RINGSPANN Brake HW 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 HW 165 FHM
E 09.774e

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: 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 HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
Version: 1
Drawn: BAHS
Checked: EISF
Pages: 24
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 HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
Version: 1
Drawn: BAHS
Checked: EISF
Pages: 24
Page: 4
1 Description of the caliper
1.1 Principle
The HW 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:
- With two breaking pin Ø46g6,
- 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.
Important!
Be careful: Check the support thickness is E+ 30mm

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
Version: 1
Drawn: BAHS
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Pages: 24
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 attaching holes are in conformity (center distances, sizes and numbers).

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
Version: 1
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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

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
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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. 2500Nm torque wrench, socket measuring 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 holding it with the lifting ring 01 on its support 02 and insert the 2
breaking pin 03 provided. Keep it in position with the 6 axis of fixation 04 M33 class 10.9
(unprovided: They are part of the Axis Box + Washers + Nuts available in option).
4. Place the second half-caliper by holding it with the lifting ring 01.
5. Place the 12 coarse washers V5 type Z M33 then place and screw with attention, the 12 nuts
V6 M33 class 10.

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
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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.

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: 9
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. 2.3
and connecting 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 100mm²/s with a
possibility to extend this range from 10 thru. 400mm²/s in case of exceptional use.
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 HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
Version: 1
Drawn: BAHS
Checked: EISF
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Page: 10
The caliper must be connected to its source at a hydraulic pressure 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 0.75mm²
Standard length of the cable: 2m.
Fig. 2.4

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
Version: 1
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Page: 11
2.4 Initial start-up
2.4.1 Hydraulic circuit bleed
Tools: Spanner, 8mm across flats, 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. 2.5.
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 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. 2.5

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
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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. 2.6.
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. 2.6
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
Beforehand, verify the thickness of the disc
Use a set of laminated shims to verify that
total gap between the pads and the disc is
equal to the “X” gap on the identification
plate.
The gap must be equal both side (a=b)

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
Version: 1
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Page: 13
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 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 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 HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
Version: 1
Drawn: BAHS
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Page: 14
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 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 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 HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
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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 HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
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5.2 Manual release: deactivation
1. With the pressure cut off, remove the cover 21 with its 6 Allen screws V09 (5mm male key).
Fig. 5.3
2. For an easier handling, it is possible the remove the connector of indicator switches Fig. 5.4.
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. 5.11
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.
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.
V09
21
V03 in release position
V03 in standby
position
14

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
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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 8% 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.
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 Fig.5.1.
4. Unscrew and remove 2 screws V04 (5 mm Allen wrench) 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 wrench Fig.5.7 or a 19mm socket on flats the wear take up screw
06 until the gap between the pad and the disc reaches the required value.
(See test sheet brake or identification plate).

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
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Fig. 5.4
7. Reinstall locking 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
15
06

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
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Fig. 5.5
5.4 Replacement of worn brake pads
Tools: 30mm AF spanner - 19mm AF spanner - 5mm Allen wrench
Procedure: For each pad
1. Put the caliper into manual release position, see chapter 5.1 and switch off the pressure.
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 reatining plate 09 + 4 screws V08 + 4 washers V17] on the side where the pad
is to be removed.
6. Loosen 2 screws V07 pad holding
7. Fit a screw M10 V30 into the end of the pad 11 (recommended length: 60 mm).

Installation and operating instructions for
Brake HW 165 FHM spring activated –
hydraulically released
E 09.774e
Issue: 08.01.2021
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8. Remove pad 11 from its pad holder 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
chapter 5.3.
Fig. 5.6