TP 0750 EN

Technical product information No.
750 EN
pneumatically actuated clutch/brake
combined unit
series 0 420
Contents
Page
About this Technical Product Information (TPI)
The ORTLINGHAUS numbering system
About the product
Delivered state
Initial assembly and commissioning
Maintenance
Fault finding
13
Complete assembly - only for customer service
14
Spare parts
17
Ortlinghaus-Werke GmbH
Edition: 11.2001
Postfach 14 40
42907 Wermelskirchen
Kenkhauser Str. 125
42929 Wermelskirchen
Deutschland
Phone +49 21 96 85-0
Fax
+49 21 96 8 55-4 44
E-Mail info@ortlinghaus.com
Internet www.ortlinghaus.com
TPI 750 EN
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 instruction
It 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 and
maintenance of the product described on the title page
Notes on the symbols used in the text

On the pages which follow, important sections of text are highlighted with
the following symbols.
This symbol means:
There is a risk of injury during the activity described or in operational
running!
This symbol means:
There is a risk of material damage during the activity described or in
operational running!
This symbol indicates sections of text to which particular attention must be
paid.
The Ortlinghaus numbering system

Example:
0 - 111 - 222 - 33 - 444 - 555
0 = Code for products

Code number for the model rage
Code number for design features
Size
Sequencial number
Other design features
Pass this TPI on to your customers ! You can either order further copies of
this TPI from us or you are free to make copies, for use by your
customers.
TPI 750 EN
About the product

Purpose and mode of functioning of the clutch/brake
combined unit
Single plate clutch/brake combined units are well suited for high torques
even where the thermal loading is high, e.g. in the accelerating and
deceleration of heavy gyrating masses with high engaging/disengaging
frequencies. They are used above all in presses and guillotine shears.
Do not use clutch/brake combined units in rooms with high air humidity or
in which the air contains oil. Otherwise there is the risk that the plates will
slip and the action of the brake will be significantly reduced.
Fig. 1: Function of the clutch/brake combined unit
Braking: Pressure springs 4 press against piston 3 in the cylinder. This

causes brake plate 2 to be pressed against the stop plate, thus bringing
about the braking action.
Engaging the clutch: Compressed air is applied to the piston via air
intake 5. This causes brake plate 2 to be released and
clutch plate 1 to engage.
The normal operating pressure is 5.5 bar, the maximum permissible
pressure 6 bar. Never operate the clutch/brake combined unit with a
higher 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 m air.
It is essential that the friction linings are kept free of oil.
TPI 750 EN
Delivered state
The clutch/brake combined units are delivered in a fully assembled state
(exception: clutch plate).
Different ways in which the plates are suspended

The clutch and brake plates can be suspended in one of three different
ways:
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 - . . -
Different friction linings

The clutch/brake combined units can be fitted with one of two different
kinds of friction linings:
- with lining segments which are glued or riveted on
- with friction blocks
Special versions
Clutch/brake combined units from size 61 and upwards can be supplied
with a cylinder of reduced volume. If desired, these can be fitted with a
wear indicator.
Clutch/brake combined units with twelve-point suspension can be fitted
with six spring pots per plate, these being positioned at intervals of 60 to
one another, in order to give quieter running when the clutch is
disengaged.
In addition in the case of the twelve-point suspension of the plates, two
damping studs (studs with spring-loaded balls) displaced at 120 to one
another can be fitted. These keep the unit be retrofitted whereby two
sleeves are removed.
Furthermore clutch/brake combined units of the size 67 and larger can be
fitted with fan blades to give additional forced cooling.
TPI 750 EN
Initial assembly and commissioning

Installation with twelve-point suspension of the plates
1
3
Fig. 2: Twelve point plate suspension
The plates are already in place when delivered. The brake plate halves
are held by spring pressure, the clutch plate halves by means of the
securing straps. For reasons of space, it can be necessary to remove the
clutch plate in order to enable the clutch/brake combined unit to be
installed. Do this before you mount the clutch/brake combined unit on the
driven shaft.
Mount the clutch/brake combined unit on the driven shaft with two
feather keys or with clamping sets.
The brake plate halves will no longer be held and will fall out if you apply
compressed air to the clutch/brake combined unit.
Ensure that this cannot happen by, for example, tightening up a number
of 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 and
tighten up the screws.
Proceed in the same way with the other plate half.
TPI 750 EN
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 3
and 3a). Lock the screws with Loctite type 242 or a similar material.
3a
Fig. 2a: Twelve-point mounting up to size 90
TPI 750 EN
Installation with twelve-point suspension of the housing

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

The housing plates are already in place when the unit is delivered. The
brake housing plate halves are held in place by spring pressure, the clutch
housing plate halves are loose.
Remove the clutch housing plate halves.
The brake housing plate halves will no longer be held and will fall out if
you apply compressed air to the clutch/brake combined unit.
Ensure that this cannot happen by, for example, inserting a number of
screws 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/brake
combined 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
TPI 750 EN
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 not
done, knocking may occur at braking. The square stud permits
longitudinal alignment to be carried out in the radial direction.
Trim and fit the studs so that there is no play and secure with the small
securing straps 2.
Place lugs 1 to which the shoulder bushes have been fitted on to the
studs.
Remove the clutch plate.
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
TPI 750 EN
Maintenance
Check during operation of the clutch/brake combined unit
Check the wear at the air gap between the clutch plate/friction block and
the piston. As the friction linings wear down, the braking time increases.
When the air gap has become equal to the maximum permissible friction
lining wear (see table on next page), you must change the plate/friction
blocks. From size 61, you can compensate for wear when the wear on the
friction linings has reached half ist max. permitted level. Check in each
case the friction lining counter surfaces for wear or scoring (request
technical service if necessary).
Fig. 5: Checking for wear

To prevent this type of damage, check the air gap between the clutch
plate/friction block and the piston regularly. Do this when the brake is
applied.
Where a wear indicator is fitted, you can compensate for wear when the
indicator pin is flush with the ring nut or projects beyond the latter. Where
the unit has a reduced cylinder volume, you must do this. Always
check the friction lining counter surfaces for wear or scoring (request
technical service if necessary).
Fig. 6: Checking for wear with wear indicator

Where a wear indicator is fitted, check the position of the indicator pin
relative to the ring nut, the friction lining half-wear point has been
reached.
TPI 750 EN
Air gap between the clutch plate/friction block and piston in mm

Size
23
29
40
50
61
62
67
72
new
0,7
0,7
0,8
0,9
1,2
1,2
1,2
max
4,7
4,7
4,8
4,9
7,2
7,2
9,2
1/2
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
Wear compensation at friction lining half-wear point

(from size 61 and upwards)
2
1
3
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
10
Size
61
62
67
72
Nm
1,5 1,5 1,5 2
77
80
83
2,5 2,5 3
87
90
91
92
3,5 3,5 4
93
4
TPI 750 EN
Tightening torques for the screws 1

- Strength class: 10.9
- Locking: locking plate
Size
23
29
40
50
61
62
67
72
Nm
10
25
25
10
25
25
Size
77
80
83
87
90
91
92
93
Nm
49
86
86
135
135
210
410
410
Removing and fitting the plates/housing plates

Make certain that no unintended machine movement can take place when
the brake plate is removed. Place blocks, for example, below the press
ram.
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 securing
straps 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.
11
TPI 750 EN
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 housing
plate.
Removal of the brake plate is carried out as for the clutch housing plate.
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.
Setting the oiler

Check the setting of the oiler regularly. It should deliver 1 to 3 drops of oil
per m3 air.
12
TPI 750 EN
Fault finding
Fault
Reason
Remedy
Clutch plate/
Friction linings/
Replace plate/friction
housing plate
pads worn down
blocks check the
slips
counter friction
surfaces
Plate/friction blocks
moist or oily
blocks, eliminate
source of moisture/oil
Air pressure too low
Increase operating
pressure to 5.5 bar
Valves defective
Replace valves
(Check: connect the

compressed air
directly)
Otherwise machine damage
request technical service
Brake plate/
Friction linings/
Carry out wear
housing plate
pads worn down
compensation. (from
size 61) Replace plates/
slips
friction blocks, check the

counter friction
surfaces
Plate/friction blocks
moist or oily
blocks check the

counter friction
surfaces
Otherwise machine damage

request technical service
13
TPI 750 EN
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 on
the clutch side. Remove two screws on the brake side which are
positioned at 180 to one another. This will make two extraction holes
accessible.
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 the
screws have just been removed. The two screws inserted should be
15mm longer than the ones they replace. Do not remove the other screws
until this have been done. These screws should be slackened/removed
uniformly (crosswise fashion). The cylinder is under spring pressure so be
sure to follow this procedure because otherwise parts could fly out and
injure you.
Further dismantling of the clutch/brake as per explosiondrawing.
14
TPI 750 EN
Assembly of the dismantled clutch/brake combined unit

Reassemble the clutch/brake combined unit in the reverse order to that for
dismantling. Clean all the parts before refitting them. Pay attention here to
the following points:
Fig. 9: Spacing of the pressure springs

Space the springs uniformly if you are not going to fit the clutch/brake
combined 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 sealing
agent; lubricate the seal surfaces with lithium soap grease.
15
TPI 750 EN
Fig. 12: Connection screws, cylinder-hub

Insert new screws and tighten up to the prescribed torque (see table
below).
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
16
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
TPI 750 EN
Spare parts
Our guarantee for our products only applies when you use
original Ortlinghaus spare parts.
00 / 12345
Abb. 13: Fabrication number
Please order spare parts only in writing. You will find the fabrication
number, 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/brake
combined unit.
In the appendix you will find the list of spare parts; this includes the
designation of each part and its item number, the latter being also shown
on the blow-up drawing. State both this item number and the designation
when ordering e.g. 12.4 - friction block.
17
TPI 750 EN
Spare parts list for Pneumatically actuated clutch/brake

combined unit 0 420- . . . -23
Item
Part
Item
Part
Hub
Cylinder
1.1
Hub
8.1
Cylinder
1.2
O-Ring
8.2
Straight pin
Ring
8.3
Screw
2.1
Ring
Plate (two-point suspension)
2.2
Straight pin
9.1
Plate (clutch and brake)
2.3
Screw
10
Two-point suspension
Pressure springs
3.1
Pressure springs
10.1
Lug (long)
Clutch plate (twelve-point
10.2
Clamping sleeve
suspension)
10.3
Screw
4.1
Clutch plate
10.4
Shoulder bush (round)
4.2
Strap
10.5
Securing ring
4.3
Spring washer
10.6
Strap
4.4
Screw
10.7
Stud (round)
4.5
Clamping sleeve
10.8
Nut
4.6
Screw
10.9
Stud (square)
4.7
Sleeve
10.10
Shoulder bush (square)
Piston
11
5.1
Piston
5.2
O-ring
11.1
Lug (short)
Brake plate (twelve-point
12
Friction block version
suspension
12.1
Housing plate halves
6.1
Brake plate
12.2
Sleeve
6.2
Screw
12.3
Screw
6.3
Sleeve
12.4
Friction block
(long lugs)
(short lugs)
Wearing part are indicated with a shaded backround
18
TPI 750 EN
Explosion drawing for Pneumatically actuated clutch/brake

combined unit 0 420- . . . -23
11.1
10.5
10.4
10.6
10.2
10.3
10.1
10.7
10.8
9.1
10.9
10.10
1.1
1.2
4.2
2.2
2.3
4.3
4.4
4.5
5.2
8.3
2.1
3.1
4.7
4.1
8.2
4.6
6.2
12.1
5.1
12.3
6.3
6.1
8.1
12.4
12.2
19
TPI 750 EN

combined unit 0 420- . . . -29 to 0 420- . . . -61
Item
Part
Item
Part
Hub
Cylinder
1.1
Hub
8.1
Cylinder
Ring
8.2
Locking washer
2.1
Ring
8.3
Screw
2.2
Straight pin
8.4
Screw
2.3
Screw
8.5
Straight pin
Pressure springs
8.6
Straight pin
3.1
Spring retension plate
3.2
Pressure spring
9.1
Base (clutch and brake)
3.3
Straight pin
10
Clutch plate
(long lugs)
(twelve-point suspension)
10.1
Lug (long)
4.1
Clutch plate
10.2
Screw
4.2
Sleeve
4.3
Screw
10.3
4.4
Strap
10.4
Securing ring
4.5
Spring ring
10.5
Strap
4.6
Screw
10.6
Stud (round)
4.7
Clamping sleeve
10.7
Nut
Piston
10.8
Clamping sleeve
5.1
Piston
5.2
Seal
10.9
Stud (square)
5.3
Seal
10.10
Brake plate
11
Two-point suspensions
(size 61 fitted bolt)
(not by size 61)
(short lugs)
(twelve-point suspension)
6.1
Brake plate
11.1
Lug (short)
6.2
Sleeve
12
6.3
Screw
12.1
Stop plate
12.2
Sleeve
7.1
Stop plate
12.3
Screw
7.2
Insulating disc
12.4
Friction block
20
TPI 750 EN

combined unit 0 420- . . . -29 to 0 420- . . . -61
11.1
10.1
10.4
10.3
10.5
10.2
10.6
10.7
9.1
10.8
10.10
3.3
10.9
2.2
2.3
4.1
4.2
4.3
5.2
6.3
6.2
1.1
2.1
7.2
3.2
8.2
8.3
3.1
4.4
4.5
4.6
4.7
5.1
12.3
12.4
12.1
5.3
8.4
6.1
8.5
7.1
12.2
8.6
8.1
21
TPI 750 EN

combined unit 0 420- . . . -62 to 0 420- . . . -93
Item
Part
Item
Part
Hub
8.3
Screw
1.1
Hub
8.4
Straight pin
Pressure springs
8.5
Screw
3.1
Pressure Spring
8.6
Locking washer
3.2
Pressure spring
8.7
Spacer
Clutch plate (twelve-point
8.8
Straight pin
suspension) up to size 80

up to size 80
4.1
Clutch plate base from size 83
4.2
Lining segment (from size 83)
9.1
Base from size 83
4.3
Sleeve
10
4.4
Screw
4.5
Strap
10.1
Lug (long)
4.6
Spring washer
10.2
Fitted bolt
4.7
Screw
10.3
4.8
Clamping sleeve
10.4
Securing ring
Piston
10.5
Strap
5.1
Piston
10.6
Stud (round)
5.2
Seal
10.7
Nut
5.3
Seal
10.8
Stud (square)
Brake plate (twelve-point
10.9
suspension) up to size 80
11
(long lugs)
(short lugs)
6.1
Brake plate base (from size 83)
6.2
Sleeve
11.1
Lug (short)
6.3
Screw
12
Stop plate
12.1
7.1
Stop plate
12.2
Sleeve
7.2
O-ring
12.3
Screw
Cylinder
12.4
Friction block
8.1
Cylinder
22
TPI 750 EN

combined unit 0 420- . . . -62 to 0 420- . . . -93
11.1
10.4
10.3
10.5
10.2
10.6
10.1
10.7
9.1
10.9
10.8
1.1
4.1
4.2
4.3
4.4
5.1
6.3
3.2
6.2
6.1
7.1
8.7
7.2
8.6
3.1
8.4
8.5
4.6
4.5
4.8
4.7
5.2
12.3
12.1
8.3
5.3
8.8
12.4
8.1
12.2
23

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What is the purpose and mode of functioning of the clutch/brake combined unit?

What is the purpose and mode of functioning of the clutch/brake combined unit?

How are the clutch and brake plates suspended in the unit?

How are the clutch and brake plates suspended in the unit?

Technical product information No.

About this Technical Product Information (TPI)

The ORTLINGHAUS numbering system

About the product

Initial assembly and commissioning

Complete assembly - only for customer service

About this Technical Product Information (TPI)

What will you find in the TPI?

Notes on the symbols used in the text

The Ortlinghaus numbering system

0 - 111 - 222 - 33 - 444 - 555

0 = Code for products

About the product

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

Braking: Pressure springs 4 press against piston 3 in the cylinder. This

Different ways in which the plates are suspended

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 - . . -

Different friction linings

Initial assembly and commissioning

Fig. 2: Twelve point plate suspension

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

Installation with twelve-point suspension of the housing

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

Installation with two-point suspension of the plates

Fig. 4: Two-point mounting

Installation with combined suspension of the plates

Fig. 5: Checking for wear

Fig. 6: Checking for wear with wear indicator

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

Wear compensation at friction lining half-wear point

Setting value with wear indicator in mm

1,5 1,5 1,5 2

Tightening torques for the screws 1

Removing and fitting the plates/housing plates

Twelve-point suspension of the plate

Twelve-point suspension of the housing plates

Two-point suspension of the plates

Setting the oiler

pads worn down

blocks check the

Air pressure too low

(Check: connect the

Carry out wear

pads worn down

friction blocks, check the

blocks check the

Otherwise machine damage

Complete assembly - only for customer service

Dismantling of the Clutch/Brake

Fig. 8: Safety procedure at dismantling

Assembly of the dismantled clutch/brake combined unit