Bosch rexroth EL 2 Assembly Instructions Manual Download Page 48

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Maintenance and repair

Bosch Rexroth AG, MIT: EL 2, 3 842 558 372/2021-10

Replacing the motor and gear



Replace the motor and gear every 20,000 hours.

Fig. 27:

SW4

=5 Nm

SW10

=8 Nm

SW5

=18 Nm

SW10

=8 Nm

558 371-24

Replacing the motor and gear



Move the lift to the lower
position.



Install the transport
securing device
(see page 43).

Remove the protective
casing.

Remove the motor.

Remove the sprocket.

Remove the gear.

Install the new gear.

Install the sprocket.

Install the new motor.

Install the protective
casing.

Please note:



Reference the zero point
after every repair.

Summary of Contents for rexroth EL 2

Page 1: ...Assembly instructions 3 842 558 372 2021 10 Replaces 2019 04 ENGLISH EL 2 Lift 3 842 998 861 ENGLISH ...

Page 2: ...Disponible au téléchargement en version imprimée ou en ﬁchier PDF à partir du répertoire médias www boschrexroth com mediadirectory Saisissez 3 842 558 373 dans le champ de recherche en haut à droite sous Search 3 842 558 373 puis cliquez sur Search IT Le presenti istruzioni di montaggio sono disponibili nelle lingue indicate qui Altre lingue su richiesta Possono essere scaricate come versione sta...

Page 3: ...1 1 Use of the Lift EL 2 12 5 1 2 Design of the Lift EL 2 12 5 2 Product description 13 5 3 Identiﬁcation of the product 14 6 Transport and storage 14 6 1 Transporting the product 14 6 2 Storing the product 14 7 Assembly 15 7 1 Unpacking 15 7 2 Installation requirements 15 7 2 1 Installation position 15 7 3 Required tools 15 7 4 Symbols used 16 7 5 Installing the product 17 7 5 1 InstEL 2lling the...

Page 4: ...product for storage later use 49 13 Disposal 49 14 Upgrading and modiﬁcation 50 15 Troubleshooting and repair 50 16 Technical data 51 16 1 Ambient conditions 51 16 2 Pneumatics 51 17 Appendix 52 17 1 Operating modes 52 17 1 1 C Form 52 17 1 2 O Form 52 17 2 Function plans 52 17 2 1 Lift EL 2 infeed 54 17 2 2 Lift EL 2 outfeed 55 ...

Page 5: ...u have understood and followed the instructions in it Table 1 Required and supplementary documentation Title Document number Document type Employee safety training 3 842 527 147 Declaration of installation 3 842 559 811 IndraDyn S Synchronmotoren MSM DE R 911 329 337 IndraDyn S Synchronous Motors MSM EN R 911 329 338 MTpro 1 3 842 539 057 With list of spare parts 1 Download from www boschrexroth c...

Page 6: ...ER 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 following symb...

Page 7: ...Intended use The product is an incomplete machine You may use the product as follows for installation in a Rexroth TS 2plus transfer system for vertically transporting Rexroth WT 2 workpiece pallets maximum load section load see the Technical Data on page 51 for the ambient conditions see page 51 The product is only intended for professional use and not for private use Intended use also includes h...

Page 8: ...sessment in accordance with DIN EN ISO 12100 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 People who assemble operate disassemble or maintain Rexroth products must not be unde...

Page 9: ...workstations and passages are kept clear Do not use EMERGENCY STOP controls for routine stopping Regularly check the EMERGENCY STOP controls to ensure that they are functioning properly Following an EMERGENCY STOP or in the event of an error or other irregularities turn the product off and secure it against being switched back on Do not reach into moving parts An idle system is not necessarily a s...

Page 10: ...es the following 1 Lift EL 2 3842998861 1 auxiliary kit cover set lift 3842998884 1 auxiliary kit cover fastener lift 3842998885 1 connection kit EL 2 3842559810 1 adapter LU 2 for EL 2 3842559809 only if ordered GM 1 auxiliary kit servo control lift CP 1 R988123198 CP 2 R988123199 CP 3 R988123201 CP 4 R988123203 CP 5 R988123204 only if ordered GM 1 attachment kit sensor fasteners EL2 R988107158 o...

Page 11: ...ivery 11 56 3 842 558 372 2021 10 MIT EL 2 Bosch Rexroth AG Fig 1 558 371 34 L GM 0 R GM 1 Examples of the lift s condition on deliveryEL 2 R Right version L Left version GM 1 with motor GM 0 without motor ENGLISH ...

Page 12: ...cations of the Lift EL 2 5 1 1 Use of the Lift EL 2 For installation in a Rexroth TS 2plus transfer system For vertically transporting WT 2 workpiece pallets 5 1 2 Design of the Lift EL 2 Extremely compact construction Conveyor medium infeed and outfeed by means of a cleat hook L Left version U Vertical transport upwards R Right version D Vertical transport downwards ...

Page 13: ... 2 Bosch Rexroth AG 5 2 Product description Fig 3 558 371 02 B A R U L D R D L U Lift EL 2 A WT return below working height B WT return above working height L Left version U Vertical transport upwards R Right version D Vertical transport downwards ENGLISH ...

Page 14: ... sufﬁciently high bearing load capacity see delivery documents for the product weight Make sure the lifting straps are correctly fastened before lifting the product Secure the product against tipping when lifting Make sure that no one but the operator is in the danger zone when lifting and lowering 6 2 Storing the product Only set the product down on a ﬂat surface Protect the product from mechanic...

Page 15: ...spose of the packaging material in accordance with the applicable regulations in your country 7 2 Installation requirements During installation be sure to maintain the ambient conditions speciﬁed in the Technical Data see page 51 7 2 1 Installation position Install the product level and plumb at right angles and axially parallel This ensures proper functioning and prevents premature wear 7 3 Requi...

Page 16: ...e lubricant gleitmo 585 K gleitmo 585 K www fuchs lubritech com Anti Seize Food Grade Anti Seize Loctite 8014 www henkel com GHD V 68 Oil Oil Oil Oil oil with speciﬁc lubricant GHD Lubricate with Structovis GHD 0 842 904 229 V 68 Mineral oil viscosity 68 according to DIN e g Aral Shell Loctite 243 Loctite 601 Secure the screws with Loctite 243 medium strength detachable www loctite de Loctite 601 ...

Page 17: ...n of the Lift EL 2 The lift is secured in its lower lifting position for transport and assembly C Only remove the securing device C once the assembly has been completed Storage of transport locking device X Installing the section supports The distance between the upper and lower transverse proﬁle of the section supports S must be equal to the lifting height S of the Lift EL 2 1 Condition on delive...

Page 18: ...x 1x F 558 371 07 H G K 2x J X O M N L Installing the LU 2 automatic lubrication unit 1 2 Required accessories E LU 2 lubrication unit 3 842 543 482 F LC 2 oil container 3 842 543 469 J K EL 2 adapter set 3 842 559 809 X LU 2 EL 2 mounting kit 3 842 562 287 Please note The marked parts of the LU 2 lubrication unit are not needed ...

Page 19: ... D SW17 N L G M H SW4 MD 8 Nm J P Installing the LU 2 automatic lubrication unit 2 2 Please note For further details see the LU 2 automatic lubrication unit assembly instructions Install the lubricating brush O Install the LU 2 lubrication unit Install the cable bushing P Attach the lubrication unit hoses ENGLISH ...

Page 20: ...t the height of the upper conveying level 1 Type X3 mm BS 2 335 BS 2 C 100 335 BS 2 C 250 335 BS 2 C H 335 BS 2 R 300 335 BS 2 R 700 335 BS 2 R H 335 Please note Depending on the lifting height of the lift the conveyor width of the belt sections and the spatial environment it may be necessary to modify the mounting position of the motor gear combination or the gear motor of the belt sections see p...

Page 21: ...gear motor Fig 9 558 371 17 SW10 4x 90 MD 8 Nm 90 90 90 90 90 90 90 SW8 2x MD 6 Nm A A A A B B B B B B 2 1 3 1 3 2 Swivel the motor gear combination or gear motor around the drive axle 1 Remove the screws A B 2 Swivel the motor gear combination or the gear motor around the drive axle in 90 intervals 3 Install the screws A B ENGLISH ...

Page 22: ...f the terminal box 1 Remove the motor from the gear 2 Install the motor in the correct position terminal box Please note Do not tilt the motor and make sure it has the necessary clearance area for installation Install the motor in the proper position terminal box and connect it to the gear If the motor is not in the proper position do NOT rotate the motor Disconnect the motor from the gear and rec...

Page 23: ... AG Fig 11 Installing the 558 371 12 3 SW13 M 25 Nm D M 25 Nm D 0 SW19 24 4 2x SW13 5x M 25 Nm D Lift EL 2 1 4 3 Align the ﬁrst Lift EL 2 so it is ﬂush horizontal and at the height of the lower conveying level 4 Connect the lift to the section supports ENGLISH ...

Page 24: ... M 25 Nm D 0 SW19 24 6 2x SW13 5x M 25 Nm D 1 2 Lift EL 2 2 4 5 Align the second Lift EL 2 so it is ﬂush horizontal and at the height of the lower conveying level 6 Connect the lift to the section supports 1 Depending on the travel of the lift and the mounting position of the motor this proﬁle may not be mounted ...

Page 25: ...25 Nm D 3 842 528 718 3 842 146 815 3 842 526 560 7 1 7 2 3 842 345 081 558 371 05 lift EL 2 3 4 7 Screw the belt section and the lifts to the ﬂoor For each connection you will need 1x foundation bracket 3 842 146 815 1x dowel 3 842 526 560 2x T bolts 3 842 528 718 2x ﬂange nuts 3 842 345 081 ENGLISH ...

Page 26: ...1 1 11 2 Lift EL 2 4 4 8 Install the protective covers 9 Only if required Install the LU 2 automatic lubrication unit see page 18 10 Remove the transport securing device C 11 Install the transport locking device C as fall protection under the lower position of the lift Keep the T bolts and ﬂange nuts 12 Check that the drive chain has the correct tension see page 27 ...

Page 27: ...9 SW13 E D MD Nm SW10 MD Nm 2 4 3 Correct tensioning of the drive chain Check after assembly and then regularly every 1 000 hours 1 Move the lift to the lower position 2 Loosen the ﬁxing screw D 3 Tension the chain tensioner E MD 1 5 Nm Tighten the ﬁxing screw D MD 8 7 Nm ENGLISH ...

Page 28: ...ents according to EN ISO 13849 Factor in the load to be transported and the transport speed Electrical work may only be carried out by qualiﬁed personnel e g connecting the motor Observe the DIN EN 60204 standard previously VDE regulation VDE 0100 for Germany or corresponding regulations in the country of use Motor connection See assembly instructions IndraDyn S Synchronous Motors MSM R 911 329 33...

Page 29: ...48051 A3 A2 A1 X5 X6 X4 4 12 2 9 8 7 PE W1 V1 U1 PE W1 V1 U1 PE W1 V1 Brake optional U1 PE ME 3 4 3 8 7 8 7 BD BD 9 3 4 2 9 VCC_Encoder Motor encoder M5 SUP E02 MSM BATTERYBOX xxxx RKG00622 GND_Encoder 3 4 Data Data VCC_Encoder Data Data Shld Battery R911346181 7 8 Battery Battery 2 9 3 4 2 9 3 4 7 8 RKG00631 RKG00631 Circuit diagram MSM ENGLISH ...

Page 30: ...e warning signs Make sure that all the electrical and pneumatic connections are either in use or covered Make sure that all bolted connections and plug in connections are properly seated All relevant protective covers must be ﬁtted Only inspect and adjust continuous conveyors that are in motion or operation when the safety guards are in place Observe DIN EN ISO 13857 when you remove or replace saf...

Page 31: ...ency 15 Restoring operation after a bottleneck or blockage 16 Restarting after unscheduled shutdown 17 Troubleshooting and remedial action intervention by operating personnel 18 Cleaning and keeping clean 19 Preventive maintenance 20 Corrective maintenance Operating states of the machine Sect 5 4 b 21 Normal operation 22 Modiﬁcation of a property or a dimension of the material or workpiece to be p...

Page 32: ...shing Shearing Eliminate the hazard by taking constructive measures for example by using a separating safety guard 3 2 3 6 10 15 Between the approaching workpiece pallet and cleat Body parts can become trapped Crushing Shearing Eliminate the hazard by taking constructive measures for example by using a separating safety guard 4 2 3 6 10 15 Between the platform of the lift and the incoming workpiec...

Page 33: ...ng Eliminate the hazard by taking constructive measures for example by using a separating safety guard 7 2 3 6 10 15 Between the rotating drive chain sprockets and chain supports Body parts can become trapped Crushing Shearing Entanglement Eliminate the hazard by taking constructive measures for example by using a separating safety guard 8 2 3 6 10 15 Between the runner block and guide rail when l...

Page 34: ...come trapped Crushing Eliminate the hazard by taking constructive measures for example by using a separating safety guard 11 2 3 6 10 15 Motor without protective cover Exposed voltage conductor Electric shock Eliminate the hazard by taking constructive measures for example by using a separating safety guard 12 2 3 6 10 15 Motor without protective cover Motor temperature 65 C Burning Eliminate the ...

Page 35: ...Start up 35 56 3 842 558 372 2021 10 MIT EL 2 Bosch Rexroth AG Example of separating safety guards tunnel provided by the customer Fig 18 558 371 20 Example of separating safety guards tunnel ENGLISH ...

Page 36: ...Table 1 Body part Minimum distance a mm Illustration Body 500 a Head most unfavorable position 300 a Leg 180 a Foot 120 a Toes 50 a 50 max Arm 120 a Hand Wrist Fist 100 a Fingers 25 a Please note When designing separating safety guards take into account the minimum distances according to DIN EN 349 Table 1 ...

Page 37: ...oading the conveyor sections can cause the conveyor medium to malfunction and lead 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 commonsense measures will reduce wear Switch off the conveyor section when the system is not in use e g during breaks at night...

Page 38: ...ad to a reduction in the drive power that is transmitted via friction In such instances special care must be taken when planning the system and the maintenance intervals must be correspondingly shortened 10 Maintenance and repair WARNING High electrical voltage Risk of serious injury or death from electric shock Disconnect the relevant system component before performing maintenance or repair work ...

Page 39: ...greasers or aggressive cleaning agents away from the toothed belt Only clean the product with a damp cloth 10 2 Inspection Drive chain Fig 19 558 371 27 SW4 MD 6 Nm SW13 E D 3 MD Nm SW10 MD Nm 2 4 3 Correct tensioning of the drive chain Regularly perform a check every 1 000 hours to visually inspect whether the conveying level of the lift is aligned with the conveying level of the infeed and outfe...

Page 40: ...wear see page 48 Replace the cleat hook if the workpiece pallet is no longer fed in or out correctly see page 44 the damping element for wear see page 44 Replace the damping element if the wear is 3 mm whether the bolt spring is fractured see page 44 Replace the bolt spring if the hook does not reset correctly see page 44 the drive shaft for wear the bearing block for wear the roller elements for ...

Page 41: ...L runner blocks Lubricate the BSCL runner blocks with grease NLGI 2 Apply with Manual grease gun Recommendation Dynalub 510 Lithium based high performance grease NLGI class 2 according to DIN 51818 KP2K 20 according to DIN 51825 Good resistance to water Anti corrosive Temperature range 20 to 80 C Approved alternative products Castrol Longtime PD2 Elkalub GLS 135 N2 Initial lubrication The BSCL run...

Page 42: ...r even crash the system causing considerable property damage Keep a maintenance schedule The running times during the system s set up and start up count towards the ﬁrst maintenance interval If you do not know the running times during the system s setup and start up lubricate the drive chain at the start of production Lubricate the drive chain after downtimes 6 months e g long set up time or tempo...

Page 43: ...renches SW3 SW4 SW5 Phillips screwdriver PZ2 Caliper 500 mm Hammer Drift punch Before carrying out any repair work Fig 22 558 371 21c C C SW13 MD 25 Nm 1 2 0 mm SW13 MD 25 Nm 1 2 Install the transport securing device Please note Move the lift to the middle position without any load workpiece pallet Install the transport securing device C ENGLISH ...

Page 44: ...L if the wear is 3 mm Fig 23 558 371 30 3 SW5 MD 25 Nm 2 1 O K K K L 1 2 M M PZ2 PZ2 Replacing the cleat hook Move the lift to the upper position Install the transport securing device see page 43 1 Remove the cleat hook K Only if required Replace the damping element L Only if required Replace the roller elements M Only if required Replace the bolt spring O 2 Install the new cleat hook K 1 Cleat ho...

Page 45: ...D SW10 MD Nm 1 4 SW13 MD Nm 2 3 Replacing the drive chain 1 2 Move the lift to the middle position Install the transport securing device see page 43 1 Loosen the ﬁxing screw D 2 Loosen the chain tensioner E After assembling the new drive chain Move the lift to the lower position 3 Tension the chain tensioner E MD 1 5 Nm 4 Tighten the ﬁxing screw D MD 8 7 Nm ENGLISH ...

Page 46: ... 5 Remove the cleat hook assembly N 6 Open the drive chain and remove it Check the sprockets for visible wear Replace worn sprockets if necessary 7 Put on the new drive chain 8 Close the drive chain 9 Install the cleat hook assembly N 1 Cleat hook C Form 2 Cleat hook O Form Tension the drive chain see page 45 Please note Reference the zero point after every repair ...

Page 47: ...rts of the chain guide Move the lift to the lower position Install the transport securing device see page 43 Remove the drive chain see page 45 1 Remove the return units F 2 Remove the upper support rail 1 G 1 only if lWT 320 mm 3 Remove the lower support rail H 4 Remove the sprockets J from the worn return units F and install them in the new ones 5 Install the new upper G and lower H support rail...

Page 48: ... 5 SW5 MD 18 Nm SW10 3x MD 8 Nm 558 371 24 Replacing the motor and gear Move the lift to the lower position Install the transport securing device see page 43 1 Remove the protective casing 2 Remove the motor 3 Remove the sprocket 4 Remove the gear 5 Install the new gear 6 Install the sprocket 7 Install the new motor 8 Install the protective casing Please note Reference the zero point after every r...

Page 49: ...enance or repair work Secure the system against being unintentionally switched on again Suspended loads can fall Falling objects can result in serious injury or even death Only use slings with a sufﬁciently high bearing load capacity see delivery documents for the product weight Make sure the lifting straps are correctly fastened before lifting the product Secure the product against tipping when l...

Page 50: ...ead 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 Troubleshooting and repair If...

Page 51: ... 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 you ...

Page 52: ...5 3 4 5 6 1 O Form TD D 1 Cleat hook pulls the WT on the upper conveying level into the lift 2 Cleat hook with WT is transported on the back panel to the lower conveying level 3 Cleat hook releases the WT on the lower conveying level 4 Empty cleat hook remains at the front 5 Empty cleat hook is transported at the front to the upper conveying level 6 Empty cleat hook pulls a WT on the upper conveyi...

Page 53: ...lets is determined using separate proximity switches Action block Explanation S Storing NS Non storing S Set R Reset T3 T3 NS D S S Y2 1 Non storing triggering of a time function with runtime T after which a switching function is triggered General abbreviations WT Workpiece pallet VE Stop gate S Signal transmitter Y Valve Z Cylinder LT Longitudinal conveyor main section QT Transverse conveyor seco...

Page 54: ...VE Axis velocity Cyclic Run Axis velocity stopAtP2 Axis velocity stopAtP3 AxisStopAtP3Cmd AxisStopAt RezoCmd AxisStopAtP2Cmd 1 2 3 WT moves from TS2 to EL2 Gripper arm takes load moving from zero point to unload point Axis in position mode Gripper arm returns to zero point Axis in velocity mode Name Related sensors or actuators E1 E2 AutoStart AutoStart button AutoStart button VEONCmd S1 S6 VEOFFC...

Page 55: ...start up Enable cyclic travel S1 WT before VE 1 S2 WT after VE 1 S3 WT on the hook S4 Hook zero point Y1 Main section VE 1 Z1 M1 Servomotor O1 Optical sensor P2A WT at control point before the vertical movement P2 WT at stopping point before the vertical movement P3A WT at control point before the horizontal movement P3 WT at stopping point before the horizontal movement R1 Outlet area occupied ro...

Page 56: ...Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax 49 711 811 7777 info boschrexroth de www boschrexroth com Subject to change 3 842 558 372 2021 10 ...

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