tp0750EN

Ortlinghaus-Werke GmbHPostfach 14 4042907 WermelskirchenKenkhauser Str. 12542929 WermelskirchenDeutschlandPhone +49 21 96 85-0Fax +49 21 96 8 55-4 44E-Mail [email protected] www.ortlinghaus.com

Contents Page

About this Technical Product Information (TPI) 2

The ORTLINGHAUS numbering system 2

About the product 3

Delivered state 4

Initial assembly and commissioning 5

Maintenance 9

Fault finding 13

Complete assembly - only for customer service 14

Spare parts 17

Edition: 11.2001

Technical product information No. 750 EN

pneumatically actuated clutch/brakecombined unitseries 0 420

Ortlinghaus-Werke GmbH TPI 750 EN

2

About this Technical Product Information (TPI)

Who is this TPI directed at?This TPI is directed at qualified personnel who– are entrusted with the assembly, commissioning and operation of the

product and who– have obtained the necessary qualifications by reading and

understanding the instructions by training or instructionIt is intended for– Fitters at the manufacturer of the machine / plant– Maintenance fitters at the machine users.

What will you find in the TPI?The TPI provides all the necessary information for the assembly andmaintenance of the product described on the title page

Notes on the symbols used in the textOn the pages which follow, important sections of text are highlighted withthe following symbols.

This symbol means:There is a risk of injury during the activity described or in operationalrunning!

This symbol means:There is a risk of material damage during the activity described or inoperational running!

This symbol indicates sections of text to which particular attention must bepaid.

The Ortlinghaus numbering system

Example: 0 - 111 - 222 - 33 - 444 - 555

0 = Code for productsCode number for the model rageCode number for design featuresSizeSequencial numberOther design features

Pass this TPI on to your customers ! You can either order further copies ofthis TPI from us or you are free to make copies, for use by yourcustomers.


3

About the product

Purpose and mode of functioning of the clutch/brakecombined unitSingle plate clutch/brake combined units are well suited for high torqueseven where the thermal loading is high, e.g. in the accelerating anddeceleration of heavy gyrating masses with high engaging/disengagingfrequencies. They are used above all in presses and guillotine shears.

Do not use clutch/brake combined units in rooms with high air humidity orin which the air contains oil. Otherwise there is the risk that the plates willslip and the action of the brake will be significantly reduced.

Braking: Pressure springs 4 press against piston 3 in the cylinder. Thiscauses brake plate 2 to be pressed against the stop plate, thus bringingabout the braking action.

Engaging the clutch: Compressed air is applied to the piston via airintake 5. This causes brake plate 2 to be released andclutch plate 1 to engage.

The normal operating pressure is 5.5 bar, the maximum permissiblepressure 6 bar. Never operate the clutch/brake combined unit with ahigher pressure since this can lead to the risk of the cylinder breaking.

• Always use dustfree, dry compressed air (a maintenance unit is required).• Set the oiler of your maintenance unit so that it delivers from 1 to 3

drops of oil per m³ air.• It is essential that the friction linings are kept free of oil.

Fig. 1: Function of the clutch/brake combined unit

12

3

4

5


4

Delivered stateThe clutch/brake combined units are delivered in a fully assembled state(exception: clutch plate).

Different ways in which the plates are suspendedThe clutch and brake plates can be suspended in one of three differentways:

Different friction liningsThe clutch/brake combined units can be fitted with one of two differentkinds of friction linings:

- with lining segments which are glued or riveted on- with friction blocks

Special versionsClutch/brake combined units from size 61 and upwards can be suppliedwith a cylinder of reduced volume. If desired, these can be fitted with awear indicator.

Clutch/brake combined units with twelve-point suspension can be fittedwith six spring pots per plate, these being positioned at intervals of 60° toone another, in order to give quieter running when the clutch isdisengaged.

In addition in the case of the twelve-point suspension of the plates, twodamping studs (studs with spring-loaded balls) displaced at 120° to oneanother can be fitted. These keep the unit be retrofitted whereby twosleeves are removed.

Furthermore clutch/brake combined units of the size 67 and larger can befitted with fan blades to give additional forced cooling.

Twelve-point suspension of the plates series 0 420- . . 9 - . . -

Two-point suspension of the plates series 0 420- . . 7 - . . -

series 0 420- . . 8 - . . -

Combined suspension of the plates series 0 420- . . 3 - . . -

series 0 420- . . 4 - . . -


5

Initial assembly and commissioning

Installation with twelve-point suspension of the plates

The plates are already in place when delivered. The brake plate halvesare held by spring pressure, the clutch plate halves by means of thesecuring straps. For reasons of space, it can be necessary to remove theclutch plate in order to enable the clutch/brake combined unit to beinstalled. Do this before you mount the clutch/brake combined unit on thedriven shaft.

• Mount the clutch/brake combined unit on the driven shaft with twofeather keys or with clamping sets.

The brake plate halves will no longer be held and will fall out if you applycompressed air to the clutch/brake combined unit.

• Ensure that this cannot happen by, for example, tightening up a numberof screws or inserting metal pins provisionally.

• Apply compressed air to the clutch/brake combined unit.• Align the brake plate until the holes in it coincide with those in the

machine.• Insert sleeve 1 Tighten up self-locking screws 2 to the prescribed torque

(see table on page 7).• Turn the flywheel or, as the case may be, the toothed wheel until a

securing hole is opposite a recess in the brake plate.• Insert one of the clutch plate halves if the clutch plate has been

removed.• Insert sleeve 1 Tighten up self-tightening screw 2 to the prescribed

torque (see table on page 7). Insert the remaining five sleeves andtighten up the screws.

• Proceed in the same way with the other plate half.

Fig. 2: Twelve point plate suspension

3

1

2


6

Always fit the clutch plate securing straps on the brake side.

• Secure the plate halves with two straps 3 ( up to size 90 four straps 3and 3a). Lock the screws with Loctite type 242 or a similar material.

Fig. 2a: Twelve-point mounting up to size 90

3 3a


7

Installation with twelve-point suspension of the housingplates (friction block version)

Fig.3: Twelve point plate suspension (friction block version)

The housing plates are already in place when the unit is delivered. Thebrake housing plate halves are held in place by spring pressure, the clutchhousing plate halves are loose.

• Remove the clutch housing plate halves.• Mount the clutch/brake combined unit on the driven shaft with two

feather keys or with clamping sets.

The brake housing plate halves will no longer be held and will fall out ifyou apply compressed air to the clutch/brake combined unit.

• Ensure that this cannot happen by, for example, inserting a number ofscrews or metal pins provisionally.

• Apply compressed air to the clutch/brake combined unit.• Align the brake housing plate until the holes in it coincide with those in

the machine.• Insert sleeve 1 Tighten up screws 2 to the prescribed torque (see table

on p. 6).• Turn the flywheel or, as the case may be, the toothed wheel until a

securing hole is opposite a recess in the brake housing plate.• Insert one of the clutch housing plate halves.• Insert sleeve 1 Tighten up screw 2 to the prescribed torque (see table on

p. 6). Insert the second sleeve and tighten up the remaining screws.• Proceed in the same way with the other clutch housing plate half.

Tightening torques for the screws 2 for the different sizes of clutch/brakecombined unit.- Strength class: 10.9- Locking agent: Loctite 262

Size 23 29 40 50 61 62 67 72

Nm 8,5 8,5 15 35 69 69 120 190

Size 77 80 83 87 90 91 92 93

Nm 190 295 580 1000 1000 1000 1500 2000

1

2


8

Installation with two-point suspension of the plates

Fig. 4: Two-point mounting

On the brake side the round stud must be fitted at the top. If this is notdone, knocking may occur at braking. The square stud permitslongitudinal alignment to be carried out in the radial direction.

• Trim and fit the studs so that there is no play and secure with the smallsecuring straps 2.

• Place lugs 1 to which the shoulder bushes have been fitted on to thestuds.

• Remove the clutch plate.• Mount the clutch/brake combined unit on the driven shaft with two

feather keys or with clamping sets.• Insert the clutch plate again (up to size 50 with hexagon head cap screws,

nuts and clamping sleeves, from size 61 with dowel screws and nuts).• Screw the plate halves to the lugs tighten up the screws to the

prescribed torque (see table below).

Installation with combined suspension of the plates• Installation is carried out in an analogous manner to that for

twelve-point and two-point suspension.

Tightening torques for the hexagon head cap screws- Strength class: Nuts up to size 50 10, from size 61 8,

screws up to size 50 10.9, from size 61 8.8- Locking: Locking agent Loctite 262

Size 23 29 40 50 61 62 67 72

Nm 15 15 15 35 49 49 86 86

Size 77 80 83 87 90 91 92 93

Nm 86 210 210 410 710 710 710 1450

2

1


9

Maintenance

Check during operation of the clutch/brake combined unitCheck the wear at the air gap between the clutch plate/friction block andthe piston. As the friction linings wear down, the braking time increases.

When the air gap has become equal to the maximum permissible frictionlining wear (see table on next page), you must change the plate/frictionblocks. From size 61, you can compensate for wear when the wear on thefriction linings has reached half ist max. permitted level. Check in eachcase the friction lining counter surfaces for wear or scoring (requesttechnical service if necessary).

Fig. 5: Checking for wear

• To prevent this type of damage, check the air gap between the clutchplate/friction block and the piston regularly. Do this when the brake isapplied.

Where a wear indicator is fitted, you can compensate for wear when theindicator pin is flush with the ring nut or projects beyond the latter. Wherethe unit has a reduced cylinder volume, you must do this. Alwayscheck the friction lining counter surfaces for wear or scoring (requesttechnical service if necessary).

Fig. 6: Checking for wear with wear indicator

• Where a wear indicator is fitted, check the position of the indicator pinrelative to the ring nut, the friction lining half-wear point has beenreached.


10

Wear compensation at friction lining half-wear point(from size 61 and upwards)

Abb. 7: wear compensation

• Realese brake and loosen screws 1.• Remove shims 2 and re-insert them between the cylinder and stop

plate 3.• Tighten up the screws again to the prescribed torque (see table 11) and

secure them.

Setting of the wear indicator (with reduced cylinder volume)

• Press the indicator pin firmly against the piston.• Screw in the ring nut until the distance between is outside edge and

indicator pin is the same as the value given in the table below.• Screw in the locknut and tighten up.

Setting value with wear indicator in mm

Size 61 62 67 72 77 80 83 87 90 91 92 93

Nm 1,5 1,5 1,5 2 2,5 2,5 3 3 3,5 3,5 4 4

Size 23 29 40 50 61 62 67 72

new 0,7 0,7 0,8 0,9 1 1,2 1,2 1,2

max 4,7 4,7 4,8 4,9 7 7,2 7,2 9,2

1/2 - - - - 4 4,2 4,2 5,2

Size 77 80 83 87 90 91 92 93

new 1,4 1,5 1,6 1,7 1,8 1,9 2,1 2,2

max 11,4 11,5 13,6 13,7 15,8 15,9 18,1 18,2

1/2 6,4 6,5 7,6 7,7 8,8 8,9 10,1 10,2

Air gap between the clutch plate/friction block and piston in mm

21

3


11

Tightening torques for the screws 1- Strength class: 10.9- Locking: locking plate

Removing and fitting the plates/housing platesMake certain that no unintended machine movement can take place whenthe brake plate is removed. Place blocks, for example, below the pressram.

• Follow the correct sequence when removing/refitting the plates:- Removal: first the clutch plate, then the brake plate- Fitting: first the brake plate,then the clutch plate

In the case of twelve-point suspension, always fit the clutch plate securingstraps on the brake side.

• Reset the wear indicactor after refitting if one is fitted.• Put the shims back in their old place outside the cylinder if appropriate.

Twelve-point suspension of the plate• Remove the straps which hold the two clutch plate halves together.• Remove the clutch plate securing screws. There are recesses in the

brake plate to simplify this.• Remove the clutch plate halves.• Apply compressed air to the unit. This will create the

necessary space for removing/refitting the brake plate.• The brake plate is removed in the same way as the clutch plate.• Refitting is carried out in the reverse order to that for removal.

Size 23 29 40 50 61 62 67 72

Nm - 6 10 25 25 10 25 25

Size 77 80 83 87 90 91 92 93

Nm 49 86 86 135 135 210 410 410


12

Twelve-point suspension of the housing plates(friction block version)• Remove the clutch housing plate securing screws.• Remove the clutch housing plate halves.• Apply compressed air to the clutch/brake combined unit. This will create

the necessary space for the removal and refitting of the brake housingplate.

• Removal of the brake plate is carried out as for the clutch housing plate.• Refitting is carried out in the reverse order to that for removal.

Two-point suspension of the plates• Remove the lug screws and remove the clutch plate halves.• Apply compressed air to the clutch/brake combined unit. This will create

the necessary space for the removal and refitting of the brake plate.• Removal of the brake plate is carried out as for the clutch plate.• When refitting, first place the lugs on the studs and then screw the

plates to the lugs.• Refitting is carried out in the reverse order to that for removal.

Setting the oilerCheck the setting of the oiler regularly. It should deliver 1 to 3 drops of oilper m3 air.


13

Fault

Clutch plate/

housing plate

slips

Brake plate/

housing plate

slips

Reason

Friction linings/

pads worn down

Plate/friction blocks

moist or oily

Air pressure too low

Valves defective

(Check: connect the

compressed air

directly)

Otherwise machine damage

–request technical service

Friction linings/

pads worn down

Plate/friction blocks

moist or oily

Otherwise machine damage

–request technical service

Fault finding

Remedy

Replace plate/friction

blocks check the

counter friction

surfaces


blocks, eliminate

source of moisture/oil

Increase operating

pressure to 5.5 bar

Replace valves

Carry out wear

compensation. (from

size 61) Replace plates/

friction blocks, check the

counter friction

surfaces


blocks check the

counter friction

surfaces


14

Complete assembly - only for customer service(see attached explosion drawing)

Dismantling of the Clutch/Brake• Remove the plates/housing disc.• Draw off the clutch/brake combined unit from the shaft. Two,

respectively three from size 50, extraction holes are provided for this onthe clutch side. Remove two screws on the brake side which arepositioned at 180° to one another. This will make two extraction holesaccessible.

Fig. 8: Safety procedure at dismantling

• Open the clutch/brake combined unit.

Insert two screws into the threaded holes on the brake side from which thescrews have just been removed. The two screws inserted should be15mm longer than the ones they replace. Do not remove the other screwsuntil this have been done. These screws should be slackened/removeduniformly (crosswise fashion). The cylinder is under spring pressure so besure to follow this procedure because otherwise parts could fly out andinjure you.

• Further dismantling of the clutch/brake as per explosion-drawing.


15

Assembly of the dismantled clutch/brake combined unitReassemble the clutch/brake combined unit in the reverse order to that fordismantling. Clean all the parts before refitting them. Pay attention here tothe following points:

Fig. 9: Spacing of the pressure springs

• Space the springs uniformly if you are not going to fit the clutch/brakecombined unit with the complete set of springs.

Fig. 10: Inserting the seals

• Use a rounded-off tool for inserting the seals.

Fig. 11: Sealing

• Smear the sealing surfaces of cylinder and rub thinly with a sealingagent; lubricate the seal surfaces with lithium soap grease.


16

Fig. 12: Connection screws, cylinder-hub

• Insert new screws and tighten up to the prescribed torque (see tablebelow).

• Reset the wear indicator if fitted.

• Put the shims back in their old place outside the cylinder if appropriate.

Tightening torques for screws:- stress classification: 10.9- replace after dismantling

Size 23 29 40 50 61 62 67 72

Nm 8,5 8,5 14 35 35 35 69 69

Size 77 80 83 87 90 91 92 93

Nm 86 135 210 210 210 410 710 710


17

Spare partsOur guarantee for our products only applies when you useoriginal Ortlinghaus spare parts.

Abb. 13: Fabrication number

Please order spare parts only in writing. You will find the fabricationnumber, under which your clutch/brake combined unit was manufactured,punched on the hub next to the position mark. Always state this number.It is made up of two digits for the year and a consecutive number,e.g. 00/12345.In addition state if possible the article number of your clutch/brakecombined unit.In the appendix you will find the list of spare parts; this includes thedesignation of each part and its item number, the latter being also shownon the blow-up drawing. State both this item number and the designationwhen ordering e.g. 12.4 - friction block.

00 / 12345


18

Spare parts list for Pneumatically actuated clutch/brakecombined unit 0 420- . . . -23

Wearing part are indicated with a shaded backround

Item Part

1 Hub

1.1 Hub

1.2 O-Ring

2 Ring

2.1 Ring

2.2 Straight pin

2.3 Screw

3 Pressure springs

3.1 Pressure springs

4 Clutch plate (twelve-point

suspension)

4.1 Clutch plate

4.2 Strap

4.3 Spring washer

4.4 Screw

4.5 Clamping sleeve

4.6 Screw

4.7 Sleeve

5 Piston

5.1 Piston

5.2 O-ring

6 Brake plate (twelve-point

suspension

6.1 Brake plate

6.2 Screw

6.3 Sleeve

Item Part

8 Cylinder

8.1 Cylinder

8.2 Straight pin

8.3 Screw

9 Plate (two-point suspension)

9.1 Plate (clutch and brake)

10 Two-point suspension

(long lugs)

10.1 Lug (long)

10.2 Clamping sleeve

10.3 Screw

10.4 Shoulder bush (round)

10.5 Securing ring

10.6 Strap

10.7 Stud (round)

10.8 Nut

10.9 Stud (square)

10.10 Shoulder bush (square)


(short lugs)

11.1 Lug (short)

12 Friction block version

12.1 Housing plate halves

12.2 Sleeve

12.3 Screw

12.4 Friction block


19

Explosion drawing for Pneumatically actuated clutch/brakecombined unit 0 420- . . . -23

10.4 10.510.6

10.710.8

10.910.10

9.1

10.1

10.2

10.3

11.1

12.2

12.112.3

12.4

2.3

1.1

1.22.2

2.13.1

4.1

4.24.3

4.5

4.4

4.74.6

5.1

5.2

6.26.3

6.1

8.1

8.2

8.3


20

Spare parts list for Pneumatically actuated clutch/brakecombined unit 0 420- . . . -29 to 0 420- . . . -61


Item Part

1 Hub

1.1 Hub

2 Ring

2.1 Ring

2.2 Straight pin

2.3 Screw

3 Pressure springs

3.1 Spring retension plate

3.2 Pressure spring

3.3 Straight pin

4 Clutch plate

(twelve-point suspension)

4.1 Clutch plate

4.2 Sleeve

4.3 Screw

4.4 Strap

4.5 Spring ring

4.6 Screw

4.7 Clamping sleeve

5 Piston

5.1 Piston

5.2 Seal

5.3 Seal

6 Brake plate

(twelve-point suspension)

6.1 Brake plate

6.2 Sleeve

6.3 Screw

7 Stop plate

7.1 Stop plate

7.2 Insulating disc

Item Part

8 Cylinder

8.1 Cylinder

8.2 Locking washer

8.3 Screw

8.4 Screw

8.5 Straight pin

8.6 Straight pin


9.1 Base (clutch and brake)


(long lugs)

10.1 Lug (long)

10.2 Screw

(size 61 fitted bolt)


10.4 Securing ring

10.5 Strap

10.6 Stud (round)

10.7 Nut

10.8 Clamping sleeve

(not by size 61)

10.9 Stud (square)


11 Two-point suspensions

(short lugs)

11.1 Lug (short)



12.2 Sleeve

12.3 Screw

12.4 Friction block


21

Explosion drawing for Pneumatically actuated clutch/brakecombined unit 0 420- . . . -29 to 0 420- . . . -61

11.1

10.3 10.4

10.5

10.6

10.8

10.7

10.2

10.1

9.1

10.10

10.9

2.3

1.1

2.1

2.23.3

3.1

3.2

4.14.2

4.3

5.1

5.2

5.3

4.44.5 4.6

4.7

6.36.2

6.1

7.1

7.2

8.1

8.2

8.3

8.4

8.5

8.6

12.2

12.3

12.412.1


22

Spare parts list for Pneumatically actuated clutch/brakecombined unit 0 420- . . . -62 to 0 420- . . . -93


Item Part

1 Hub

1.1 Hub

3 Pressure springs

3.1 Pressure Spring

3.2 Pressure spring

4 Clutch plate (twelve-point

suspension) up to size 80

4.1 Clutch plate base from size 83

4.2 Lining segment (from size 83)

4.3 Sleeve

4.4 Screw

4.5 Strap

4.6 Spring washer

4.7 Screw

4.8 Clamping sleeve

5 Piston

5.1 Piston

5.2 Seal

5.3 Seal

6 Brake plate (twelve-point

suspension) up to size 80

6.1 Brake plate base (from size 83)

6.2 Sleeve

6.3 Screw

7 Stop plate

7.1 Stop plate

7.2 O-ring

8 Cylinder

8.1 Cylinder

Item Part

8.3 Screw

8.4 Straight pin

8.5 Screw

8.6 Locking washer

8.7 Spacer

8.8 Straight pin


up to size 80

9.1 Base from size 83


(long lugs)

10.1 Lug (long)

10.2 Fitted bolt


10.4 Securing ring

10.5 Strap

10.6 Stud (round)

10.7 Nut

10.8 Stud (square)



(short lugs)

11.1 Lug (short)



12.2 Sleeve

12.3 Screw

12.4 Friction block


23

Explosion drawing for Pneumatically actuated clutch/brakecombined unit 0 420- . . . -62 to 0 420- . . . -93

11.1

10.310.4 10.5

10.6

10.7

10.1

10.2

9.1

10.9

10.8

1.1 4.14.2

4.3 4.4

5.1

5.25.3

6.17.1

7.2

8.1

8.3

12.1

12.2

12.312.4

3.1

3.2

4.5

4.6

4.74.8

6.36.2

8.8

8.7

8.6

8.5

8.4

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tp0750EN