RINGSPANN Brake HS 165 FHM User manual

Schaberweg 30-38
Phone [phone]
Fax [phone]
www.ringspann.com
[email protected]
61348 Bad Homburg
Germany
Installation and operating instructions for
Brake HS 165 FHM
E 09.778e

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: 2
Important
Please read these instructions carefully before installing and operating the product. Your particular
attention is drawn to the notes on safety.
These installation and operating instructions are valid on condition that the product meets the
selection criteria for its proper use. Selection and design of the product is not the subject of these
installation and operating instructions.
Disregarding or misinterpreting these installation and operating instructions invalidates any product
liability or guarantee by RINGSPANN; the same applies if the product is taken apart or changed.
These installation and operating 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, the product or the machine into which it is installed, should be
stopped immediately and either RINGSPANN or an accredited RINGSPANN agent should be
informed.
•Switch off the power supply before commencing work on electrical components.
•Rotating machine elements must be protected by the purchaser to prevent accidental contact.
•Supplies abroad are subject to the safety laws prevailing in those countries.
This is a translation of the German original version!
In case of inconsistencies between the German and English version of this
installation and operating instruction, the German version shall prevail.

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: 3
Contents
1DESCRIPTION OF THE CALIPER
1.1 Principle
1.2 Delivery condition
2INSTALLATION
2.1 Preparing the positioning area
2.2 Installing the disc
2.3 Installing the caliper
2.4 Initial start-up
3OPERATIONAL RUNNING
3.1 Caliper tightening
3.2 Caliper untightening
3.3 Caliper manual release
4PERIODIC MAINTENANCE
5MAINTENANCE
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 and wear contacts (mechanicals) adjustment
6SPARE PARTS
7TROUBLESHOOTING

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: 4
1 Description of the caliper
1.1 Principle
The HS 165 FHM calipers are hydraulic fail-safe calipers; the braking force is applied by spring
washers and hydraulic pressure is necessary to hold the brake released. The stack of spring
washers is adjusted in factory. This adjustment, combined with adjustment of the pads gap,
determines the braking torque value.
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.
As well as these instructions, please also consider the catalogue data for the 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 installation and maintenance work when
there is no hydraulic pressure available.
1.2 Delivery condition
The caliper is delivered in the following conditions:
- In manual release position, i.e. manually locked in open position,
- With pads installed,
- Adjusted with the nominal lining gap,
- The holding force adjusted according to customer’s specifications,
- Mechanical contacts adjusted,
- With bleed screw in correct position.
- As well as these instructions, please also consider the catalogue data for the brake at
www.RINGSPANN.de and the drawings in the individual sections.

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).

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: 6
Brake HS 165 FHM-420 L-H (Thrustor mounted left shown)
Fig. 2.1

Installation and operating instructions for
Brake HS 165 FHM spring activated –
hydraulically released
E 09.778e
Issue: 27.05.2021
Version: 3
Drawn: BAHS
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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.

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: 8
Important!
If these conditions are not complied with, the caliper cannot be
assembled or will not operate to standard. Contact RINGSPANN
for more details.
First clean the disc tracks with the degreasing agent:
- Quick drying degreaser (CRC / KF)
Important!
BE CAREFUL: The disc must be degreased and free of any deposits so
as not to decrease the friction coefficient.
2.3 Installing the caliper
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 position 257,5 +/-9 mm Fig. 2.2 use the
balancing screw (16mm on flats) and that the disc is parallel // 0,3 to the brake pad. Check
that the support balance in relation to the disc is less than 0,2mm. Check that the disc is fully
between the pads.
2. Brake HS 165 FHM-420 H check the disc position 8mm mini fixed pad side 2a; 18mm mini
from the other side 2b Fig. 2.3.

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: 9
A 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.

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: 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.

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: 11
3. Position the screws M30 class 8.8 for caliper to the basement connection.
The tightening torque (Cs) which has to be applied on the screws M30 class 8.8 rows for each
nut is: Cs = 1200Nm ±10% with greased screws.
Brake HS 165 FHM-420 R-V 8 screws M30 class 8.8
Brake HS 165 FHM-420 L(R)-H 6 screws M30 class 8.8
Important!
Check the tightening torque
4. Check, after having tightened to torque, that the whole part has not moved.
2.3.4 Orientation of the piston 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 temperature range from 0 through 60°C, recommended oil is ISO HM32. By
instance, RINGSPANN uses FUCHS RENOLIN EXTRA 32S.
Use a mineral oil with a viscosity range between 10 and 380mm²/s (optimal range between 12
and 100mm²/s) while allowing for the ambient temperature conditions
Important!
This oil must be clean
(maximum permitted level of pollution as per NAS 1638: 10µm).
Use only new fluid and never mix several types all brands of fluid.

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: 12
The caliper must be connected to its source at a hydraulic 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 0.75mm²
Standard length of the cable: 2m.
Fig. 2.6

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: 13
2.4 Initial start-up
2.4.1 Hydraulic circuit bleed
Tools: AF spanner, 6mm ID flexible hose.
Important!
Take the necessary precautions to avoid the oil being sprayed onto the
disc.
1. Connect the bleed 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 the hose)
Important!
This file must be clean
(maximum permitted level of pollution as per NAS 1638: 10µm).
Use only new fluid and never mix several types all brands of fluid.
Fig. 2.7

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: 14
2.4.2 Deactivate the manual release
The principle is to position the stopping rings in the piston groove once the pressure is applied.
They are fixed in position by 2 screws Fig. 2.8.
When the caliper is in operating mode, the rings are screwed 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
First check the thickness of the disc. Use a set of
laminated shims to verify that total gap between
the pads and the disc is corresponds to the “PG=
Pad Gap on the type plate.
The pad gap must be equal both side PG = (a+b)

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: 15
2.4.4 Control of the general running
Important!
Be Careful: The disc must be degreased and free from any deposits so as
not to decrease the friction coefficient.
Check the 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 contact is activated.
3.3 Caliper manual release
Manual release keeps the caliper open without hydraulic pressure.
Refer to chapter 5.1 and chapter 5.2.

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: 16
4 PERIODIC MAINTENANCE
Every two months, check:
- As a general rule, inspect the entire system for correct operation
- Check that there is not any leakage
- Also, check the brake pad gap see chapter 5.3.
Attention!
When the remaining lining thickness reaches 3mm, proceed to pad
exchange as per chapter 5.4. If this rule is not observed, a loss of
breaking force may occur.
Every two years, replace:
- Oil in the power pack (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 screws V09.
4. For an easier handling, it is possible the remove the connector of indicator switches
Fig.5.1. Unlock the connector by insert the screwdriver behind the connector and turn 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
Fig. 5.1
Slot
Screwdriver

Installation and operating instructions for
Brake HS 165 FHM spring activated –
hydraulically released
E 09.778e
Issue: 27.05.2021
Version: 3
Drawn: BAHS
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Page: 17
5. Put the 2 retaining segments 14 in the piston groove 04 Fig. 5.2.
6. Screw 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
V09
21
V03 in release
position
V03 in standby
position
14

Installation and operating instructions for
Brake HS 165 FHM spring activated –
hydraulically released
E 09.778e
Issue: 27.05.2021
Version: 3
Drawn: BAHS
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Page: 18
5.2 Manual release: deactivation
1. With the pressure cut off, remove the cover 21 with its 6 Allen screws V09.
Fig. 5.3
2. For an easier handling, it is possible the remove the connector of indicator switches Fig. 5.1.
Unlock the connector by insert the screwdriver behind the connector and turn 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. 5.1.
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 them in the standby position on the
cover 21, one on the other, using the 2 screws V03. See Fig.5.3.
5. Reinstall cover 21 and retighten 6 screws V09 Fig.5.2 chapter 5.1.
6. Reengage connectors in the switches and lock it using screwdriver turn it to 1/4 turn
clockwise.
V09
21
V03 in release position
V03 in standby
position
14

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: 19
5.3 Adjustment of brake pad clearance, pad wear take up
Danger!
Frequently check the total gap between pads and the disc.
(a 1mm increase to this gap corresponds to 9% loss of torque).
Refer to the RINGSPANN Datasheet for the nominal clearance.
Attention!
When the remaining lining thickness reaches 3mm, proceed to pad
exchange as per chapter 5.4. If this rule is not observed, a loss of
breaking force may occur.
Only 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 washers V14 Fig.5.4.
5. Remove the locking washer 15 to free the wear take up screw 06 Fig.5.4.
6. Screw or unscrew using a flat spanner Fig.5.5 or socket, to adjust the screw 06 until the gap
between the pad and the disc reaches the required value see type plate brake “PG” Pad
Gap. The Pad Gap is to check on both side and if the version R-V additional readjust with
the screw M16 readjust.

Installation and operating instructions for
Brake HS 165 FHM spring activated –
hydraulically released
E 09.778e
Issue: 27.05.2021
Version: 3
Drawn: BAHS
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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