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Help needed - Kontronik fun 480 & gear box


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taggarc

I recently acquired a Kontronik Fun 480.  It has a number of problems that i need  to try and resolve so looking for some tips / helpful advice.

Wiring 

Firstly the wire covering is very damaged / exposed.  What would be the best way of repairing this ?  Could I get away with some heat shrink tubing (space looks tight and there is a lot of metal in the area ) or would I have to dismantle the motor and if so what is the best way of going about it (do i need any special tools and or the bits likely to spring out form everywhere) ?

Gearbox 

Secondly the gearbox was very sticky / not smooth so I took it off and gave it a bit of a clean.  However, the main problem seemed to be that the top of the gear box was not evenly joined to the side of the gearbox and whatever was used to join it spilled onto the groves of the inner gearbox side wall and as a result the gear box cogs where catching on it.  I have now managed to separate  the gearbox (bottom and top) but how do I best put it  back together (there are no threads for this bit so I assume it was held together by a joining compound). 

What is the best way to make sure the joining compound, if that was used before,  doesn't run down the inside and I have an even joint  all around the top and side of the gearbox (unlike last time)?  One of the pins for the cogs  also appears to be missing a washer - are these a specialist items or can they be obtained relatively easy ?  Finally what is the best thing to lube the gearbox with? 

Lots of questions I know,  but any help or advice would be greatly appreciated 

Thanks

taggarc

Kontronic fun 480.JPG

Kontronik wiring problem.JPG

Kontonik bottom of motor.JPG

Kontronic top of motor.JPG

Kontronik gearbox top and bottom.JPG

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Dick Whitehead

Long time since I used my Kontronik motors, but I would definitely try heat-shrink on the wires. They have a good enamel coating on the individual strands for insulation so the heat-shrink should be adequate.

I have never seen that part of the gearbox come apart, so can't really help with that bit, however I did find Kontronik were always helpful so I would contact their support and ask for advice https://www.kontronik.com/en/support/support.html

If you use WhatsApp you could include some of the photos.

Dick

 

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EssexBOF

Yes, as has been said Kontronik are very helpful and do a repair service as well, probably not cheap now with being outside EU.

I would take the 3.5connectors off and slide heat shrink over the existing braided covers. Two layers might be better than one.

I did have a 480, come apart on a launch, some years ago(wondered why it had stopped!!)  fortunately all the gears, needle roller bearings etc were lying in the fuselage, so was able to assemble it up, using Loctite Screw Lock on assembly. 

Clean all the old gunge off the cover, then reassemble with Loctite Screw Lock or Bearing Lock. Apply the Loctite to the half that has the pins for the gears to slide onto, so that when you slide the two parts together, any excess Loctite is pushed to the outside of motor. Do not use excessive amount of Loctite.

Bit of an aside I know, but was introduced to Loctite products some 50 + years ago now, by a bit of an eccentric employer, in fitting bearings into the halves of an assembly. Machined the housings so as there was approx .002-3", clearance on the bearing housing. Bearing assembled on the shaft that they would run on, then slid into the housings. check to make sure shaft rotated smoothly with no binding. Left to cure, brilliant better than all that boring out to get an interference fit on the bearings, then getting the shaft fit well.

Also great for making extended drills, by attaching a rod to the drill, by turning end of drill down to fit a hole to suit in extension rod, with again .002-3" / .1mm clearance where the two parts join together. Loctite together. You can heat the join up, if you want to disassemble to us as was.

Brian

BARCS 230

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tonym

I've got one of those somewhere - here's the 'manual'. Click the images to make bigger and maybe to download them full size.

IMG_20210218_165728.thumb.jpg.bceced9e89216bbfd08e04c39c384d85.jpg
IMG_20210218_165758.thumb.jpg.e6874f6de2b6bfc7a95c8d86a6f7dae3.jpg

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taggarc

Well what can I say absolutely fantastic info and tips  (also tried to find the manual before and failed).    Thank you everybody. 

I note that the manual says: "Caution - the cables of the motor are the original winding of the motor and therefore not solderable - do not cut them "

Does this mean that I should not desolder and resolder the bullets when fitting the heat shrink or should it be okay as I do not intend to cut them but only solder, where they were soldered before ?

I take it there is no good reason for one of the pins not to have a washer so will have to try and source something - they look ultra thin!

Also what would be the best lubricant to use on the gear box ?

Thanks

Taggarc

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Dick Whitehead

No problem re-soldering where they were soldered before as the enamel coating has already been removed from the wires at that point. However if you cut the wires you have to remove the enamel before soldering and that is a devil of a job - people who have tried it usually end up spending hours scraping it off each individual strand!

For grease I would definitely ask Kontronik for advice, but I have used CRC multi Grease in some gearboxes and it seems to work. I got mine from RS, but cheaper sources may be available.  https://uk.rs-online.com/web/p/greases/0174182/

Dick

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f3fman

I don't think you need to unsolder the bullets, just find heatshrink large enough to go over them, it doesn't matter if it doesn't shrink all the way down to be tight on the wires as you are just insulating them from the others.  🙂

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Kluber Isoflex NBU 15 is regularly recommended for gearboxes but it's not cheap. You don't need to use lots BTW, use a tooth pick to work small amounts in to the teeth, excess grease tends to find its way out.....Here's a post about GB assembly I saved years ago for future reference, basically clean everything then clean again before greasing  https://www.rcgroups.com/forums/showpost.php?p=18807624&postcount=349

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taggarc

Guys thanks for all the info on grease (wow the NBU15 certainly isn't cheap).   However, it looks like I have an additional problem having trawled through all the RC Groups posts on Kontronik gear boxes (thanks to Feefo's link above) and that is a potential exploding gearbox . 

 https://www.rcgroups.com/forums/showthread.php?1475513-Exploded-Kontronik-gearbox

Seems in addition to one of the small spacers / washers on the three rods,  I need a "rub plate" or  "gear retainer washer" to keep the needle bearings in place.  Apparently it is a stainless steel washer with the following dimensions:  23.75mm OD,12.10mm ID, 0.2mm thick.

Picture here of it in Feefo's link above.  

I don't suppose anybody has one of these or a knackered Kontronik fun gearbox or even a good gearbox from a knackered motor which I could purchase ?

Thanks

Taggarc

Planet retaining washer.jpg

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Hi there, sorry only just seen this post, you're had a lot of good advice and I can't add anything but if you can't fix it l have a Kontronic  BL 480 137 with the 5.2 gearbox it's been used but is in good condition excellent combination but too heavy for what I'm flying now. £100 posted. If you don't like it when you get it send it back for a full refund. I'm in hospital at the moment, probably for another week so I can't do anything right now  but it may give you something to think about. Rayg

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EssexBOF
3 hours ago, Rayg said:

Hi there, sorry only just seen this post, you're had a lot of good advice and I can't add anything but if you can't fix it l have a Kontronic  BL 480 137 with the 5.2 gearbox it's been used but is in good condition excellent combination but too heavy for what I'm flying now. £100 posted. If you don't like it when you get it send it back for a full refund. I'm in hospital at the moment, probably for another week so I can't do anything right now  but it may give you something to think about. Rayg

Sorry to hear you are in hospital, Ray. get well soon.

Brian

 

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Jef Ott

As Brian says above... Get well soon Ray. 


Think I've still got a new one knocking about too, if anyone else needs one.

 

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On 20/02/2021 at 16:41, taggarc said:

Guys thanks for all the info on grease (wow the NBU15 certainly isn't cheap).   However, it looks like I have an additional problem having trawled through all the RC Groups posts on Kontronik gear boxes (thanks to Feefo's link above) and that is a potential exploding gearbox . 

 https://www.rcgroups.com/forums/showthread.php?1475513-Exploded-Kontronik-gearbox

Seems in addition to one of the small spacers / washers on the three rods,  I need a "rub plate" or  "gear retainer washer" to keep the needle bearings in place.  Apparently it is a stainless steel washer with the following dimensions:  23.75mm OD,12.10mm ID, 0.2mm thick.

Picture here of it in Feefo's link above.  

I don't suppose anybody has one of these or a knackered Kontronik fun gearbox or even a good gearbox from a knackered motor which I could purchase ?

Thanks

Taggarc

Planet retaining washer.jpg

Best bet would be contact Kontronic, I'd hope their customer service would stretch to sending the part out with minimal cost

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taggarc

Will give Kontronik a call over the next few days and let you know how I get on.  Once again thanks for all the help and advice .  Taggarc

 

 

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