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Bosch rexroth BS 2/G-250, Assembly Instructions Manual

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Bosch rexroth BS 2/G-250 Assembly Instructions Manual Download Page 9

 

Safety instructions 9/84

 

3 842 564 989/2022-06, MIT: HQ 2/G-H, BS 2/G-250, 

Bosch Rexroth AG

2.3  Improper use

Any use other than that described in the section "Intended use" is considered 
improper and is not permitted.
Bosch Rexroth AG is not liable for any damage resulting from improper use. 
The user alone bears any risks associated with improper use.
The following foreseeable misuses also constitute improper use:

 

• Transporting goods other than those specified.

 

• Using the product without a safeguard (provided by the customer).

 

• Using the product in accumulation operation.

 

• Transporting people on the product or transported material.

 

• Climbing onto the product.  

– The product is not accessible.

 

• Private use.

2.4  Personnel qualifications

The activities described in this document require basic knowledge of mechanical, 
electrical and pneumatic systems, as well as familiarity with the corresponding 
technical terms. Additional knowledge regarding the use of lifting gear and 
corresponding slings is required for transporting and handling the product. 
To ensure safe use, these activities should therefore only be performed by qualified 
personnel or by an instructed person acting under the direction of such a person.
"Qualified personnel" refers to those who can recognize potential hazards and 
take appropriate safety measures based on their technical training, knowledge, 
experience, and understanding of the relevant regulations pertaining to the work 
being performed. Qualified personnel must comply with the relevant technical 
regulations and have the necessary expertise.

Bosch Rexroth offers training support for specialized fields. You can find an 
overview of the training content online at: http://www.boschrexroth.de/didactic

2.5  General safety instructions

 

• Observe the applicable accident prevention and environmental protection 

regulations.

 

• Observe the safety rules and regulations of the country in which the product is 

being used.

 

• Only use Rexroth products that are in proper working order.

 

• Heed all the notices on the product.

 

• Persons who assemble, operate, disassemble or maintain Rexroth products 

should not be under the influence of alcohol, drugs or medication that may affect 
their ability to respond.

EN

GLISH

Summary of Contents for rexroth BS 2/G-250

Page 1: ...ctions 3 842 564 989 2022 06 Replaces ENGLISH HQ 2 G H BS 2 G 250 HQ 2 C H Lift transverse unit belt section 3 842 996 370 HQ 2 G H 3 842 999 022 BS 2 G 250 3 842 999 002 HQ 2 C H HQ 2 C H HQ 2 G H 564 988 00 ENGLISH ...

Page 2: ...argar del archivo de medios www boschrexroth com mediadirectory En el buscador en la parte superior derecha donde pone Search introduzca 3 842 564 992 a continuación haga clic en Search PT BR Este manual de montagem está disponível nos idiomas especificados aqui Outros idiomas mediante pedido Como versão impressa impressão ou como arquivo PDF mídia para download do índice de mídias www boschrexrot...

Page 3: ...3 5 1 1 Using of lift transverse unit 13 5 1 2 Version of lift transverse unit 13 5 2 Specifications for BS 2 G 250 14 5 2 1 Use of BS 2 G 250 belt section 14 5 2 2 Version of the BS 2 G 250 belt section 14 5 3 Product description HQ 2 G H and HQ 2 C H 15 5 4 Product description for BS 2 G 250 20 5 5 Identification of the product 21 6 Transport and storage 21 6 1 Transporting the product 21 6 2 St...

Page 4: ...ing the lifting speed 49 9 Operation 50 9 1 Information on operation 50 9 1 1 Wear 50 9 1 2 Measures to reduce wear 50 9 1 3 Loading the workpiece pallet 50 9 1 4 Environmental factors 51 10 Maintenance and repair 52 10 1 Cleaning and care 52 10 2 Inspection 53 10 2 1 Conveyor chain 53 10 2 2 Lift unit 53 10 3 Maintenance 53 10 3 1 Conveyor chain 54 10 3 2 Bearings 55 10 3 3 Gear 55 10 3 4 Motor 5...

Page 5: ...sal 74 14 Upgrading and modification 74 15 Troubleshooting 74 16 Technical data 75 16 1 Ambient conditions 75 16 2 Pneumatics 75 17 Appendix 76 17 1 Function plans 76 17 1 1 Implementation in transverse section TFE 1 77 17 1 2 Implementation in longitudinal section TFE 2 78 17 1 3 Outfeeding from longitudinal conveyor TFE 3 79 17 1 4 Infeeding to longitudinal conveyor TFE 4 80 ENGLISH ...

Page 6: ... the product if he documentation marked with the book symbol is available and you have understood and followed the instructions in it Table 1 Required and supplementary documentation Title Document number Employee safety training 1 3 842 527 147 Declaration of Incorporation 1 3 842 358 415 BS 2 G 250 3 842 557 182 HQ 2 G H MTpro 1 with spare parts list 3 842 539 057 1 Download at www boschrexroth ...

Page 7: ...ng DANGER Indicates a hazardous situation that will result in serious injury or death if not avoided WARNING Indicates a hazardous situation that may result in serious injury or death if not avoided CAUTION Indicates a hazardous situation that may result in minor to moderate injury if not avoided NOTICE Property damage the product or the surrounding area could get damaged 1 3 2 Symbols The followi...

Page 8: ...pad 2 Safety instructions 2 1 About this section The product has been manufactured in accordance with the generally accepted rules of current technology Nevertheless there is a risk of personal injury and property damage if you do not read this section and follow the safety instructions in this document f Read this documentation carefully and completely before you start working with the product f ...

Page 9: ...nsporting and handling the product To ensure safe use these activities should therefore only be performed by qualified personnel or by an instructed person acting under the direction of such a person Qualified personnel refers to those who can recognize potential hazards and take appropriate safety measures based on their technical training knowledge experience and understanding of the relevant re...

Page 10: ... on Before commissioning make sure that all seals and plugs for the plug connectors are correctly installed and not damaged to prevent liquids and foreign bodies from entering the product Allow the product to acclimatize for a few hours prior to commissioning in order to prevent water condensation from forming in the housing Make sure that all electrical and pneumatic connections are either in use...

Page 11: ...tage Secure the system against being switched back on Dispose of the product in accordance with the regulations in your country 2 7 Personal protective equipment Appropriate protective clothing should be worn when handling using the product e g safety shoes close fitting clothing a hair net for long loose hair As the system owner or operator you are personally responsible for ensuring the use of a...

Page 12: ...ery includes the following HQ 2 G H HQ 2 C H 1 lift transverse unit HQ 2 G H HQ 2 C H Lateral guides Fastening material Pneumatic elements such as fittings throttle check valves etc Position monitoring kit 1 assembly instructions for HQ 2 G H BS 2 G 250 HQ 2 C H lift transverse unit belt section 1 installation declaration for lift transverse unit HQ 2 G H HQ 2 C H BS 2 G 250 1 BS 2 G 250 belt sect...

Page 13: ...g from the main section Infeeding to the main section 5 1 2 Version of lift transverse unit Extremely compact construction Suitable for tight spaces Pneumatic drive lifting electric drive transverse conveyor Maximum load see Technical data on Page 75 Conveyor medium HQ 2 G H Duplex chain roller chain HQ 2 C H Flat top chain For HQ 2 G H with BS 2 G H Only WT 2 with PE wear pads can be transported ...

Page 14: ... with two HQ 2 G H lift transverse units Transverse conveying of the WT 2 workpiece pallet as a dead end section of up to 2000 mm with reversible operation 5 2 2 Version of the BS 2 G 250 belt section Ready to use conveyor section Maximum section load see technical data on page 75 Conveyor medium Duplex chain roller chain Only for transporting WT 2 workpiece pallets with PE wear pad Suitable for r...

Page 15: ... M8 8x M8 x 20 8x 8 x M8 2 4x M8 4x 8x 8x M8 x 20 4x 2x 2x M8 8x M8 x 20 4x B B1 B2 FST 6 4 6x M6 x 35 6x M8 x 14 HQ shown here 480 x 640 mm infeeding version A Motor mounting M center standard A Motor mounting R right B Flat top chain HQ 2 C H B Duplex roller chain HQ 2 G H C Damper kit DA 2 100 H infeeding shown D Mounting bracket 4x E Mounting kit F Lateral guide stop G Position monitoring kit ...

Page 16: ...6 370 Load up to 240 kg 1 BS 2 BS 2 H BS 2 G 250 ST 2 ST 2 H WT 2 2 WT 2 F 2 WT 2 H 3 WT 2 F H 3 HQ 2 C H here 480 x 640 mm 3 842 999 002 Load up to 240 kg 1 BS 2 BS 2 H ST 2 ST 2 H WT 2 WT 2 F WT 2 H WT 2 F H 1 Note the maximum section load of the conveyor section see Technical data on page 75 2 Note the selection parameter wear pad In conjunction with the duplex chain the PE wear pad is required...

Page 17: ...t standard Motor mounting M left1 Outfeeding Infeeding Reversible operation Please note The main direction of transport of the lift transverse unit is always the same as the direction of rotation of the motor 1 The customer must switch to motor mounting M on left see section 7 6 1 HQ 2 G H with BS 2 G 250 HQ 2 C H Conversion to motor mounting M left by customer on page 25 ENGLISH ...

Page 18: ...6 Fig 4 564 988 12 S B MD 25 Nm SW13 MD 25 Nm SW13 MD 25 Nm SW13 MD 25 Nm SW13 HQ Possible installation of lateral guide S as a non damped stop B S Lateral guide mounted as a lateral guide B Lateral guide mounted as a non damped stop instead of a damper only makes sense with unloaded WTs ...

Page 19: ... 2 WT 2 F Any motor mounting Outfeeding Infeeding Reversible operation Fig 5 UM RS BS 2 G 250 HQ BS ST AS BS ST UM BS ST RS HQ HQ 2 G H HQ 2 C H AS BS ST Main transport direction HQ 2 G H HQ 2 C H bQ mm 480 640 800 1040 1200 bL mm 640 800 1040 1200 HQ 2 G H bQ x bL mm x mm 480 1200 x 640 1200 HQ 2 C H bQ x bL mm x mm 480 1200 x 640 1200 ENGLISH ...

Page 20: ...h AG MIT HQ 2 G H BS 2 G 250 3 842 564 989 2022 06 5 4 Product description for BS 2 G 250 Fig 6 B A b b 25 b 75 50 554 988 17 40 100 107 BS 2 G 250 belt section A Motor gear combination motor mounting R hanging B Duplex chain roller chain ...

Page 21: ...iently high bearing loads for product weight see delivery documents f Make sure the lifting straps are correctly fastened before lifting the product f Secure the product against tipping over when lifting f Make sure that no one but the operator is in the danger zone during lifting and lowering 6 2 Storing the product Only set the product down on a flat surface Protect the product from mechanical s...

Page 22: ...le Fig 8 HQ BS 2 G 250 attachment points for lifting F 2000 554 988 19 X X X X f Dispose of the packaging material in accordance with the applicable regulations in your country 7 2 Installation requirements f During installation be sure to maintain the ambient conditions specified in the Technical data see page 75 7 2 1 Installation position f Install the product level and plumb at right angles an...

Page 23: ...Required tools HQ Hex wrench SW13 Hex socket wrenches SW3 SW4 SW5 SW6 Posidriv screwdriver PZ2 Rubber mallet Spirit level 7 4 Required accessories for BS 2 G 250 Leg set for holding up the belt section 3 842 996 320 SZ 2 3 842 996 321 SZ 2 H 3 842 996 323 SZ 2 U H 3 842 996 325 SZ 2 T H Please note Support the belt section in the immediate vicinity of the drive and return unit The maximum distance...

Page 24: ...equired tightening torque Nm PH3 PZ2 Screwdrivers for cross head screws PZ Pozidriv screw driver size PH Phillips screw driver size gleitmo 585 K Lubricate lubricate with specific grease lubricant Fuchs Lubritech gleitmo 585 K www fuchs lubritech com The marked parts are not required for the described assembly Dispose of the parts or use them for other purposes 2 1 3 Graphical depiction of the ins...

Page 25: ...stomer Fig 9 564 988 20 1 1 7 7 B1 B B2 Conversion to motor mounting M left by customer 1 2 Please note only if necessary The customer must perform the conversion from motor mounting M right standard on delivery to motor mounting M left before installing the lift transverse unit B1 Flat top chain for HQ 2 C H B2 Duplex chain roller chain for HQ 2 G H 1 Remove the covers from the drive heads ENGLIS...

Page 26: ... 2 Alu aluminum Kst plastic A 2 Remove the belt section C1 with return unit Kst couplings D hexagonal shaft E and protective tube F 3 Disassemble the motor gearbox combination G the flanges J H K and the return unit Alu Kst 4 Rotate the flanges K H J by 180 and place the aluminum deflector Alu Kst on the new flange side The gear will stay aligned B 5 Assemble the motor gearbox combination G the fl...

Page 27: ...n of the mounting bracket Required accessories Mounting kit for HQ 2 G H and HQ 2 C H and BS 2 or ST 2 included in the scope of delivery 1 Mark the assembly position of the mounting bracket 2 Suspend the mounting brackets in the section profile 3 Insert the T bolts into the section profiles and gently pull on the flange nuts mounting bracket can still be moved ENGLISH ...

Page 28: ...e unit shown here using HQ 2 G H 480 x 640 mm as an example Please note Never use the drive shaft for lifting Use a lift aid to lift the product The positions indicated with an X in the drawing are used as lifting points for a round sling 1 Set the lift transverse unit in the section profile 2 After aligning the lift transverse unit tighten all mounting bracket screws Please note Use a workpiece p...

Page 29: ...n here using infeeding as an example Please note For use with WT 2 H WT 2 F H and HQ 2 G H or HQ 2 C H A Infeeding B Outfeeding Required accessories Up to 100 kg WT weight 1 Damper kit DA 2 100 H 3 842 998 745 Up to 250 kg WT weight 1 Damper kit DA 2 250 H 3 842 998 746 f Pre assemble the kit according to the infeeding A or outfeeding B function 1 For more information see the catalogue for the TS ...

Page 30: ...damper kit DA 2 H infeeding example DA 2 100 H Table 9 Dimensions for installation of the damper kit DA 2 H infeeding Track width in the longitudinal conveyor Inatalling HQ 2 G H or HQ 2 C H in BS 2 bL mm A mm B mm 480 359 180 640 519 260 800 679 340 1040 919 460 1200 1079 540 Please note For use with WT 2 H WT 2 F H and HQ 2 G H or HQ 2 C H Install the kit on the lift transverse unit Please note ...

Page 31: ... DA 2 H outfeeding example DA 2 250 H Table 10 Dimensions for installation of the damper kit DA 2 H outfeeding Track width in the longitudinal conveyor Inatalling HQ 2 G H or HQ 2 C H in BS 2 bL mm A mm B mm 480 359 149 5 640 519 229 5 800 679 309 5 1040 919 429 5 1200 1079 509 5 Please note For use with 1 WT 2 H WT 2 F H and HQ 2 G H or HQ 2 C H f Install the kit on the lift transverse unit Pleas...

Page 32: ...infeed Fig 16 564 988 27 MD 25 Nm SW13 SW5 MD 8 7 Nm bQ b L HQ 2 G H HQ 2 C H HQ 2 G H HQ 2 C H mounting DA 2 100 C damper infeed Please note For use with WT 2 WT 2 F and HQ 2 G H or HQ 2 C H Required accessories DA 2 100 C damper 3 842 525 734 f Install the damper on the center of the section profile to the lift transverse unit ...

Page 33: ...Fig 17 564 988 28 MD 25 Nm SW13 bQ b L HQ 2 G H HQ 2 C H HQ 2 G H HQ 2 C H installation of damper DA 2 150 E outfeeding Please note For use with WT 2 WT 2 F WT 2 H WT 2 F H and HQ 2 G H WT 2 H WT 2 F H and HQ 2 C H Required accessories DA 2 150 E damper 3 842 548 644 f Install the damper on the center of the lift transverse unit ENGLISH ...

Page 34: ...50 slide stop Table 11 Dimensions for installation of the VA 2 D 250 slide stop Track width in the longitudinal conveyor Inatalling HQ 2 G H or HQ 2 C H in BS 2 bL mm A mm B mm 640 519 237 800 679 317 1040 919 437 1200 1079 517 Please note For use with WT 2 H WT 2 F H and HQ 2 G H or HQ 2 C H Required accessories Installing the VA 2 D 250 slide stop kit 3 842 998 796 f Install the kit on the lift ...

Page 35: ...e 12 Possible installation of lateral guide S as a non damped stop A Motor mounting M Standard Motor mounting M left Any motor mounting Outfeeding A3 S2 A3 S2 S2 S2 A3 S2 A3 S2 S2 S2 A3 S2 A3 S2 S2 S2 Infeeding S2 S2 S2 S2 S2 S2 S2 S2 Reversible operation A3 S2 A3 S2 S2 S2 A3 S2 A3 S2 S2 S2 A3 S2 A3 S2 S2 S2 ENGLISH ...

Page 36: ... 25 Nm SW13 HQ 2 G H installation as a lateral guide S or as a non damped stop A Please note Always stop the loaded workpiece pallets with dampers Only ever use the lateral guides with unloaded workpiece pallets as a non damped stop A S Lateral guide mounted as a lateral guide S A Lateral guide mounted as a non damped stop A instead of a damper ...

Page 37: ...Bosch Rexroth AG Fig 20 564 988 38 bL 640 mm bL 640 mm 2 7 6 1 6 1 6 6 B1 B B B2 B1 B2 HQ position of the lateral guides f Mount the lateral guides as a lateral guide S or a non damped stop A B Flat top chain HQ 2 C H B Duplex chain roller chain HQ 2 G H ENGLISH ...

Page 38: ...on monitoring kit for HQ 2 G H and HQ 2 C H 3 842 567 133 Sensor IEC EN 60947 5 2 2004 3 842 558 990 1 Install the switching element for HQ 2 G H and HQ 2 C H 2 Install the retaining section and the bracket of the kit 3 Install the switch bracket to the profile 4 Install the sensor to stop Insert the switch into the switch bracket and adjust the switching distance 5 Set the switch brackets along t...

Page 39: ...ponent before assembling disassembling or connecting the product to the pneumatic system f Secure the system against being unintentionally switched on again For the compressed air and operating pressure specifications see page 75 Fig 22 X Y 564 988 40 HQ pneumatic connection Please note Connect the pneumatics at X and Y This charges the system more quickly and evenly The pneumatic hoses on all 4 p...

Page 40: ... 989 2022 06 Fig 23 564 988 41 D8 D8 D8 D8 5 3 4 2 1 HQ pneumatic circuit diagram Please note Approaching the central position f Lower to the bottom position f Then depressurize the valve middle switching position Built in springs lift the HQ to the central position ...

Page 41: ...25 Nm D BS 2 G 250 564 988 42 SZ 2 SZ 2 H SZ 2 SZ 2 H BS 2 G 250 installing the belt section on leg sets 1 2 1 Install the belt section on 2 to 4 leg sets Please note Install one leg set each in the immediate vicinity of the drive and return unit Install the leg sets under each of the cross connectors of the belt section Max distance between 2 leg sets 2000 mm ENGLISH ...

Page 42: ... 2 H BS 2 G 250 SZ 2 SZ 2 H 2 564 988 43 BS 2 G 250 installing the belt section on leg sets 2 2 2 Align the belt section flush horizontally and by height 3 Screw the belt section to the floor For each connection you will need 1x foundation bracket 3 842 146 815 1x dowel 3 842 526 560 2x T bolt 3 842 528 718 2x flange nut 3 842 345 081 f Install the motor see the installation instructions enclosed ...

Page 43: ...unting position of the motor gear combination Fig 26 SW10 2x M 8 7 Nm D A A A A 564 988 44 90 90 90 90 BS 2 G 250 mounting position of the motor gear combination 1 Remove the screws A 2 Pivot the motor gear combination or the gear motor around the drive axis in 90 intervals 3 Install the screws A ENGLISH ...

Page 44: ...n the motor nameplate see Fig 27 on page 45 Wire the motor either into a wye connection or a delta connection in accordance with the wiring diagrams see Fig 28 on page 45 and the wiring diagram in the terminal box The motor is fitted with a bimetal temperature monitoring switch potential free thermal contact 230 V AC 300 mA Wire the motor so that it is de energized when the switch is triggered Ins...

Page 45: ...ig 27 554 988 45 Motor nameplate example Fig 28 U1 1U1 1V1 1W1 1U1 1V1 1W1 2U1 2V1 2W1 2U1 2V1 2W1 1U2 1V2 1W2 1U2 1V2 1W2 V1 W1 U1 V1 W1 TW1 TW2 PE TW1 TW2 PE 554 988 46 T1 T2 PE T1 T2 PE Delta wye wiring diagrams Fig 29 554 988 47 Optional motor connection with plug AT S ENGLISH ...

Page 46: ...ip the transfer system with EMERGENCY STOP devices The surfaces of motors and gears can reach temperatures of over 65 C under certain load and operating conditions In these cases you must comply with the respective applicable accident prevention regulations UVV by taking appropriate constructive measures safety guards or by affixing displaying appropriate warning signs Make sure that all electrica...

Page 47: ... and workpiece pallet Trapping of limbs Shearing Danger zone is in work area or at transport speeds v 15 m min hazard should be removed with a safety measure e g guards 4 Between cross connector main section profile and workpiece pallet 5 Between HQ damper and workpiece pallet 6 Between front and back belt section profile stop gate pallet and workpiece pallet WT moves toward main belt 7 Between to...

Page 48: ...is required 3 Conveyor medium between running conveyor and stationary workpiece pallet e g during separation Trapping of limbs Crushing Do not reach into the system while it is running 4 Between workpiece pallets Body parts can be crushed Crushing Do not reach into the system while it is running In the work area or at transport speeds v 1m min a constructive solution e g separation of the workpiec...

Page 49: ... with protective devices in place These must be provided by the customer Fig 30 564 988 53 X Y HQ 2 G H adjusting the lifting speed Please note Mount the corresponding workpiece pallet WT load before setting the lifting speed During configuration aim at an even and smooth lifting movement of the HQ f Throttle the extract air evenly using both throttle check valves to adjust the speed of the liftin...

Page 50: ...ead to the premature breakdown of motors and gears If pneumatically activated components are overloaded it is not possible to guarantee their function 9 1 2 Measures to reduce wear The following obvious measures will reduce wear Switch off the conveyor section during line downtime e g during breaks at night and on weekends Do not select a higher speed for the conveyor section than that required fo...

Page 51: ...ounding area such as sand and silicates e g from construction as well as machining processes in the transfer system e g welding beads pumice dust glass shards chips waste parts etc Maintenance intervals should be significantly shortened under these circumstances Resistance to media and contamination does not mean that functional safety is guaranteed in every case Liquids that thicken as they evapo...

Page 52: ...rk Only inspect and adjust continuous conveyors that are in motion or operation when the protective equipment is in place Observe DIN EN ISO 13857 when you remove or replace protective equipment and or bypass safety equipment Test runs with open paneling should only be performed by a person with appropriate knowledge and experience using tip switches and if there is no possibility of interference ...

Page 53: ...sverse unit chain could be washed out For this see section 10 3 1 Conveyor chain on page 54 f Replace the conveyor chain when wear becomes visible at the latest however when it has increased in length by 3 see section 10 7 4 Replacing flat top chain on page 68 10 2 2 Lift unit Check the pneumatic connections regularly for leaks 10 3 Maintenance CAUTION Sudden movements falling workpiece pallets Ri...

Page 54: ...roller chain HQ 2 G H The chains are lubricated at delivery Lubricate the conveyor chain when restarting after longer downtimes and every 1000 h 564 988 54 BS 2 G 250 lubrication of the duplex chain roller chain Lubricate flat top chain HQ 2 C H The conveyor chain is delivered lubricated Grease the conveyor chain with 1 2 g oil m chain before the first start up then with 2 3 g oil m chain every 10...

Page 55: ...epend on the ambient and operating conditions 10 3 5 LU 2 automatic lubrication unit The LU 2 automatic lubrication unit lubricates the lift transverse unit chain while in operation The LU 2 automatic lubrication unit consists of the following components LU 2 lubrication unit 3 842 543 482 LC 2 oil container 3 842 543 469 Adapter kit AS 2 R 300 700 for HQ 2 C H 3 842 543 485 Adapter kit AS 2 C 100...

Page 56: ...LC 2 Set AS 2 R 300 700 Set AS 2 C 100 250 558 998 56 LU 2 automatic lubrication unit Please note Install the LU 2 either at the next closest cross connector in the section next to the HQ or on the underside of the section You install the adapters of the LU 2 automatic lubrication unit in the holes marked ...

Page 57: ...ex wrench SW13 Hex socket wrenches SW3 SW4 SW5 SW6 Posidriv screwdriver PZ2 Caliper 500 mm Rubber mallet Drift punch Required accessories For flat top chain Chain lock 3 842 535 333 Disassembly tool 8 981 010 510 for shortening trimming the chain Fig 33 8 981 010 510 3 842 551 234 564 988 57 Accessories for replacing the chain ENGLISH ...

Page 58: ...l motor mounting B External motor mounting 1 Remove the motor 2 Remove the protective cap on the new motor 3 Lubricate the drive shaft 4 Install the motor Please note The end faces of the motor and gear must be undamaged The gear hub comes lubricated with anti seize lubricant Do not tilt the motor and make sure it has the necessary clearance area Install the motor in the proper position terminal b...

Page 59: ... also be as in the chapter 7 6 on page 25 are carried out Required tools Hex wrenches SW8 SW10 1 Remove the motor 2 Remove the gear 3 Remove the plugs and insert them in the new gear 4 Install the new gear 5 Install the motor Please note The end faces of the motor and gear must be undamaged The gear hub comes lubricated with anti seize lubricant Do not tilt the motor and make sure it has the neces...

Page 60: ...motor mounting MA M using HQ 2 G H as an example Required tools Hex wrenches SW3 SW4 Hex wrenches SW8 SW10 SW13 Preliminary steps Allow the belt section to run briefly and position the chain lock B on the drive sprocket f Make sure the system is de energized and depressurized and secure it against being switched back on 1 Only applies to HQ 2 G H Loosen the headless setscrews of the belt section a...

Page 61: ...proper position Do NOT rotate the motor Disconnect the motor from the gear and reconnect it For belt sections with cross connectors if possible do not open the cross connectors but rather the gearbox as in chapter 7 6 on page 25 dismantle Only open the cross connectors if necessary otherwise the belt section will lose its alignment 2 Only applies to BS 2 G 250 Loosen the profile connectors A 3 Rem...

Page 62: ...12 Mount the belt section on the lift frame Please note f Check the right angled alignment of the belt section The coupling C of the drivetrain should be easy to move 13 Arrest the belt section Please note The belt section must be tensioned firmly vibration test and flat without gap on the lift frame f If there is a gap between the belt section and the lift frame Remove the belt section from the l...

Page 63: ...ning the conveyor chain using HQ 2 G H as an example Please note f Check the correct chain tension regularly every 1000 h f Re tension the chain if the chain dips the chain is raised there is operating noise 1 Loosen the chain tensioners 2 Move shake the chain back and forth a bit to allow the chain tensioner the maximum tensioning distance f The resulting elongation is compensated by spring force...

Page 64: ... system is de energized and depressurized f Secure the system against being switched back on Please note Applies for HQ 2 G H You can replace the roller chain without removing the belt section from the lift unit To replace worn guides or if space is restricted remove the belt section from the lift unit For removal and installation of the belt section from the lift unit see pages 61 and 62 1 Remove...

Page 65: ...ng bolts f Make sure the chain tensioner remains tensioned during assembly and cannot loosen unintentionally Fig 41 SW3 4 5 5 SW4 4 SW4 MD 18 Nm 6 3 3 SW4 MD 5 Nm 564 988 65 5 5 MD 2 5 Nm HQ 2 G H BS 2 G 250 Slackening the duplex chain using HQ 2 G H as an example shown without lift unit 4 Loosen the chain tensioners 5 Slacken the chain as much as possible 6 Re tighten the chain tensioners ENGLISH...

Page 66: ...8 Pull the chain back from the drive heads 9 Only necessary if you want to replace the guides or the sprocket Remove the sliding piece Assembly tip Before you pull out the worn out chain Connect the new chain with the worn out chain chain lock Pulling out the worn out chain will pull in the new chain 10 Pull the chain completely off of the belt section f Replace the chain f Check the sprocket and ...

Page 67: ... the HQ 2 G H example 11 Slide the chain from the chain tensioner along the return level up to the drive head 12 Guide the chain up and around the drive gear 13 Guide the other end of the chain to the drive head 14 Close the chain 15 Loosen the chain tensioner To tension the chin pull the chain tensioner as far back as possible and fasten it in place 16 Install the covers on the drive heads 17 Ins...

Page 68: ... the chain is deformed Use the disassembly tool to remove the affected area with a generous margin on either end NOTICE Running direction of conveyor chain Make sure the running direction of the conveyor chain is the same as the main direction of transport Fig 44 Running direction of chain NOTICE Conveyor chain failure Inadequate lubrication of the conveyor chain can result in conveyor chain failu...

Page 69: ...e lift unit must be removed Required tools Hex socket wrench size 3 Hex socket wrench size 4 Preliminary steps Allow the belt section to run briefly and position the flat top plate with hole A chain lock position on the drive sprocket f Now deenergize and depressurize the system and secure it against being reactivated 1 Remove the headless setscrew of the belt section locking mechanism 2 Remove th...

Page 70: ... crushing due to unintentionally loosening the fastening bolts f Make sure the chain tensioner remains tensioned during assembly and cannot loosen unintentionally Fig 47 564988 73 SW3 5 6 6 6 6 SW4 7 SW4 HQ 2 C H Slackening the flat top chain 5 Loosen the chain tensioners 6 Slacken the chain as much as possible 7 Re tighten the chain tensioners ...

Page 71: ... AG Fig 48 564988 74 10 9 10 9 11 11 8 3 842 551 234 HQ 2 C H Removing the flat top chain 8 Open the flat top chain chain lock under flat top plate with hole 9 Pull the chain back from the drive heads 10 Remove the sliding piece 11 Pull the chain completely off of the belt section ENGLISH ...

Page 72: ...gthen the new chain 12 Slide the chain from the chain tensioner along the return level up to the drive head 13 Guide the chain up and around the drive gear 14 Install the sliding piece 15 Guide the other end of the chain to the drive head 16 Connect the chain together and attach the flat top plate with hole 17 Loosen the chain tensioner To tension the chin pull the chain tensioner as far back as p...

Page 73: ...relevant system component before performing any maintenance or repair work f Secure the system against being unintentionally switched on again Suspended loads may fall Falling objects can result in severe injury or even death f Use only slings with sufficiently high bearing loads for product weight see delivery documents f Make sure the lifting straps are correctly fastened before lifting the prod...

Page 74: ...t Careless disposal may lead to environmental contamination Dispose of the product in accordance with the regulations in your country 14 Upgrading and modification Do not modify the product The Bosch Rexroth warranty only applies to the configuration as delivered and to approved upgrades The manufacturer will not accept any warranty claims for systems with unapproved modifications or upgrades 15 T...

Page 75: ...nity of industrial equipment producing chemical emissions Do not install or operate near sources of sand or dust Do not install or operate in areas that are regularly subjected to high energy forces caused for example by presses or heavy machinery Resistant to many media that are commonly found in manufacturing such as water mineral oil grease and detergents Contact your Rexroth representative if ...

Page 76: ...VE 2 stop gates are used to stop workpiece pallets The position of the workpiece pallets is queried with separate sensors Action block Explanation S Storing NS Non storing S Set R Reset T3 T3 NS D S S Y2 1 Non storing trigger of a time function with runtime T after which a switching function is triggered General abbreviations WT Workpiece pallets VE Stop gate S Signal transmitter Y Valve Z Cylinde...

Page 77: ...1N3 1N5 NS Y1 T3 T3 NS Y2 Z2 S Y3 Z2 R Y3 Z2 S4 1N4 NS NS D Y4 Z4 Z1 2 1 1 558 993 39 Start pulse after end of start up Enable cyclic travel S2 WT after VE S3 WT in position on HQ S4 Release secondary section HQ free S5 HQ down Y1 Main section VE Z1 Y2 HQ up Z2 Y3 HQ down Z2 Y4 Extend DA damper Z4 stop position Notes Approaching the central position see page 40 Distance Z1 Z3 lWT 200 mm ENGLISH ...

Page 78: ...93 40 S2 S3 S1 S1 S2 S3 1N1 1N2 1N3 1N4 NS Y1 NS F T T F T2 D NS T2 D Z1 NS Y3 Z2 S Y2 Z2 R Y2 Z2 NS Y4 Z4 2 1 1 558 993 41 Start pulse after end of start up Enable cyclic travel S1 WT after VE S2 WT in position on HQ S3 Release secondary section HQ free Y1 Secondary section VE Z1 Y2 HQ up Z2 Y3 HQ down Z2 Y4 Extend DA damper Z4 Notes Distance Z1 Z3 bWT 200 mm ...

Page 79: ...S D Y1 Z1 NS Y2 Z2 NS Y3 Z2 S Y3 Z2 R Y3 Z2 NS Y4 Z4 1N5 558 993 43 Start pulse after end of start up Enable cyclic travel S1 WT after VE S2 WT in position on HQ S3 Release secondary section HQ free S4 Release main section HQ free S5 HQ down Z2 Y1 Main section VE Z1 Y2 HQ up Z2 Y3 HQ down Z2 Y4 Extend DA damper Z4 A1 Straight ahead signal Notes Approaching the central position see page 40 Distance...

Page 80: ...N2 1N3 1N4 1N5 S3 S4 1 NS Y1 Z1 NS Y5 Z5 S Y3 Z3 NS Y2 Z2 R Y3 Z3 NS Y4 Z3 R P10 S P10 NS T T F T3 F D NS T3 D 2 1 1 1 1 P10 S1 1 558 993 45 Start pulse after end of start up Enable cyclic travel S1 WT before VE 1 S2 WT after VE 1 S3 WT in position on HQ S4 WT after HQ S5 WT before VE 2 S6 WT after VE2 Y1 Secondary section VE 1 Z1 Y2 Main section VE 2 Z2 Y3 HQ up Z3 Y4 HQ down Z3 not required Y5 E...

Page 81: ... 81 84 3 842 564 989 2022 06 MIT HQ 2 G H BS 2 G 250 Bosch Rexroth AG ENGLISH ...

Page 82: ...82 84 Bosch Rexroth AG MIT HQ 2 G H BS 2 G 250 3 842 564 989 2022 06 ...

Page 83: ... 83 84 3 842 564 989 2022 06 MIT HQ 2 G H BS 2 G 250 Bosch Rexroth AG ENGLISH ...

Page 84: ...Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax 49 711 811 7777 info boschrexroth de www boschrexroth com Subject to modifications 3 842 564 989 2022 06 ...

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