OI are incomplete.
Keep these OI in a safe place, make them accessible to all users at all
times and pass them on to your customers! If necessary, you can down-
load our OI or TPI via the internet from the “Service” directory at www.
ortlinghaus.com. You are also free to make copies of this example. Always
keep the OI near to the machine or system in order to ensure direct acces-
sibility.
On delivery of the product, the attached OI represent the latest technical
development at the time of publication. Any supplements provided by us
should be added to the OI by you or future owners.
We reserve the right to make technical changes to these OI as part of tech-
nical further development. Please ensure that you have the most recent
version of the information.
This information can be requested by telephone (for telephone number see
front page) and obtained in text form or downloaded from the internet at
www.ortlinghaus.com under “Download”.
1.1. Who are the operating instructions aimed at?
These OI are aimed at qualified specialist personnel, especially:
➜assembly fitters of the machinery/plant system manufacturer;
➜industrial mechanics/fitters of the machinery operator;
➜other qualified and properly trained specialist personnel, responsible for
and thereby entrusted with project planning, assembly, commissioning,
operation, maintenance, decommissioning, storage and disposal of the
product.
Persons tasked with using the product must read the OI carefully before
conducting any work. If these prerequisites are not fulfilled, there is a risk
of the product being used incorrectly with severe damage to the product
and subsequent damage to other items as well as physical or fatal injury
and health hazards to the user or third parties. Reference is made in addi-
tion to paragraph 1.5 of the OI.

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
4 11.2011
1.3. Use of these instructions
➜Read through these OI completely before working with the product.
➜The instructions in the OI must be complied with.
➜Consider the product drawing as well as any design calculations.
➜These OI are part of the product and should be kept accessible for all
users.
➜If the product is passed on to a third party then pass these OI on as
well.
1.2. What can be found in the operating instructions?
These OI with the product drawing contain all the necessary information
related to the product named on the cover page for the proper utilisation
throughout the various stages of operation.
Note the residual dangers and safety information provided for the stages
of operation.
1.4. Notes on the symbols used in the text
Our products are produced in accordance with our knowledge of latest
engineering practice at the time of design and are operationally safe
and are subject to constant product enhancement. Nonetheless there is
a danger to personnel and property if the following instructions are not
complied with. For hazard-free installation, function and operation the most
important passages in the following pages are highlighted with symbols.
These symbols mean:
NOTE!
➜Pay special attention to this text.
1.4.1. Personal injury
WARNING!
• Hazard while performing the described activity or as a result of hazards
during machine operation.
➜Potentially severe head injury.
WARNING!
• Hazard while performing the described activity or as a result of
hazardous electrical voltage during machine operation.
➜Potentially severe head injury.
ATTENTION!
• Hazard while performing the described activity or as a result of hazards
during machine operation.
➜Potential physical injury or risk to health.

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
11.2011 5
1.5. Personnel qualifications and training
Work on our products may only be carried out by professionals (authorized
persons) who possess appropriate qualification or professional training
pertaining to the tasks to be carried out, and who acknowledge and under-
stand the content of these OI.
Professional personnel (authorized persons) must acknowledge and observe
the applicable safety standards.They must use appropriate safety equip-
ment. Furthermore, professional personnel (authorized persons) must be
able to detect possible hazards that could arise in the course of carrying out
their work.
The level of responsibility, expertise, qualification and monitoring of profes-
sional personnel (authorized persons) is the responsibility of the operator.
If personnel do not possess the requisite qualifications and knowledge then
they must be trained and instructed accordingly.
1.6. The Ortlinghaus numbering system
Example: 0 111 - 222 - 33 - 444 555
0 = Code digit for products
Code digits for series
Code digits for design characteristics
Design size
Serial no.
Further design characteristics
WARNING!
• Hazard while performing the described activity or as a result of non-
observance of explosion protection during machine operation.
➜Potentially severe head injury.
1.4.2. Product / machinery / plant system damage
CAUTION!
• Hazard while performing the described activity or as a result of mechan-
ical hazards during machine operation.
➜Potential material damage.
Non-observance of safety notices results in a loss of any claim for
compensation.

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
6 11.2011
2. Technical data / intended purpose
2.1. Intended Use
Hydraulically released spring-applied multi-plate brakes are characterised
by a low spatial requirement, low moment of inertia of the rotating parts
and very reliable switching cycles. They are largely maintenance-free.
Cylinders and pistons are corrosion-protected as standard.
Due to the automatic, spring-loaded braking process, they are to be used
as safety brakes - especially in lifting gear - in case of failure of the pres-
sure oil. In such cases, they enable "emergency release" of the piston by
means of pull-back screws.
2.2. Appropriate use
Our products are intended exclusively for use in accordance with the tech-
nical data stipulated per the design shown on the product drawing
(0 . . . - . . . - . . - . . . . . .)
The order-specific design which was performed by Ortlinghaus may only
be used for the intended application.
The technical data specified by the customer is a component of the
intended use. Insofar as a specification sheet which has been approved by
both sides is present, it is also essential. The customer is responsible for
the correctness of its data.
Our product is intended to be integrated into a system or machine or to be
assembled with other components to form a system or machine. For this
reason, the product should only be brought into circulation once the system
or machine into which the product is to be integrated has completely
fulfilled the applicable EU machinery directive.
Intended use also includes complying with the directions given in this oper-
ating manual, and paying attention to any residual dangers. Remaining
hazards are described in the hazard warning sections of the following
chapters. During the various applications (operating stages) in which
damage to the machine or hazards to personnel can arise, the operator
must ensure that appropriate safety measures are applied. Observe the
applicable national regulations pertaining to accident prevention and envi-
ronmental protection.

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
11.2011 7
2.3. Improper use
Any other use or use going beyond the use described in the chapter
“Intended purpose” and “Proper use” is considered to be improper use.
Ortlinghaus is not liable for damages arising from this.
Especially, but not exclusively, improper use of our product includes:
➜use as a bearing in the sense of supporting and guiding moving
machine parts with respect to the stationary part
➜overloading by excessive speed, excessive torque during gear changes
or braking or by excessive operating pressure (also temporarily by pres-
sure peaks)
➜overloading by excessively long sliding actions on the friction surfaces
(e.g. by overloading)
➜operation with insufficient cooling or with an operating pressure that is
too low
➜loading by an excessively high switching frequency e.g. in activation
mode
➜operation with an incorrect fluid medium with wet-running system
NOTE!
➜If the safety instructions and residual hazards are not observed then this
is also considered improper use.
WARNING!
• Unauthorised conversions and modifications on the product are not
permitted for reasons of safety.
➜Modifications to or on our products are prohibited. Where this is not
observed, any claims made against Ortlinghaus-Werke GmbH will be
deemed void.

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
8 11.2011
2.4. Functional description
The operating pressure required to disengage the brake is:
Size 80, 86, 90 80 +5 bar
Size 94, 96, 98 90 +5 bar
CAUTION!
➜Never operate the brake at a higher pressure, as otherwise there is a
risk of shearing screws.
The oil pressure for backup actuation is adjustable and may be 80 bar or
90 bar (size 94, 96, 98). Simultaneous oil pressure on connections 1 and 3
(see "2.5.4. Brake with backup actuation") must be avoided because of the
risk of a malfunction.
NOTE!
➜Install a throttle directly in front of the main valve to prevent short term
pressure peaks over 85 bar (size 80, 86, 90) or 95 bar (size 94, 96, 98).
2.4.1. Brakes
The brake is applied in the depressurised state.
With the axial force of the springs (1) the piston (2) pushes the plate pack
(4) against the flywheel (6), thus establishing a frictional connection.
2.4.2. Release brake
Pressure oil is fed via the cylinder (5) into the cylinder chamber of the
brake. The piston (2) is pushed against the spring pressure into its end
position; the brake is released.
4
2
1
6
5LubricationPressure oil (switch oil)
Oil return
Incremental sender
(optional)
Fig. 1: Function

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
11.2011 9
2.5. Variants
Variants available in this series:
2.5.1. Type key for variants
0128 - . . . - . . - .. ....
0 12 Friction surfaces
1 16 Friction surfaces
2 20 Friction surfaces
3 24 Friction surfaces
4 Anomalous number of friction surfaces
5 12 Friction surfaces, with speed sender
6 16 Friction surfaces, with speed sender
7 20 Friction surfaces, with speed sender
8 24 Friction surfaces, with speed sender
9 Anomalous number of friction surfaces, with speed sender
0 Normal version 36/36 springs
1 Normal version 30/30 springs
2 Normal version 24/24 springs
3 Normal version 18/18 springs
4
5 Normal version 32/32 springs, with additional piston for inch mode
6 Normal version 30/30 springs, with additional piston for inch mode
7 Normal version 24/24 springs, with additional piston for inch mode
8 Normal version 18/18 springs, with additional piston for inch mode
9 Anomalous spring array
0 Hub with recess for clamping device
1 Hub with key slot
2 Hub with recess for clamping device and inner lubrication
3 Hub with key slot and inner lubrication
4 Hub with splines
5 Hub predrilled
6 Hub with tangential wedge connection

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
10 11.2011
2.5.2. Rotatable brake (0128-...-..-....50)
24
1
Fig. 2: Function of the "rotatable" brake
2.5.3. Brake with inner lubrication (0128-..2/3-..-......)
2
1
3
Fig. 3: Function of the brake with inner lubrication
Lubrication
oil return
3Pressure oil (switch oil)
Lubrication
3Pressure oil (switch oil)
Pressure-free return
3Pressure oil (switch oil)
Lubrication

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
11.2011 11
2.5.4. Brake with backup actuation (0128-. 5 to 8 .-..-......)
4
5
89
2
7
1
13
3
2
Fig. 4: function of the brake with backup actuation
Brake with backup actuation
The piston 5is impinged with pressure oil via the connection 1(piston
chamber 8) and the braking torque is raised.
Releasing of the brake with backup actuation
The pressure oil connection 1(piston chamber 8) must be depressurised.
The pressure oil on the connection 3 (piston chamber 9) moves the piston
against the force of the pressure springs (4. This releases the plates 7.
Lubrication Pressure (brake servo) Pressure (release brake)

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
12 11.2011
3. Transport, packaging
The delivery is to be checked for transport damage and any apparent
deficiencies upon receipt. In the event of damage, inform Ortlinghaus
accordingly. Only products that are in technically flawless condition are to
be installed or commissioned.
NOTE!
➜Read the OI before commencing further work.
3.1. Hazard notes on transport, packaging
3.2. Condition on delivery
The scope of the deliverables is defined on the shipping documents.
Check whether the delivery is complete and correct. The packaging is in
accordance with the order.
Hazard Cause Effects Remedial actions, safety
information
Loose parts can shift during
transportation Moving part comes into contact
with static part
Injury, crushing,
abrading,
catching,
rollover
Secure loose parts against moving and do
not reach into assemblies during transporta-
tion
Falling objects Note the position of the packaging (note
TOP direction!), wear safety footwear
Transportation, handling,
moving Falling objects Use of secure lifting gear with sufficient load capacity
Open the packaging, lift with
adequately rated lifting acces-
sories
Gravity (stored
energy) Note the position of the packaging (note TOP direction!), use appropriately dimen-
sioned lifting accessories, wear safety
footwear
Greased or oiled parts could
become dislodged during
transportation
Slippery surfaces Secure parts, set down on stable and non-
slip base, wear safety footwear and gloves
When removing from pack-
aging, transportation without
packaging
Sharp edges,
pointed parts Secure parts for transportation, check for damage and sharp edges before removing
parts, wear safety gloves/footwear
If stored on its circumferen-
tial edge No stability/struc- tural safety Secure parts against rolling or tipping during transportation
Straining,
posture Fatigue, musculo- skeletal strain Note weight information, use transportation devices, perform work in upright position
Fluids seeping out during
transportation Fluid Poisoning, fire hazard,
allergisation
Take protective measures when dealing with
leakages
Sliding Remove fluid
Mechanical hazards:
Material/substance hazards:
Ergonomic hazards:
The brake is delivered with pre-bolted housing and inserted plates. The
hub is enclosed separately. In versions with "inner lubrication" or with
backup actuation, the plates are enclosed separately.

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
11.2011 13
3.3. Transport
Only use lifting gear with sufficient load capacity for transportation.
Observe the following instructions for transportation.
Refer to the product drawing for the location of the transport threads and
the precise weight. Tighten the transport bolts as prescribed.
WARNING!
• Load the transport threads uniformly and only in a vertical direction.
➜Pay attention to the load bearing capacity of the lifting accessories.
If the existing screws are used as an aid then steel cables must not be
used for transportation as the threads on the screws could be damaged.
If there is transportation damage then this must be reported immediately.
It is not permitted to commission or operate the equipment without having
carried out a proper inspection.
Table 2: Transport threads and approximate weights
Fig. 5: Transport aids
CAUTION!
➜Avoid hard impacts during transport.
12
Built
dimensions
Thread 1+2 Approx.
weight
80 M 10 + M 10 200 kg
86
M 10 + M 10 300 kg
90
M 12 + M 16x1,5 470 kg
Built
dimensions
Thread 1+2 Approx.
weight
94 M 16 + M 16 950 kg
96
M 16x1,5 + M 16x1,5 1500 kg
98
M 30 + M 30 2900 kg

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
14 11.2011
4. Installation and assembly instructions
The supplier or operator is responsible for the installation of the product
described. Comply with the applicable regulations and requirements as
well as these OI. Check the operational readiness before installation. Use
appropriate lifting gear for handling whilst the installation work is being
carried out.
Follow the instructions for installation.
WARNING!
• Observe the hazard notes in chapter “Maintenance” and “Repair, modifi-
cation”!
➜Observe the applicable environmental regulations.
It is necessary to carry out a check for compliance with the geometric
tolerances after installation. It may be necessary to correct radial and axial
misalignments by adjusting the shaft(s) and other machine parts. Note that
there may be thermal expansion, shaft bending and soft mountings/bear-
ings. Check tightening torques of all bolts and correct if necessary.
WARNING!
• Please obtain the values required for the check from the product drawing
or contact Ortlinghaus-Werke.
➜Personal injury or machinery damage are potential effects of non-obser-
vance and are caused, for example, by components breaking or heat
generated by contact with moving parts.
➜If the geometrical installation conditions are not observed, our product
must not be installed.
4.1. Installation conditions
• Moving parts must be safeguarded by the customer against unintended
contact, without significantly compromising the ventilation.
• The installation area, with its connection faces, and the product must be
free of grease, dust or other contamination.
• It must be ensured that the friction components are not contaminated by
operating fluids such as oil or grease (other than the specified operating
fluids) during installation or subsequent operation. Exceptions are the
lubricants approved for operation. If clamping rings are used for shaft
connection then no oil must emerge from these after installation.
• There must be no damage present at the joints of the machine.
• Observe the fitting and position tolerances and the data on the product
drawing. Otherwise small cracks or gaps from angular or radial misalign-
ment of the shaft/machine are created.
• Ensure that there is adequate space available in the installation area.
4.2. Fundamental installation variants
It is not possible to deal with special installation variants - custom-made
for machine construction - here. However, we would like to show how our
products can be integrated with some examples.

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
11.2011 15
4.3. Installation
Fig. 6: Installing the brake
Fig. 7: Installation of the "rotatable" brake
Flange
Cylinder
Ring
Actuator unit
Hub
Drive shaft
Brake housing
Machine body
Locking bolts
Housing bolt
Bolt
actuator unit
Drive bolt
Flange
Cylinder
Ring
Bolt actuator unit
Actuator unit
Drive bolt
Locking bolts
Housing bolt
Hub
Drive shaft
Brake
housing
Machine
body

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
16 11.2011
Fig. 8: Installation of the brake with inner lubrication
Fig. 9: Installation of the brake with backup actuation
Flange
Cylinder
Ring
Actuator unit
Hub
Drive shaft
Brake housing
Machine body
Drive bolt
Housing bolt
Bolt
actuator unit
Locking bolts
Hub
Drive shaft
Brake
housing
Machine
body
Locking bolts
Housing bolt
Actuator unit
Flange
Cylinder
Ring
Bolt actuator unit
Drive bolt

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
11.2011 17
• Unscrew brake housing from the actuator unit and bolt and pin onto the
machine body.
Table 3: Tightening torques of the bolt housing/machine
Size 80 86 90 94 96 98 Unit
Thread M 12 M 16 M 20 M 27 M 30 M 36 -
Tightening torques 130 310 620 1550 2100 3700 Nm
➜DIN 912-10.9
• Fix the hub to the shaft. Ensure that the axial position is correct! When
fixing with a tensioning set, observe the manufacturer's installation
instructions and remove any plastic plugs!
• Install plates in accordance with the condition on delivery, alternately,
i.e. outer then inner plate and so on. The first and last plate is always an
outer plate.
• Bolt the actuator unit to the brake housing. Observe the tightening
torques of the housing bolts. Secure housing bolts with LOCTITE 262.
CAUTION!
• Actuator unit and brake housing are labelled.
➜Labelling must be flush!
Table 4: Tightening torques of the housing bolts (actuator unit/
housing)
Size 80 86 90 94 96 98 Unit
Thread M 8 M 10 M 12 M 16 M 20 M 20 -
Tightening torques 37 75 130 310 620 620 Nm
➜DIN 912-10.9
• Remove locking bolts .
CAUTION!
• The brake springs are active and press the piston of the actuator unit
against the plates.
➜The locking bolts should be carefully stored for any later removal!
• Instead of the locking bolts, insert the enclosed separately delivered
sealing plug DIN 906.
• For versions with internal oil, the bell housing should be installed. The
aerator / aspirator should be mounted in the topmost position. The
holding straps are to be attached!
Table 5: Locking bolts
Size 80 86 90 94 96 98
Thread M 8x25 M 10x40 M 12x45 M 12x50 M 16x70 M 20x80
➜DIN 912-10.9

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
18 11.2011
5. Commissioning
Prior to commissioning, the connection on the drive side and output side
must be checked for correct attachment and a functional test carried out.
Furthermore, a functional test must also be carried out after maintenance
or repair with a stationary system or machine.
With hydraulic systems, the existing contamination must be filtered out
before first use. The piston chamber should be bled via the connection
provided (if available) prior to commissioning.
Check for unusual noises, vibrations and oscillations. Monitor the oper-
ating temperature. If unusual heating should be detected in the first hours
of operation, the commissioning is to be halted.
5.1. Hazard notes on commissioning
Hazard Cause Effects Remedial actions, safety
information
Mechanical hazards:
Dynamic operation and
function: Torque too high -->
adjoining parts are heavily
loaded --> Risk of breakages
Torque too low -->
Accelerated / braked parts do
not reach speed or standstill
in good time
Acceleration/
braking (kinetic
energy)
Running over,
sliding away,
crushing
Exclude personnel from remaining in the
hazardous area of the equipment, test in
integrated condition, slow increase of load,
adjust pressure system, check and observe
residual pressure, deactivate mechanical
emergency air venting before commis-
sioning
Pressure system: Reduction
of product-related function
caused by back-pressure in
pressure line
Acceleration/
braking (kinetic
energy)
Running over,
sliding away,
crushing
Monitor pressure in the pressure supply
lines
Assembly: Influencing of
the function through incor-
rect installation position and
locking of inner drive/shaft to
outer drive.
Encroachment of
a moving part on
a static part
Running over,
sliding away,
crushing
Check installation position in accordance
with drawing, secure inner drive in axial
direction, check for freedom of movement
and correct positioning of parts before
commissioning
Assembly/over-pressure:
Nullification of the function
due to breakage of the screws
or locking rings due to high
pressure or faulty assembly
resulting from incorrect
number of screws, property
class, tightening torque, for
example
Falling objects/
high pressure Running over, sliding away,
crushing
Observe data in the OI/drawing, screw tight-
ening torque, check number and property
class, secure screws against loosening,
observe and monitor max. permissible
pressure
Stability/structural
safety
Switching on the pressure
supply: Loosening of faulty
pressure connections, separa-
tion of fastening screws
Leakage of
medium under
pressure
Risk of injury
from media under
pressure piercing
body parts,
scalding
Before commissioning, check pressure tight-
ness at low pressure, set pressure limiting
valve such that max. permissible value
cannot be exceeded (provide sufficient
safety margin!)
During commissioning Hazards from
commissioning Personal injury Ensure no persons are allowed to enter or remain in the danger zone of the equipment

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
11.2011 19
Hazard Cause Effects Remedial actions, safety
information
Thermal hazards:
Noise hazards:
Oscillation hazards:
Dynamic switching processes,
high speeds, excessive oil
level in product (wet running)
Objects or mate-
rials with high/low
temperature
Burning Operator instructions, clearance grille or
temperature sensor, observe oil fill quantity/
coolant oil flow, monitor speeds
Contact with parts under the
influence of speed, incorrect
installation position (radial/
axial) and locking of inner
drive/shaft to outer drive,
operating pressure/air pres-
sure too low or missing, incor-
rectly aligned parts
Moving parts Discomfort, strain Check attachment of product and inner fric-
tional puller, observe installation position in
accordance with drawing, check clearance,
observe minimum required actuation/air
pressure and monitor, if necessary monitor
piston end position
Dynamic switching processes
and load Friction surfaces Discomfort, strain None
Radial misalignment between
inner drive and outer drive Out-of-balance rotating parts Discomfort, strain Check the fastening of the clutch/brake and the inner drive, check installation position in
accordance with drawing, check for freedom
of movement of the clutch/brake
High rotational speeds Misalignment of
moving parts Discomfort, strain Check the fastening of the clutch/brake and the inner drive, check installation position in
accordance with drawing, check for freedom
of movement of the clutch/brake, comply
with speed limit and monitor if necessary
Assembly/pressure system:
Influencing of the effective-
ness of the function due to
incorrect axial and radial
mounting position and locking
of inner frictional puller/shaft
to the outer frictional puller,
insufficient pressure at the
piston
Machine move-
ment Running over, sliding away,
crushing
Check installation position in accordance
with drawing, secure inner drive in axial
direction, check for freedom of move-
ment and correct positioning of parts prior
to commissioning, observe and monitor
minimum necessary operating pressure/air
pressure and monitor piston end position if
necessary (e.g. by means of microswitch,
incorporation into machine control)
Reaching into moving or
rotating parts Moving parts Crushing, catching Covering openings to product
Rotating parts
Material/substance hazards:
Ergonomic hazards: Straining,
posture Fatigue, musculo- skeletal strain Note weight information, use transportation devices, perform work in upright position
Leaks:
Operation with unsealed
product (wet running) during
assembly/removal of oil pres-
sure connections
Aerosol, fluid,
vapour Respiratory prob- lems, allergisation Seal exterior of product, apply liquid sealant to all joints and connecting parts, check for
leaks prior to commissioning and during
operation at suitable intervals

Ortlinghaus-Werke GmbH Operating instructions TPI 1240 EN
20 11.2011
5.2. Function test
WARNING!
• The product must be screwed together using all provided securing
screws on the machine body.
➜Stick to the specifications from Chapter “Size and tightening torque of
the screws”.
• Charge the brake with the required air pressure while it is stationary.
• Check the piston function.
• After the pressure has been released, the piston must press against the
discs by spring force, actuating the brake.
• In the event of wet running, check the amount of cooling oil and, if neces-
sary top up or adjust the flow rate.
Hazard Cause Effects Remedial actions, safety
information
Hazards in connection with the operational environment of the machine
Under static and dynamic
load: Influence of function
and torque by way of corro-
sion and ageing processes in
organic substances
Impurities, dust,
moisture Running over, crushing At suitable intervals: Check load bearing parts for corrosion,
perform oil change, check function, if neces-
sary house product and protect against
corrosion, replace corroded or damaged
parts
5.2.1. Test run of brake
The brake must undergo a test run of at least 20 hours. Usually there is
then no more plate wear. When initially commissioning of the system the
basic contamination must be filtered out before releasing the brake for
the first time. When operating with Ortlinghaus hydraulic-components,
the discharge cock of the accumulator group should be opened and the
hydraulic system run for approx. 2 hrs in a depressurised state.