Replacing the brake rotor on the hoist drive

If the brake rotor on the hoist drive is thinner than permitted, the brake rotor must be replaced.

If additional parts need to be replaced: see Replacing the entire brake.

 

 

Removing the fan cover

Fan cover

Rib screws

*    Unscrew the rib screws (3x) of the fan cover.

*    Take off the fan cover.

 

 

Only for fan blades on the motor shaft

 

Removing the fan blade

Circlip

 

Fan blade

 

*    Remove the circlip.

*    Remove the fan blade.

 

 

 

Only for auxiliary fans without frame

 

Schaden

Do not allow the auxiliary fan to hang from the connection cable!

If the auxiliary fan hangs from the connection cable, it could break.

If present, unplug the plug-in connection so that the auxiliary fan can be laid aside during the assembly. If no plug-in connection is present, leave the auxiliary fan connected and secure it after removal (e.g. with a lashing strap).

 

 

 

Plug-in connection

Hexagon head screw

 

*    If present: Unplug the plug-in connection from the auxiliary fan.

*    Release the hexagon head screws (3x) on the auxiliary fan and remove the auxiliary fan.

*    If the auxiliary fan does not have a plug-in connection: Leave the auxiliary fan connected and secure it on the hoist motor, e.g. with a lashing strap.

 

 

 

Only for auxiliary fans with frame

 

Schaden

Do not allow the auxiliary fan to hang from the connection cable!

If the auxiliary fan hangs from the connection cable, it could break.

Unplug the plug-in connection so that the auxiliary fan can be laid aside during the assembly.

 

 

Plug-in connection

 

Fillister-head screw

Mount

*    Unplug the plug-in connection from the auxiliary fan.

*    Release the fillister-head screws (2x) on the auxiliary fan and remove the auxiliary fan.

 

 

 

Uncovering the brake

O-ring

 

*    Remove the O-ring.

*    Clean the entire brake with compressed air.

 

 

Disassembling the magnet body

 

Warnung stürzende Last

Danger from falling bottom block!

If the hoist drive, the hoist motor or the brake are removed, the cable drum of the wire rope hoist will no longer be supported. This can cause the wire rope to unwind in an uncontrolled manner and fall down with the bottom block.

Secure the bottom block on the wire rope hoist!

 

Power supply

Magnet body

Hexagon head screws

 

*    Disconnect the power supply of the magnet body.

*    Release the hexagon head screws (3x).

*    Pull the magnet body from the motor shaft.

 

 

Removing the old brake rotor

 

Brake rotor

 

*    Pull the brake rotor from the hub and from the motor shaft.

 

 

Installing the new brake rotor

 

Hub

Brake rotor

O-ring

*    If present: Check whether the O-ring lies fully in the groove of the hub.

*    Slide the brake rotor over the motor shaft onto the hub.

 

 

Mounting the magnet body

 

Magnet body

Hexagon head screws

 

*    Slide the magnet body onto the motor shaft.

*    Screw the hexagon head screws (3x) hand-tight.

If necessary, replace the hexagon head screws and banjo bolts with new ones.

*    Connect the power supply of the magnet body.

 

 

Setting the air gap

Magnet body

Banjo bolt

Hexagon head screw

Feeler gauge

*    Unscrew the hexagon head screws (3x) by a half turn.

*    Screw in the banjo bolts (3x) by a half turn in the direction of the magnet body.

*    Read off the nominal width of the air gap from the table.

 

Dimension

Value

Air gap between anchor plate and magnet body

Between 0.4 mm and 1.1 mm

Target value for air gap

0.4 mm

 

Size

Brake lining thickness (minimum) [mm]

Hoist motor L6

Hoist motor H6

Hoist motor U6

800.4

9.3

9.3

9.3

1000.7

9.3

9.3

11.3

2000.3

9.3

11.3

-

3000.4

11.3

12.3

-

5000.3

12.3

13.8

-

6000.3

13.8

-

-

7000.1

-

13.8

13.8

 

 

*    Insert the appropriate feeler gauge directly next to one of the hexagon head screws in the air gap between magnet body and anchor plate.

*    Tighten the hexagon head screws so that the feeler gauge can still be pulled from the air gap.

●   The air gap on this hexagon head screw is now adjusted to the set width.

*    Repeat the steps for all hexagon head screws (3x).

 

 

Concluding the setting of the air gap

 

Banjo bolt

Torque wrench

 

*    Screw the banjo bolts (3x) in the direction of the hoist motor until hand-tight.

*    Screw on the hexagon head screws (3x).

 

Hexagon head screw

Tightening torque

M6x70

10 Nm

M8x80

25 Nm

M8x90

25 Nm

M8x100

25 Nm

 

 

●   The brake is fixed with screws.

*    Check the air gap next to all three hexagon head screws. If different than the set width, repeat the adjustment.

 

 

Covering the brake

O-ring

 

*    Insert the O-ring.

 

 

Only for fan blades on the motor shaft

 

Fitting the fan blade

Circlip

 

Fan blade

 

*    Insert the fan blade on the motor shaft.

*    Insert the circlip.

 

 

 

Only for auxiliary fans without frame

 

 

Plug-in connection

Hexagon head screw M5x10

 

*    Place the auxiliary fan on the magnet body.

*    Bolt on the auxiliary fan with hexagon head screws M5x10 (3x).4,8 Nm. Secure with thread-locking compound (medium tightness).

*    If necessary: Insert the plug-in connection from the auxiliary fan.

 

 

 

Only for auxiliary fans with frame

 

Plug-in connection

 

Fillister-head screw M4x16

Mount

*    Place the auxiliary fan on the mount.

*    Screw the auxiliary fan onto the mounting using fillister-head screws M4x12 (2x). 2,4 Nm. Secure with thread-locking compound (medium tightness).

*    Insert the plug-in connection from the auxiliary fan.

 

 

 

Closing the fan cover

Fan cover

Rib screws

*    Attach fan cover.

*    Screw in the rib screws (3x) of the fan cover.