Publication Number: 8/04 TSplus Modular Transfer Systems ... · • Maintenance Provides information on preventive maintenance. • Repair Gives step-by-step procedures for re-placing

Installation, Operation and Maintenance

IndustrialHydraulics

Electric Drivesand Controls

Linear Motion andAssembly Technologies

ServiceAutomation

MobileHydraulicsPneumatics

TSplus Modular Transfer SystemsLift-Transfer UnitModel EQ2/U

Publication Number:8981 500 326 8/04

TSplusLinear Motion and Assembly Technologies 8981 500 326 8/04

1

Bosch Rexroth Corp.2

Table of Contents

Module WarrantyBOSCH REXROTH CORPORATION warrants to the original pur-chaser the modules manufactured by us to be free from defects inmaterials and workmanship under normal use and service. Our obliga-tion under this warranty shall be limited to the repair or exchange ofany part or parts which may thus prove defective under normal useand service within one (1) year from date of installation by the originalpurchaser. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALLOTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDINGTHE WARRANTY OF MERCHANTABILITY OR FITNESS FOR USE,AND WE NEITHER MAKE NOR AUTHORIZE ANY OTHER PER-SON TO MAKE FOR US, ANY WARRANTY IN CONNECTION WITHTHE SALE.

This warranty shall not apply to the modules or any part thereof thathas been subject to accident, negligence, alteration, disassembly,abuse, or misuse after delivery by us. The term “Original Purchaser”,as used in this warranty, shall be deemed to mean the customer towhom the modules were originally sold.

Our obligation under this warranty is limited to the modules only, andexcludes wear items, such as belts, etc., and we may not be respon-sible for system concept, design, engineering, or function beyond this.

All rights are held by ROBERT BOSCH GMBH and BOSCH REXROTHCORPORATION, also regarding patent claims. We retain all powers ofdisposition, such as for copying and/or for passing-on to third parties. Wereserve the right to make technical changes at any time without no-tice. Errors and omissions excepted.

© 2004, Bosch Rexroth Corporation

Important Safety Information! ....................................................... 3

Introduction ....................................................................................... 4

Design and Detailed Description ................................................ 5

Application and Function ............................................................... 6

Technical Data .................................................................................. 7

Module Installation .......................................................................... 8

Using T-bolts and T-Nuts ........................................................... 8

Attach LTU to Conveyor Section ............................................. 8

Mounting Proximity Switch ....................................................... 9

Set Belt Tension ........................................................................ 10

Connect the Motor Wiring ...................................................... 10

LiabilityIn no event can the manufacturer accept warranty claims or liability claimsfor damages resulting from improper use or misuse of the equipment or asa result of changes made to the equipment other than those authorized bythe manufacturer. The manufacturer will accept no claim in which non-original spare parts have been used.

Environmental ProtectionAlways dispose of worn, damaged or obsolete parts in a responsible man-ner. Some components, such as gearboxes, contain lubricating oil whichcan pollute the environment. It is the user’s responsibility to dispose of allhazardous material within the components following all local, state andfederal guidelines.

Wiring for CE Applications ..................................................... 11

Pneumatic Connections ..........................................................12

Lower Guard Installation ......................................................... 14

Operating Instructions ................................................................. 15

Maintenance ...................................................................................15

Repair ...............................................................................................16

Replacing the Toothed Belt .................................................... 16

Replacing the Toothed Belt Drive Pulley ............................. 17

Replacing the Motor ................................................................. 18

Replacing the Gearbox ............................................................18

Replacing the Pneumatic Lift Cylinder ................................19

Bosch Rexroth Corp.Linear Motion and Assembly Technologies8981 500 326 8/04 TSplus 3

SAFETY FIRST!Important safety information is containedthroughout this manual to alert you to po-tentially dangerous situations and help pre-vent accidental injury and propertydamage.

The safety warning symbol above has beenincluded to warn you of hazards that canhurt or kill you and others, and/or causeserious damage to the equipment andother property. In addition, the followingsafety alert words are used:

DANGERMeans that you or others will beseriously or fatally injured if instructionsare not followed.

WARNING! Means that you or others may beseriously or fatally injured if instructionsare not followed.

CAUTION! Means that you or others may be injuredif instructions are not followed.

Important Safety Information!

IMPORTANT: This manual must bereviewed with all equipment operatorsas part of your operator trainingprogram!

Material Hazards:

Some components, such as gearboxes,contain lubricants or other materials that canrepresent a potential health hazard ifhandled, stored, or disposed of improperly.

Please contact Bosch for copies of theMaterial Safety Data Sheets (MSDS) for thelubricating oil used in gearboxes and otherpotentially hazardous materials.

Review All Safety Information:

Please review the safety information in-cluded on this page and throughout thismanual with all installers, operators, andmaintenance personnel of this equipment.

Please read all assembly, and maintenanceinstructions carefully before beginning set-up of the components in this document.Where appropriate, warning symbols have been included in this publication toalert you of potential or impending danger.

• Be sure to read and observe all safetywarnings in this document as well asthose attached to the individual mod-ules. Failure to do so could result inpotential risks to your health and safetyas well as those around you.

• Covers and guards have been designedto eliminate pinch points and exposureto moving chains and gears. DO NOToperate the conveyor or any of the othercomponents in the system with theguards removed. Serious injury may re-sult!

• All set-up maintenance and repair workshould be performed only by properlytrained, qualified personnel. All opera-tors must be properly trained in the useof this equipment.

• A qualified electrician must make all elec-trical connections when wiring the com-ponents installed in the TSplus system.Be sure to follow all local, state and fed-eral regulations when installing electri-cal devices of any type. The customerassumes responsibility for the controlsystem, and must provide an EMER-GENCY-OFF SWITCH or switches forall workstation operators to meet all ap-plicable industry and OSHA require-ments. In general, emergency-offswitches must be present at easily ac-cessible locations for all operators ofthe installed TSplus conveyor system.

• All power supplies must be LOCKEDOUT before beginning maintenance orrepair work of any type on the conveyorsystem. Proper LOCK OUT proceduresinclude the identification of the lockedout power supply with a tag to preventthe accidental restoration of power.

• TSplus pneumatic components are de-signed to operate in a range of 4–6 Bar(58–87 psi). It is the users responsibil-ity to install a filtered, regulated air sup-ply to limit the pressure to thatrecommended by the manufacturer.Before beginning any maintenance orrepair, bleed off the pressure lines toall components to prevent unexpectedor accidental movement of a systemcomponent which could result in per-sonal injury.

• TSplus drives, returns and conveyor sec-tions and components are designed totransport Bosch WT2, WT2/A, WT2/A-H workpiece pallets. Proper usageis defined as the transport and posi-tioning of parts and assemblies via theworkpiece pallet and fixture during theassembly process. In no instancesshould the pallet payload, the down-ward force applied to the pallet, or thetotal load carrying capacity of the en-tire system be exceeded. Exceedingpublished specifications will result inpremature wear or system failure andmay cause damage to the motor, gear-box, roller chain, seals and other com-ponents.

• CAUTION! Do not operate or work nearmechanical equipment when wearingloose clothing. Moving componentssuch as roller chain, drive belts, driveshafts and pallets can snag long belts,scarves, ties and other loose fitting gar-ments, pull the worker into the equip-ment and cause serious, or in extremecases, life threatening injury.

• CAUTION! Operators having long hairmust wear appropriate head protection(hair nets, hats, and hair caps) to mini-mize the risk associated with workingnear moving machinery. Hanging haircan get caught in moving componentssuch as roller chain, drive belts, driveshafts and pallets, pull the worker intothe equipment and cause serious, orin extreme cases, life threatening injury.

SAVE THESE INSTRUCTIONS

WARNING!


1


Introduction

Like all Bosch flexible assembly systems,TSplus is constructed solely from standard-ized modules that are precisely matchedto each other. One important benefit of thismodular design is that you can interlinkmanual and automatic work stations freely,making TSplus suitable for virtually anyassembly task. The EQ2/U Lift Transfer Unit(LTU) module allows you to transfer pal-lets laterally off of the main conveyor line.

NOTE: Accumulation is not permitted onthe EQ2/U Lift Transfer Unit!

About this manualThe manual is divided into the followingsections to make it easier to use:

• Design and Detailed Description Supplies an overview of the compo-nents that make up the EQ2/U. Thissection will familiarize you with the mod-ule.

• Application and Function Gives general information about theEQ2/U Lift Transfer Unit.

• Technical Data Provides the most important technicalspecifications.

• Assembly Lists step-by-step instruction for install-ing the EQ2/U.

• Initial Start-up Describes the final procedures for get-ting the EQ2/U up and running.

• Maintenance Provides information on preventivemaintenance.

• Repair Gives step-by-step procedures for re-placing any parts subjected to wear.

This manual describes the primary compo-nents that make up the EQ2/U Lift Trans-fer Unit (refer to page 5 for a descriptionof primary components and their functions).

Other TSplus modules are available andvary according to the configuration of thesystem. These modules are described inseparate manuals and include the follow-ing:

• Transverse Conveyor Sections

• Drives, Returns, and Conveyor Sections

• Cushioned and Standard Stop Gates,Rockers

• Proximity Switch Mounting Kits

• Accumulation Control Kits

• Lift-Position Units

• Lift-Rotate Units

• Curve Modules

• Vertical Transfer Units

Contact Rexroth for information on theseand any other modules for flexible assem-bly.

If this module was ordered as CE compli-ant, please contact our applications engi-neering department for a copy of the latestmanufacturer’s CE declaration if required.


Design and Detailed Description

The EQ2/U includes a drive motor to powerthe toothed belts, one spring centered 3-position pneumatic cylinder, stop bar/guidebar, protective covers, pneumatic connec-tions and mounting hardware.

A proximity switch mounting bracket is alsoincluded. Due to the stroke, all three posi-tions may not be sensed, as three proxim-ity switches will not fit into the spaceavailable. It is recommended that the cen-ter “pallet stop position” be sensed and thesignal lost on the up and down strokes. Theproximity switch mounting bracket can alsobe ordered separately under part number:3842 311 894.

In the EQ2/U (1 on Fig. 1), the motor andgearbox power the toothed belt conveyorvia the belt drive gears. A double actingpneumatic cylinder on the LTU may be con-figured to lower the toothed belt convey-ors below the transport surface to allowpallet pass-through, or raise the pallet onthe toothed belt conveyors above the trans-port surface. In the raised position, thetoothed belts transfer the pallet across atrack roller section or transverse conveyoronto the receiving LTU. The pneumatic cyl-inders on the receiving LTU then exhaustand lower the pallet to the transport sur-face of the parallel line. A protective cover(2) protects the mechanism of the LTU fromdirt and damage and helps prevent acci-dental injury. Proximity switches may bemounted to detect raised or lowered sta-tus of the LTU. The EQ2/U includes allmounting hardware and a pneumatic instal-lation kit (3) which includes flow controlvalves, push-lock connectors, and a muf-fler.

CAUTION! DO NOT operate theEQ2/U with any of the protective cov-ers removed! Serious injury may resultif the EQ2/U is operated withoutguards!

4x

1) rectangular opening with B =160mmL

3

Figure 1


1


The EQ2/U Lift Transfer Unit (LTU) is used to transfer pal-lets perpendicularly off the conveyor. It is used primarily at“corners” and “intersections”, but can also be used for pal-let routing changes.

“Corner Transfer” requires LTU operation in the “Pallet Stop”and “Transfer” positions as shown.

“Intersection Transfer” requires LTU operations in the “PalletStop”, “Transfer” and “Clear” positions as shown. Intersec-tion Transfer permits the pallet to be directed off the mainline or allows the pallet to pass through depending on theprocess requirement.

Application and Function

“Corner Transfer”

Optional Cushioned

Stop

EQ 2/U

RockerStop

“IntersectionTransfer”

Raised“Transfer”Position

Centered“Pallet Stop”

Position

Lowered“Clear”Position

10 mm1 mm11 mm

TransportLevel

BL 160 shown

The LTU lift plate is powered up and down by a pneumatic cylinder.In the spring centered, “Pallet Stop” position, the LTU belts are lo-cated 1 mm below the bottom of the pallet. A stop bar mounted tothe lift plate may be used to stop pallets on the LTU, or inverted sopallets pass through freely. An optional cushioned stop may be in-stalled when pallet payloads exceed 30 kg or with transport speedsof 12 m/min or greater.

The LTU is raised to the “Transfer Position” by applying air pressureto the bottom of the cylinder. This lifts the LTU to a position 10 mmabove the nominal conveyor height. As the LTU rises, the LTU beltsengage the pallet and directs (or accepts) the pallet.

The LTU is lowered to the “Clear Position” by applying air pressureto the top of the cylinder. This pushes the LTU down to a position 11mm below the nominal conveyor height. Use the lowered positionwhen it is required to allow pallet pass through on the main con-veyor at spur lines and test stations for example.

Track Rollers

or Transverse Conveyor

Pallet Flow

Receiving Lift Transfer

Unit

Sending Lift

Transfer Unit

In operation, a pallet transferring from one parallel line to anadjacent line requires the use of a sending EQ2/U and a re-ceiving EQ2/U located at each end of a set of track rollers ora transverse conveyor.

The sending LTU waits in “Pallet Stop” mode below the trans-port surface level until a pallet passes over the LTU and isstopped by the stop rail or a cushioned stop triggering a prox-imity sensor that activates the LTU. The pneumatic cylinders inthe LTU then energize, lifting the pallet off the main line, acrossthe non-powered track rollers or powered transverse conveyor,and onto the waiting LTU. The waiting LTU then lowers thepallet back to the transport surface of the parallel line.


Technical Data

BQ

BQ

+44

BL -30

BL

5*

7

21

80 90

BQ + 30

450

2121

Str

oke

Str

oke

Protectivecover

Transverseconveyor transport

direction

Long

itudi

nal

conv

eyor

tran

spor

tdi

rect

ion

Top of Transportmedia

BL2+3.5

BL2+12.5

60

160 240 320 400 480

160 • • • • •240 • • • • •320 • • • • •400 • • • •

Transfer Width, BQ

EQ2/U Available Sizes

Tran

sfer

Len

gth,

BL

N/A

Nominal belt speed = 6, 9, 12, or 18 m/minLoad Capacity = 30 kgMotor rated power = .12 HPMotor RPM @ 50 Hz = 1400Motor RPM @ 60 Hz = 1700Motor electrical specifications = see motor data plateAir pressure = 4-8 barCylinder diameter = 50 mmCylinder stroke = 21 mmAir fittings = 8 mm (5/16 ) push-lock

Nom.M/min

691218

HP.12.12.12.12

208/60.58 .58 .58 .58

240/60.58 .58 .58 .58

380/50.43 .43 .43 .43

415/50.38 .38 .38 .38

480/60.25 .25 .25 .25

575/60.34 .34 .34 .34

Full Load Amps @Actual Speed

50 Hz5.6 8.3 10.5 21.0

60 Hz6.8 10.1 12.7 19.1

NOTE: Electrical data for reference only. Refer to motor data plate for actualamperage ratings


1


Module Installation

Using T-Bolts and T-NutsThe EQ2/U, like virtually all Bosch con-veyor modules, attaches to T-slots in theconveyor profile with T-bolt or T-nut fasten-ers. (Fig. 3). Simply insert the T-bolt intoslot (A), and tighten down the hex nut. Asit tightens, it will turn the T-bolt 90° in theslot (B), creating a friction lock (C). Thesame principle applies to T-nuts. The maxi-mum allowable torque is 25 Nm (18.5 ft-lbs).

ASSEMBLY TIP: T-Bolts also have a markon the end of the threaded shaft that willbe perpendicular to the T-slot when the T-Bolt is in its locked position.

Figure 3

Attach LTU to Conveyor Section(Fig. 4 and 5)

1 Mark the location on the conveyor linewhere the LTU is to be installed.

2 Remove center plate guard cover.

3 Loosely mount the LTU mounting brack-ets to the inside T-slots on the conveyorline using T-bolts and flange nuts onunits with BL=240 or greater.

4 Lower EQ2/U from above onto the twomounting brackets.

5 Secure the LTU to the mounting bracketwith 2 socket head cap screws and 2flange nuts.

NOTE: On units with BL =160, mount thebase plate of the LTU to the bottom of theconveyor profile using T-bolts and flangenuts.

6 Check LTU alignment (Fig. 5), and ad-just position in conveyor system as re-quired.

7 Refer to Fig. 4 and tighten the M8 flangenuts in the mounting brackets andmounting plate to 25 Nm (19 lb-ft).

8 Reinstall the center plate guard cover.

B L = 240mm shown

BL

7

Figure 4

B L = 160mm

A

B

C

Mark


Track Rollers

or TransverseConveyor

Pallet Flow

Straight Edge

Receiving Lift

Transfer Unit

Sending Lift

Transfer Unit

Figure 5

BL = 160 BL 240

INSET

Figure 6

Mounting Proximity Switch(Fig. 6)

NOTE: It is recommended that the center“pallet stop” position be sensed and thesignal lost on the up and down stroke.

Refer to INSET “A” and install a proximityswitch (not supplied) in the proximity switchmounting bracket. Adjust the sensing dis-tance to 1mm.

Refer to Chapter 16 in the TSplus catalogfor available proximity switches.

Module Installation

NOTE: Use a straightedge to be sure thatthe Lift Transfer Units and track rollers arein perfect alignment from side-to-side, asshown in Fig. 5. This is critical for pallettransfer.


1


Set Belt Tension (Fig. 7)

NOTE: Incorrect toothed belt tension canlead to premature belt failure! Alwayscheck toothed belt tension prior to initialoperation!

Check the tension by moving the plain flatwashers (2) under the hex nuts on theguide rods. If the washers cannot bemoved set the belt tension as describedin the following steps.

Remove lock nuts (3). Turn hex nut (1) inor out until the plain flat washer (2) is justloose enough to turn around the guideshaft. Reinstall the lock nuts.

Figure 7

Connect the Motor Wiring(Fig. 8)

For CE applications, refer to the next pagefor instructions on installing and connect-ing the terminal block.

NOTE: All electrical wiring must be con-nected by a qualified electrician.

Refer to the motor data plate and the sche-matic in Fig. 8 and connect the motor to apower supply.

To avoid damage to the connecting cable,position the terminal box cap so that thecable can be inserted (A) from the direc-tion of the fan housing (B).

Briefly supply power to the motor to checkfor correct motor rotation. Reverse connec-tions in terminal box to change rotation.

NOTE: The customer assumes responsi-bility for the control system and must pro-vide an EMERGENCY OFF SWITCH forthe EQ2/U.

(Blk/Yel)T4

(Blk) T1

(Red/Yel) T6 T3 (Red)

T5 (Blu/Yel)

T2 (Blu)

Grn/Yel TR (Gnd)

L2

L3

L1

Delta Connection (Low Voltage)

T4

T1

T6T3

T5

T2

Grn/Yel TR (Gnd)

L2

L3

L1

“Y” Connection (High Voltage)

Blu

Red

Blk

Star Splice(Blk/Yel, Blu/YelRed/Yel)

MotorData Plate

A

B

Figure 8

Module Installation


Beige

Blue Orange#4-40 Screw#4-40 Screw

Electrical Connections for CEApplicationsThe optional terminal block (Fig. 9) is in-cluded when the EQ2/U is ordered as aCE compliant unit. Refer to the terminal boxmounting instructions included with the ter-minal box and the following steps for CEcompliant applications only.

Figure 9

Terminal Block Assembly Instructions

1 Attach the terminal box to the motor ac-cording to the mounting instructions in-cluded with the terminal box. SeeFig. 9.

2 Assemble the terminal block compo-nents to produce an assembly havingthe following order: support block,beige middle, blue middle block, orangeblock and beige end block. See Fig. 9.

3 Secure the terminal block assembly tothe terminal box using two #4-40screws in the position shown. Tightenin the range 3 to 5 lb-in.

5 For a “DELTA” connection, terminate themotor and line leads as follows:

a Insert the red-yellow motor lead, theblack motor lead and a line lead intothe blue middle block.

b Insert the black-yellow motor lead,the blue motor lead and a line leadinto the orange middle block.

c Insert the blue-yellow motor lead, thered motor lead and a line lead intothe beige end block near the motorlead exit.

Module Installation

6 For a “Y” connection, terminate the mo-tor and line leads as follows:

a Insert the black-yellow, and blue-yel-low and red-yellow motor leads intothe beige middle block opposite themotor lead exit.

b Insert the black motor lead and a linelead into the blue middle block.

c Insert the blue motor lead and a linelead into the orange middle block.

d Insert the red motor lead and a linelead into the beige end block nearthe motor lead exit.


1


5/3 Way Open Center Position Valve (Not Included)

D8

A B

1 2

Single Acting – Lift Only Operation

Muffler

1 2

C5/3 Way Open Center Position Valve (Not Included)

D8

D8

A B

1 2

1 2

C

Controls Flow of air from cylinder during lowering cycle. Increasing flow will cause the unit to lower at a faster rate. Adjust as needed for payload.Controls flow of air into cylinder for lift cycle. Increasing flow will cause the LTU to lift at a faster rate. Adjust as needed for payload.Controls the exhaust flow of air from cylinder as it is being lifted. Increasing air flow will cause the LTU to lift at a faster rate but also reduce end of stroke cushioning. Adjust as needed for payload.

Double Acting – Lift and Lower Operation

A

B

C

Module Installation

Pneumatic Connections (Fig.10 and Fig. 11)

NOTE: Use a 5/3 way open center posi-tion control valve (not included) to directairflow to the module. A 2-way valve willnot work because the center position islost and the upward flow cannot be con-trolled.

The EQ2/U Lift Transfer Unit must be sup-plied with a filtered, regulated compressedair supply of 4–6 bar (58–87 psi). The cus-tomer must provide any necessary airpreparation equipment.

1 Refer to the schematics in Fig. 10 toconnect the lift cylinder for single act-ing “Lift Only” operation or double act-ing “Lift and Lower” operation.

Figure 10

NOTE: In end of line configurations wherepallets do not need to pass through theLTU, the EQ2/U can be set up for Lift Onlyoperation. The springs in the cylinders willreturn the LTU to the centered or “home”position.

CAUTION! Carefully check the dia-gram on the flow control valves againstthe pneumatic schematic to maintainproper air flow and module operation.

2 Remove the two plastic plugs from thelift cylinder on the EQ2/U. Connect the“A” and “B” flow controls and push-lockconnectors as shown in Fig. 11 to thelower cylinder fitting.

3 Connect the “C” flow control and muf-fler (pushlock connector for double act-

ing) to the upper cylinder fitting. Makethe required compressed air connec-tions using 8mm (5/16”) tubing to thepush-lock connectors.

NOTE: If a different air line size is used,the customer is responsible for installingthe necessary fittings.

4 Adjust the flow controls A, B, and C asdescribed in Fig. 10 to regulate lift andlower operation as determined by pal-let payload.


Module Installation

B

A

MufflerSingle Acting

Push-lock ConnectorDouble Acting

Push-lockConnector

or

C

Figure 11


1


Lower Guard Installation

CAUTION! The lower guard mustbe installed after all installation workhas been completed. Never operate theEQ2/U with any of the guards re-moved.

1 Using the sheet metal screws includedwith the guarding, pre-assemble the sixindividual sheet metal guards as shownin Fig. 12.

NOTE: Use the upper bore holes on thecover plate for 80 mm conveyor profiles.Use the lower bore holes for 100 mm con-veyor profiles.

2 Loosely install a T-nut and socket headcap screw in each of the 4 cornermounting tab holes.

3 Lift the guard into position as shown inFig. 13 making sure that no wires orpneumatic hoses are being pinched.

4 Attach the guard to the bottom T-slot inthe conveyor profile using the 4 T-nutsin the mounting tab holes

5 For EQ2/U units with a BL =160mm,fasten the pneumatic hose to the guardusing a 3mm diameter hole and a com-mercial hose clamp, Fig. 14. This willprevent damage to the hose caused bythe operation of the toothed belts.

80 mm Profiles100 mm Profiles

4x

5

"X"

Ø 3

Figure 12

Figure 13

Figure 14

Module Installation


The TSplus conveyor and EQ2/U LiftTransfer Unit is designed to transportRexroth WT2 workpiece pallets or WT2workpiece pallet frames with integrated fix-tures built into the pallet design. Since theconveyor is modular in design and part ofa larger operating assembly system, it isthe responsibility of the integrator or enduser to provide a control system and oper-ating procedures. For your safety, pleaseobserve the following guidelines when op-erating the conveyor:

Operating Instructions

WARNING!

• Use a qualified technician who is fa-miliar with the control system during theinitial start-up.

• In case of control system failure, DONOT attempt to catch or in any wayprevent a pallet from falling from theend of the conveyor. Use the emer-gency stop switch to halt conveyormovement!

• Do not operate or work near mechani-cal equipment when wearing looseclothing. Moving components such asroller chain, drive belts, drive shafts andpallets can snag long belts, scarves,ties and other loose fitting garments,pull the worker into the equipment andcause serious, or in extreme cases, lifethreatening injury.

• Operators having long hair must wearappropriate head protection (hair nets,hats, and hair caps) to minimize the riskassociated with working near movingmachinery. Hanging hair can getcaught in moving components such asroller chain, drive belts, drive shafts andpallets, pull the worker into the equip-ment and cause serious, or in extremecases, life threatening injury.

CAUTION!• KEEP HANDS CLEAR of movingconveyors and pallets. Pallet accumu-lation creates a crush hazard betweenpallets, stop gates, and guide rails. Acrush and pinch hazard exists betweenLift Position Units, Lift Transfer Units,and Lift Rotate Units. Assembly opera-tions should be performed ONLY whenthe workpiece pallet has come to acomplete stop.

• DO NOT perform pressing operationson a workpiece pallet without the useof a Lift Position Unit.

• DO NOT operate the conveyor or anyother components in the system withthe guards removed. It is the operator’sresponsibility to make sure that allguards, covers, and other safety equip-ment is in place before the system isput into operation.

Maintenance

WARNING! LOCK OUT all powersupplies and release pressure fromcompressed air lines before beginningmaintenance work of any type.

The gearbox and motor used in the TSplusconveyor are maintenance-free. The follow-ing cleaning and adjustment procedures,however, will help keep your conveyor inalmost new condition if performed on aregular basis.

1 Remove all dirt & grease. Wipe theconveyor clean of any excess grease,dirt or any foreign substances everymonth, and at the same time check theconveyor unit for wear. Replace anyparts showing signs of excess wear(see section titled “Repair.”)

2 Retighten all fasteners. Check all fas-tening elements for tightness, and re-tighten to 18 lb-ft (25 Nm), if necessary.

3 Lubricate the toothed belts. If the ap-plication permits, apply a thin coat ofNo. 10 machine oil to the toothed beltson a monthly basis to help prolong beltlife.

4 Check adjacent components. Makesure that idler rollers turn freely, that allcomponents are properly aligned andthat there are no obstructions.

5 Check the toothed belts and guidesfor wear. The toothed belts and guidesshould be checked for excessive wear.If belts have stretched or worn to thepoint where they do not fit tightly to thepulleys, or show tears, cracks, or othervisible damage, they should be re-placed. If guides are worn or damaged,they should be replaced. See page 10to adjust toothed belt tension.


1


Repair


Toothed belts can be changed without re-moving the EQ2/U from the conveyor sys-tem. Always replace toothed belts in pairsto maintain smooth pallet flow. Always usegenuine replacement belts from BoschRexroth

1 Remove the socket head cap screws,lockwashers and pallet guide from theside of the LTU as shown in Fig. 15.

2 Lift up on the gearmotor to reduce belttension.

3 Slide the toothed belt off the drive pul-ley and upper guide rollers.

4 Follow steps 1, 2 and 3 above and re-move the belt from the other side.

5 Apply a thin coat of No. 10 Machine oilto the new toothed belts.

6 Follow steps 3, 2, and 1 above and in-stall the new belts on the LTU. Tightenthe socket head cap screws to 4Nm.

7 Follow the instructions on Page 10 andtension the new belts

CAUTION! Replace the LowerGuard if you removed it to gain accessto the gearmotor.

Replacing the Toothed Belt(Fig. 15)

EQ 2/U, B = 240mm illustratedL

4

5

Figure 15



Toothed belt pulleys can be changed with-out removing the EQ2/U from the conveyorsystem. Always use genuine replacementparts from Bosch Rexroth

1 Lift up on the gearmotor as shown inFig. 16. In the following steps do notlet the gearmotor drop or the modulemay be damaged.

2 Remove the toothed belt from the drivepulley.

3 Remove the snap ring from end of thedrive shaft.

4 Slide the drive pulley off the drive shaft.Install the new drive pulley and reversethe steps above to complete installa-tion.

NOTE: Follow the steps on Page 10 andcheck the belt tension after replacing thedrive pulley


Replacing the Toothed BeltDrive Pulley (Fig. 16)

EQ 2/U, B = 240mm illustratedL

Figure 16


1



The motor can be changed without remov-ing the EQ2/U from the conveyor system.Always use genuine replacement partsfrom Bosch Rexroth.

• Be sure electrical supply is locked outand disconnect motor wiring.

• To remove the Electric Motor, removethe four M5 socket head cap screwsthat attach the motor to the gearbox.Slowly lower the motor from the gear-box once the screws have been re-moved.

• Apply anti-sieze compound to the newmotor shaft and attach the motor to thegearbox with the screws you removedearlier. Reconnect electrical wiring.

NOTE: Check motor for correct rotationbefore putting the conveyor system backinto operation.


Replacing the Motor (Fig. 17)

Repair

LEQ 2/U, B = 240mm illustrated

SW4M5 (4x)

SW5M6 (4x)

Apply Anti-seize6


Replacing the Motor (Fig. 17)

The gearbox can be changed without re-moving the EQ2/U from the conveyor sys-tem. Always use genuine replacementparts from Bosch Rexroth.

1 Be sure electrical supply is locked outand disconnect motor wiring. Removethe snap ring from the end of the driveshaft.


Replacing the Gearbox (Fig. 17)

2 On the opposite end, slide the driveshaft and pulley out of the gearbox.

3 Remove the four socket head capscrews that hold the gearbox to the LiftTransfer Unit. Slowly lower the gearboxand motor out of the LTU.

4 Remove the 4 socket head cap screwsthat attach the motor to the gearbox ifchanging just the gearbox.

5 Apply anti-sieze compound to the mo-tor shaft and drive shaft and attach thenew gearbox to the motor.

6 Reverse steps 4, 3, 2, and 1 to installthe new gearmotor assembly into theEQ2/U.



Figure 17


Repair


Replacing the Pneumatic LiftCylinder (Fig. 18)

The pneumatic cylinder block should onlybe replaced as a unit. Always use genuinereplacement parts from Bosch Rexroth.

1 Be sure electrical supply is locked outand disconnect motor wiring and pneu-matic connections. Remove the EQ2/U from the conveyor system. Positionthe unit on a bench as shown and re-move the 4 socket head cap screwsthat hold the gearmotor assembly to themounting plate. Remove the gearmo-tor.

2 Remove the 4 hex nuts and lift off thegearmotor mounting plate and springs.

3 Turn the unit over as shown and removethe cover plate.

4 Remove the snap ring and flat washerfrom the end of the lift cylinder.

5 Turn the unit over as shown and removethe socket head cap screws that holdthe mounting plate to the pneumatic cyl-inder.

6 Carefully remove the springs and wash-ers from the lift cylinder.

7 Install the new cylinder by reversingsteps 6 to 1 above.



SW13

SW5(4x)

SW4(4x)

SW4(4x)

Figure 18


1


Bosch Rexroth CorporationLinear Motion andAssembly Technologies816 E. Third StreetBuchanan, MI 49107Telephone (269) 695-0151Facsimile (269) 695-5363www.boschrexroth-us.com

Printed in the United States8981 500 326 8/04

Documents

Publication Number: 8/04 TSplus Modular Transfer Systems ... · • Maintenance Provides information on preventive maintenance. • Repair Gives step-by-step procedures for re-placing