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2019
Columbus McKinnon Industrial Products GmbH
Maintenance Of Gearbox
To service the gear, the gear cover must be removed. To do this, detach the nuts on the two retainers. The gear hood can then be
removed.
The following aspects of the exposed gear must be checked:
• Hood and sealing for damage and cracks
• Gear wheels for visible faults such as wear, cracks, etc.
• Locking rings for stability
The gear must be re-lubricated after the inspection. We recommend using a graphite grease such as Klüber Grafloscon A-G1 Ultra or
Reiner Chemie Ceplattyn 300.
Servicing of motor and motor brake
Motor
Motor
Under normal conditions the motor is practically maintenance-free. Every 2.1/2 years the bearings are to be inspected, cleaned and
repacked half-full with grease. We recommend K 3 N / KL 3 N DIN 51825 / DIN 51502.
Electromagnetic brake
Servicing the disc brake is reduced to checking and adjusting the brake air gap.
Depending on the efficiency of the drive motor, the RPE electric rope winches are equipped with two different brake systems:
Units with a motor output of 0.55 kW (RPE 2-13, RPE 5-6) have a so-called single contact area brake (EFB),
Units with a motor output of 1.1 kW (RPE 5-12, RPE 9-6, RPE 10-6) have a so-called double contact area brake (ZFB).
The two brake systems are to be serviced differently as they have different designs:
NOTE: The type of brake system (EFB or ZFB) can also be found on the motor ratings plate under "Brake".
Single contact area brake (EFB):
Servicing the disc brake is reduced to checking and adjusting the brake air gap.
The disc brake air gap should be between 0.2 and 0.6 mm. This guarantees a short reaction time and low noise emission.
A readjustment is necessary, if the wear of the brake lining has aggravated to such an extent that the maximum permissible air gap of
the brake has been reached.
1. Remove the fan guard (15).
2. Remove abrasion dust with compressed air
3. Check the minimum thickness of the brake lining.
ATTENTION: Change the fan module on reaching the minimum lining thickness of 1.5 mm.
4. Place two spacer plates (thickness: 0.2 mm) between the magnet body (1) and the anchor plate (42).
5. Turn the screw (31) in the rotor shaft until the spacer plates can still be removed.
6. Remove the spacer plates.
7. Place the fan guard (15) and fasten it.
8. Connect the brake and check it.
Double contact area brake (ZFB):
The disc brake air gap should be between 0.3 and 0.6 mm. This guarantees short response times and low noise emission. The brake air
gap must be readjusted if the wear of the brake lining has aggravated to such an extent that the max. permissible air gap of the brake is
reached:
• Take out the fan guard after detaching the fastening screws.
• Pull the dust protection ring (80) out of the groove in the magnet body (1) and slide it over the motor-side bearing shield.
• Remove abrasion dust with compressed air.
• Check the minimum thickness of the brake disk.
ATTENTION: The minimum thickness of the brake disc is 8.5 mm. Upon reaching this dimension at minimum one position of
the brake disc, the unit must be shut down immediately and the brake disc must be replaced without any delay.
• Loosen the hexagon bolt (6) by half a turn.
ATTENTION: The hexagon bolts must be replaced with new ones after the 2nd adjustment at the latest.
• Turn the hollow screw (5) approx. 1 mm into the magnet body (1).
• Tighten the hexagon bolts (6) until the brake air gap between the anchor plate and the magnet body is 0.3 mm (to be checked with a
feeler gauge).
• Loosen the hollow screws (5) up to the fixed attachment on the bearing shield or additional friction disc (60) from the magnet body (1).
• Tighten the hexagon bolts (6) uniformly.
• Check the brake air gap again with a feeler gauge to determine size and uniformity, reset if necessary.
NOTE: The brake air gap must be of the same size at all points. Hence, measurements must be carried out at several points around the
brake disk.
• Tighten the hexagon bolts (6) with a torque wrench (torque: 10.0 Nm)
• Install the O-ring (8) in the groove between the anchor plate (2) and the magnet body (1).
• Mount the fan guard and fix it with fastening screws.
• Perform function check.
ATTENTION: Do not allow the brake friction pads to come in contact with lubricants, etc.
ATTENTION: While checking the air passage, the motor should be switched off and the unit should be without load.
