RINGSPANN DR 085 FHM-100, Installation And Operating Instructions Manual

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 Rail Clamp DR 085 088 FHM E 09 797e ...

Page 2: ...ting 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 indic...

Page 3: ...it 2 4 Electrical connection 2 5 Bleeding the hydraulic circuit 2 6 Deactivating the manual release 2 7 Adjusting the pad clearance 2 8 Rail clamp balancing procedure 2 9 General operational check 3 OPERATIONAL FUNCTIONING 3 1 Tightening the rail clamp 3 2 Loosening the rail clamp 3 3 Manual release of the rail clamp 3 4 Hand pump operation oft he rail clamp 4 PERIODIC MAINTENANCE 4 1 Maintenance ...

Page 4: ...rake at www ringspann com and the drawings in the individual sections The rail clamps can be optionally delivered with an integrated hydraulic power unit type HCO2R or type HTP3 see Fig 1 2 The rail clamps are fitted with a manual release device that mechanically maintains the rail clamp in released position without having to use the power source This release is useful for installation and mainten...

Page 5: ...rating 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 b...

Page 6: ...e 2 2 3 Please also note the brake catalogue data at www RINGSPANN de and the drawings in the individual paragraph 2 2 Installing the rail clamp 2 2 1 Tooling list 1 Torque wrench 2000 Nm socket 46 mm A F Bracket attachment 2 Flat 8mm wrench Hose int Ø6mm Bleed ref 11271 17 2 2 2 Rail clamp handling Place the assembly by lifting with the two lifting rings or handling sling if the rail clamp is fit...

Page 7: ...ds with guide rollers 1 Check screws V1 and V2 Make sure they do not extend into the inside of the roller support Do the same for V3 and remove it if necessary Fig 2 3 2 Place assembly in the greased slots of the clamp lever ensuring that the roller screw heads are facing upwards Fig 2 4 3 Screw the 2 screws V1 and V2 until they come into contact with the bottom of the lever lamages Fig 2 5 V1 V3 ...

Page 8: ...bly must not fall without the presence of a rail 2 2 4 Alignment procedure Make sure that the support surface is clean and dry Make sure that there is sufficient space around the rail clamp Check that the attachment holes are compliant spacers dimensions and number Important If these conditions are not complied with the caliper cannot be assembled or will not operate to standard Contact RINGSPANN ...

Page 9: ...n and operating instructions for Rail Clamp DR 085 088 FHM spring activated hydraulically released E 09 797e Issue 14 09 2022 Version 2 Drawn BAHS Checked OHLM Pages 39 Page 9 Rail clamp DR 085 FHM 050 100 Fig 2 6 ...

Page 10: ...nd operating instructions for Rail Clamp DR 085 088 FHM spring activated hydraulically released E 09 797e Issue 14 09 2022 Version 2 Drawn BAHS Checked OHLM Pages 39 Page 10 Rail clamp DR 085 FHM 200 300 400 Fig 2 7 ...

Page 11: ...ng activated hydraulically released E 09 797e Issue 14 09 2022 Version 2 Drawn BAHS Checked OHLM Pages 39 Page 11 Rail clamp DR 088 FHM 500 Fig 2 8 Image description Pos 6 Manual release Pos 8 Brake off monitoring switch Pos 30 Eyebolts Pos 41 Storage position for release nut ...

Page 12: ...Installation and operating instructions for Rail Clamp DR 085 088 FHM spring activated hydraulically released E 09 797e Issue 14 09 2022 Version 2 Drawn BAHS Checked OHLM Pages 39 Page 12 Railtolerance ...

Page 13: ...tical tolerance TV mm A55 25 1 3 A65 20 4 A75 20 2 5 A100 15 5 A120 15 5 60E1 15 2 5 Other types Please consult RINGSPANN Tab 2 1 1 Observe the dimensions B with 2 5 indicated see Tab 2 1 2 Center the rail clamp transversely in relation to the rail 3 Guide pads rollers or pads alone optional carefully on either side of the rail when engaging the rail clamp on the rail With Rollers Fig 2 9 Without ...

Page 14: ...crews M30 class 10 9 Rail clamp DR 088 FHM 500 6 screws M30 class 10 9 The tightening torque Cs which has to be applied on the screws M30 class 10 9 rows for each nut is Cs 1515Nm 5 µ 0 10 with greased screws Important Check the tightening torque After tightening with the torque make sure that the entire assembly has not shifted The swiveling brake pad holders and the swiveling rail caliper levers...

Page 15: ...essure min DR 085 FHM 100 110bar Opening pressure min DR 085 FHM 200 105bar Opening pressure min DR 085 FHM 300 105bar Opening pressure min DR 085 FHM 400 115bar Opening pressure min DR 088 FHM 500 110bar MAX PRESSURE 130bar For an ambient temperature range from 0 through 60 C recommended oil is ISO HM32 As examble RINGSPANN uses FUCHS RENOLIN EXTRA 32S Outside of the above mentioned temperature r...

Page 16: ...th HCO2R built in hydraulic power unit Refer to the hydraulic power unit HCO2R manual for more information Important Power units are normally supplied with oil and are ready for operation However check that the level is correct and that transport has not caused any leakage Transport protection remove before usage Remove the plug screwed onto the filler hole and screw the breather plug supplied ble...

Page 17: ...nd operating instructions for Rail Clamp DR 085 088 FHM spring activated hydraulically released E 09 797e Issue 14 09 2022 Version 2 Drawn BAHS Checked OHLM Pages 39 Page 17 Fig 2 13 Fig 2 14 Breather plug Plug 7 F1 ...

Page 18: ...ith HTP3 built in hydraulic power unit Refer to the hydraulic power unit HTP3 manual for more information Important Power units are normally supplied with oil and are ready for operation However check that the level is correct and that transport has not caused any leakage Transport protection remove before usage Remove the plug screwed onto the filler hole and screw the breather plug supplied Fig ...

Page 19: ... F1 see Fig 2 13 2 For the electrical connection of the unit 7 refer to the hydraulic power unit s manual HCO2R HTP3 power unit Only for Rail clamp with power unit type 3 Remove the unit s cover optional by unscrews the 4 screws F2 see Fig 2 15 4 For the electrical connection of the unit 7 see Fig 2 12 refer to the hydraulic power unit s manual HTP3 2 4 1 Electrical connection switches Opening and...

Page 20: ...88 FHM operates properly the cylinder must be bled On the bleed screw 11271 17 install a hose 6 mm whose end is immersed into a container 1 Pressurize the rail clamp 2 Hold the hose in place slightly loosen the bleed screw until there is a release of oil and air 3 Wait until there are no more air bubbles in the oil during the release 4 Tighten the bleed screw without forcing 5 Check the oil level ...

Page 21: ...ion 2 Drawn BAHS Checked OHLM Pages 39 Page 21 2 6 Deactivating the manual release Important Manual release must be deactivated for the rail clamp to operate correctly To make the rail clamp operational the nut 4 must imperatively be removed and stored on the tube 5 with its pin Fig 2 18 4 Manual release activatd 5 Manual release deactivated ...

Page 22: ...st the end part 9 Procedure 1 Supply the rail clamp with its minimum release pressure and maintain the pressure during the entire operation Important Do not use manual release to do this the hydraulic pressure must be maintained 2 Loosen the locknut 8 46 mm A F 3 Tighten the screw 2 using the hex wrench 21 mm A F until the pads are moderately tightened on the rail 4 To obtain the pad gap loosen th...

Page 23: ...must be deactivated for the rail clamp to operate correctly 2 8 Rail clamp balancing procedure After setting the pad gap the two levers must be oriented vertically in relation to the rail For this the two screws 17 which act as a stop for the two levers 16 will balance the rail clamp Fig 2 20 Fig 2 21 9 r e l e a s e a c t i v a t d 10 rel ea se ac tiv at d 2 r e l e a s e a c t i v a t d 8 r e l ...

Page 24: ...18 on the two balancing screws 17 16 mm A F 2 Adjust the two screws 17 to distribute the pad gap in relation to the rail 3 Adjust the two screws 17 so that they exceed by an equal distance see Fig 2 23 in order to get the thruster in a horizontal position 4 After setting apply Loctite on the thread of screws 17 and block the two locknuts 18 then place a varnish mark on the latter Fig 2 22 Fig 2 23...

Page 25: ...dicated on the identification plate PG X mm Check for correct balancing of the rail clamp see chapter 2 8 Check the correct function of the sensor Fig 2 24 Information THE SYSTEM IS NOW OPERATIONAL 3 OPERATIONAL FUNCTIONING 3 1 Tightening the rail clamp The absence of hydraulic pressure tightens the pads on the rail 3 2 Loosening the rail clamp Supply the rail clamp with hydraulic pressure to open...

Page 26: ...aulic power unit for more information 4 PERIODIC MAINTENANCE Attention The rail clamps DR 085 088 FHM with diamond pads are intented for purely static uses Any dynamic braking requires a replacement of the pads The rail should be free of lubricants and oils so that the coefficient of friction does not drop If this instruction is not observed braking force may be lost The air gap must be adjusted a...

Page 27: ...year Maintenance level 3 Every 10 years Every 7 years Hard working environment Rail clamp subject tob be in contact with seawater in sea sprays 4 1 Maintenance level 1 It is necessary to check the following points 1 Ensure that the rail brake is movable on these 2 pins If necessary clean and lubricate the following parts Remove the pads See chapter 5 4 Swing completely the rail clamp on one side c...

Page 28: ...ulically released E 09 797e Issue 14 09 2022 Version 2 Drawn BAHS Checked OHLM Pages 39 Page 28 Contact faces between levers and support Axle lubricaters of the levers optional Fig 4 2 Areas of contact with pads Fig 4 3 Swing completely the rail clamp on other side repeat operation of greasing ...

Page 29: ...of the rollers supporting in the flat area of the rail Fig 4 4 3 Pad gap and pads condition 14 diamond tipped not dull 4 Proceed to pad gap adjustment as per chapter 2 7 5 Check the condition of the actuator s 15 dust seal 4 2 Maintenance level 2 Perform level 1 maintenance Check gap pads see chapter 2 7 Replacing oil of hydraulic pack 4 3 Maintenance level 3 Perform level 1 and level 2 maintenanc...

Page 30: ...ire operation 2 Tighten the nut 4 onto the screw 11 see Fig 5 1 The rail brake is fully released when the tip of the screw is flush with the nut see Fig 5 2 Fig 5 1 Fig 5 2 Information It is not necessary to use a wrench the nut can be placed manually If however a wrench is used the tightening torque is limited to 1100Nm 5 2 Manual release Deactivation 1 Supply the rail clamp with a minimum pressu...

Page 31: ...VEMENTS ARE STILL POSSIBLE EVEN AFTER THE OPENING PRESSURE HAS BEEN SWITCHED OFF 5 3 Adjusting the pad gap See section 2 7 5 4 Replacing the pads Attention The rail clamps DR 085 088 FHM with diamond tipped pads are intented for purely static uses Dynamic braking requires a replacement of the pads Procedure 1 Activate the manual release see chapter 5 1 2 Untighten the two counternuts 18 on both ad...

Page 32: ...FHM spring activated hydraulically released E 09 797e Issue 14 09 2022 Version 2 Drawn BAHS Checked OHLM Pages 39 Page 32 Fig 5 3 4 Unlock the counternut 8 see Fig 5 4 5 Undo the screw 2 see Fig 5 4 by means of the hexagon end in order to maximize the pad gap Fig 5 4 ...

Page 33: ...leased E 09 797e Issue 14 09 2022 Version 2 Drawn BAHS Checked OHLM Pages 39 Page 33 6 To change one pad swing the rail clamp to the opposite side Fig 5 5 7 Remove from each roller set the two screws 19 the two tube 23 the two helical springs 20 as well as spacers 24 in case of rails A55 or A120 Fig 5 6 ...

Page 34: ...operating instructions for Rail Clamp DR 085 088 FHM spring activated hydraulically released E 09 797e Issue 14 09 2022 Version 2 Drawn BAHS Checked OHLM Pages 39 Page 34 Fig 5 7 8 Remove the pads as shown below Fig 5 8 ...

Page 35: ...acers 24 in case of rails A55 or A120 back in place 11 Proceed to pad gap adjustment as per chapter 2 7 12 Proceed to rail clamp balancing as per chapter 2 8 13 Control the correct positioning of the guide roller onto the rail sides 5 5 Setting the braking force Information The braking force is factory set and checked by using a test bench Force value may be adjusted giving more or less strain to ...

Page 36: ...e displacement of the piston The switch must be pressed in when the rail clamp is released If this switch needs to be adjusted Please contact RINGSPANN Fig 5 10 5 7 Adjustment switch Information The switch is factory set and does not need any adjustment The switch 14 is used to indicate excessive pad gap This detection guarantees a compliant braking force value It is triggered by the stop plate 15...

Page 37: ...tment range 0 to 15 sec This limiter which can be adjusted using a knob is used to slow down the closingtime of the rail clamp Procedure Supply the brake with a minimum pressure of 120 bar to open it Tighten or loosen the limiter knob to the desired closing time Cut off the pressure and check the closing time Adjust the knob if necessary Attention NEVER CLOSE THE LIMITER FULLY There are two differ...

Page 38: ...l A55 JGS DR 085 RINGSPANN A55 GL Rail A65 75 100 JGS DR 085 RINGSPANN A100 GL Rail A120 JGS DR 085 RINGSPANN A120 GL Set of diamond pads Rail A55 JGS DR 085 RINGSPANN A55 DIAM Rail A65 75 100 JGS DR 085 RINGSPANN A100 DIAM Rail A120 JGS DR 085 RINGSPANN A120 DIAM In case of order please specify Type Nr of the rail clamp and item Nr of the part There is a type plate on the brake with a 16 digit ar...

Page 39: ...Supply the pressure The rail clamp does not remain released Tightness of the hydraulic unit hose fittings cylinder piston Replace the defective element The opening time is long Check the pump rate and the circuit bleed Change the pump Bleed the circuit see chapter 2 5 Locking force is not provided Check the pad gap Adjust the pad gap see chapter 2 7 Check the condition of the pads Replace the pads...