Contents Preventive maintenance Introduction.............................................................................................................................. 4 XT Pallets XTPP...................................................................................................................... 5 XT Compact conveyor XTUC S11........................................................................................... 6 XT Conveyor XTUC.................................................................
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Preventive maintenance 2002-12-11 3
Introduction General introduction The following maintenance interval is recommended for XT equipment: Well-maintained equipment will ensure the life expectancy. This manual is designed to offer assistance for your planned maintenance schedule. Only competent persons, who are familiar with FlexLink equipment, should carry out maintenance of the XT modules. If there are any doubts as to the most suitable procedure for maintenance, consult your FlexLink supplier.
XT Pallets XTPP Recommended inspection interval Inspection is recommended every 1500 operating hours or every 3rd month depending on which case that occurs first. C Check wear or damage of pallets 1 Make random samples and inspect a couple of pallets. C 2 Check the bushings. Worn bushings (A) indicate poorly adjusted locate or rotate stations. B A 3 Check the frame. Worn surface (B) indicate poorly height-adjusted transfer stations. Check stop function at transfer station.
XT Compact conveyor XTUC S11 Recommended inspection interval 3 If the elongation on the conveyor chain causes a chain slack (E), it must be shortened. Split the chain and remove the necessary number of links, see “Replace chain on XT Compact conveyor module” on page 35. Inspection is recommended every 1500 operating hours or every 3rd month depending on which case that occurs first. Check wear or damage of conveyor chain E 1 Run the conveyor to inspect the whole chain.
Check motor temperature 1 Measure the motor temperature. 2 Operation temperature > approx. 90ºC indicates overload of conveyor. Check pallet weights and queues and compare to system specifications. Measure temperature Other observations Use “Trouble shooting” on page 62. Cleaning conveyor chain Only warm water (50ºC), with soap if necessary, may be used for cleaning conveyor chains. Other instructions “Replace driving belt on XT Compact conveyor module” on page 40.
XT Conveyor XTUC Recommended inspection interval shortened, see “Replace chain on XT conveyor module – End drive unit” on page 16 or “Replace chain on XT conveyor module – Catenary drive unit” on page 21. Initial inspection of the chain slack is required after the first 100 operating hours. After that, inspection is recommended every 1500 operating hours or every 3rd month depending on which case that occurs first. Check wear or damage of conveyor chain 1 Run the conveyor to inspect the whole chain.
Check the slide rails 1 Run the conveyor. Irregular movement of the chain or noise may be caused by damaged slide rail (E). 2 If you suspect damage, try to detect deformations of the slide rail. (only necessary on the upper side of the conveyor). 3 If slide rail has to be replaced, see “Replacement of slide rail” on page 28. E E Measure temperature Other observations Use “Trouble shooting” on page 62.
Transfer units XTPT Recommended inspection interval Inspection is recommended every 1500 operating hours or every 3rd month depending on which case that occurs first. Check wear or damage of conveyor chain 1 Run the transfer to inspect the whole chain. Example of damage to look for is listed below: D: Lift A) Wrong chain pitch or broken top plate. D: Lowering B) Non-plain chain. C) Worn out top plates, min. thickness (t) 1 mm. Other observations A Use “Trouble shooting” on page 62.
Locating station XTPX P11 A Recommended inspection interval Inspection is recommended every 1500 operating hours or every 3rd month depending on which case that occurs first. B: Lift Check wear of guide pins 1 Examine the guide pins (A).
Lift and locate stations XTPX P12 Recommended inspection interval Inspection is recommended every 1500 operating hours or every 3rd month depending on which case that occurs first. B: Lift Check wear of guide pins 1 Examine the guide pins (A). 2 If the guide pins have to be replaced see “Mounting guide pins to locating, lift-and-rotate and liftand-locate station” on page 59. B: Lowering Other observations Use “Trouble shooting” on page 62.
Lift and rotate station XTPR Recommended inspection interval Inspection is recommended every 1500 operating hours or every 3rd month depending on which case that occurs first. Check wear of guide pins B 1 Examine the guide pins (A). D 2 If the guide pins have to be replaced see “Mounting guide pins to locating, lift-and-rotate and liftand-locate station” on page 59. C:Lift C:Lowering Check speed of rotating movement 1 Run the unit with loaded pallets.
Stops and dampers Recommended inspection interval Not included Inspection is recommended every 1500 operating hours or every 3rd month depending on which case that occurs first. Check the damping function B 1 Check the damping function. 2 If needed, fine adjust the damping function (A) when the system is running. CAUTION! Heavy pallets in combination with an over damped stop can damage the stop. Other observations Use “Trouble shooting” on page 62.
Mounting instructions 2002-12-11 15
Replace chain on XT conveyor module – End drive unit Introduction Valid for motor types M and HM (centre mounted motor) and L and R (side mounted motor). If nothing else is specified the instruction steps are valid for both centre and side mounted motor. Tools Box wrench 10 mm Box wrench 7 mm Slip joint pliers Pin insertion tool XLMJ 4 Screwdriver Clamp Instruction 1 Side mounted motor. Use the screwdriver to remove the plastic cap on the motor.
3 Remove a pin (that holds the chain together) in the driving end by pressing it through the chain. Use the pin insertion tool. 4 Centre mounted motor (A) - Remove the fan cover. Use the 7 mm box wrench. Feed the chain out through the drive wheel and turn the fan until the chain is loose. Side mounted motor (B) - Feed the chain out through the drive wheel and turn the drive shaft until the chain is loose. CAUTION! Make sure that the short loose end of the chain runs smoothly through the plastic guides.
7 Insert the chain from below, with the nose forward (see previous step). 8 Feed the chain into the conveyor until it reaches the drive wheel at the driving end. Repeat steps 7 and 8 for the second chain. 9 Centre mounted motor (A) - Remove the fan cover. Use the 7 mm box wrench. Feed the chains to the drive wheel and turn the fan until the chains are hanging a bit below the conveyor.
11 Join the chain endings. Make sure that the joint ball has not been removed and re-assembled upside down. CAUTION! Wrongly positioned joint ball will lead to chain damage when running the chain. Check rib down 12 Press the pin through the chain. Use the pin insertion tool. TIP! Use a clamp (A) to keep the chain stretched. A 13 Make sure that the pin snaps into the correct position (centred). 14 Centre mounted motor - Fit the fan cover to the motor and tighten the screws. Use the 7 mm box wrench.
15 Side mounted motor. Fit the plastic sleeve on the drive shaft. 16 Side mounted motor. Fit the motor on the drive shaft and tighten the screw. Use a 10 mm box wrench. Fit the plastic cap. CAUTION! Make sure that the torque arm fork has entered the cage in a correct way. An unlocked rotating motor can cause personal injury.
Replace chain on XT conveyor module – Catenary drive unit Introduction The chain only runs on top of the conveyor. Tools Box wrench 10 mm Slip joint pliers Pin insertion tool Screwdriver Instruction 1 Remove the roller bridge between the conveyors. 2 Use the screwdriver to remove the plastic cap on the motor. Loosen the screw for the motor with the 10 mm box wrench. 3 Lift off the motor from the drive shaft.
4 Remove the plastic sleeve from the drive shaft. 5 Detach the screws (4×M6) holding the slack protection. Use the 10 mm box wrench. 6 Remove the slack protection cover. 7 Remove a pin (holding the chain together) by pressing it through the chain. Use the pin insertion tool.
8 Feed the chain out through the drive wheel by turning the drive shaft until the chain is loose. CAUTION! Make sure that the short loose end of the chain runs smoothly through the plastic guides. Risk for the plastic guides to brake. 9 Pull out the chain from below the idler end unit. 10 Unpack the new chain. Note that the chain can only be mounted in its direction of travel (marked with an arrow). Direction of travel 11 Insert the chain from below, with the nose forward (see previous step).
12 Feed the chain via the idler end into the conveyor. 13 Feed the chain into the conveyor until it reaches the drive wheel at the drive end. Repeat steps 12 and 13 for the second chain. 14 Feed the chains to the drive wheel and turn the drive shaft until the chains are hanging a bit below the conveyor. CAUTION! Make sure that the chains enter the drive wheel correctly. Risk for the plastic guides to brake. 15 Use a pair of slip joint pliers to insert the pin halfway into the chain link.
16 Join the chain endings. Make sure that the joint ball has not been removed and re-assembled upside down. CAUTION! Wrongly positioned joint ball will lead to chain damage when running the chain. Check rib down 17 Press the pin through the chain. Use the pin insertion tool. 18 Make sure that the pin snaps in to the correct position (centred). 19 Fit the slack protection covers.
20 Fit and tighten the screws (4×M6). Use the 10 mm box wrench. 21 Fit the plastic sleeve on the drive shaft. 22 Fit the motor on the drive shaft. 23 Fit and tighten the screw. Use the 10 mm box wrench. Fit the plastic cap. CAUTION! Make sure that the torque arm fork has entered the cage in a correct way. An unlocked rotating motor can cause personal injury.
24 Place the roller bridge between the conveyors.
Replacement of slide rail Introduction This instruction is primarily intended for conveyor XT, but can also be used as a guideline for the XT Compact conveyor.
3 Remove the slide rail that shall be replaced. 4 Mark up all old rivet holes at the bottom of the beam with a marker. 5 Chamfer the top and side faces on the slide rail (compare/copy old slide rail). 6 Mount the slide rail, make sure to not fit it upside down. Leave a 4 mm distance in the joint between two slide rails.
7 Use drill fixture 3923584 to drill the rivet holes. Place it so the new hole is about 20 mm behind the mark for the old hole, then turn the handle to lock it in position (never use the old rivet holes). 8 Drill new holes for the rivets using a 3,2 mm drill. 9 Countersink the holes to ensure that the top of the rivet is below the surface of the slide rail. 10 Fit the rivets in the holes and press them together with the rivet tool.
11 Check that the rivets do not protrude over the slide rail surface. Check both top and underneath surface of slide rail for protruding metal. Repeat steps 7 to 11 following the old pattern of rivets. 12 When you reach the end, cut the slide rail so that there is a 4 mm distance to the next piece of slide rail. 13 Press the slide rail in place.
Replace motor on XT conveyor drive unit – Side mounted Introduction Valid for motor types L and R (side mounted motor). Tools Box wrench 10 mm Box wrench 13 mm Screwdriver Instruction 1 Disconnect all electrical wiring from the motor. Use the screwdriver to remove the plastic cap on the motor. Loosen the screw for the motor with the 10 mm box wrench. 2 Detach the motor from the drive shaft. Dismount the torque arm and fit it on the new motor, use the 13 mm box wrench.
Replace motor on XT conveyor drive unit – Centre mounted Introduction Valid for motor types M and HM (centre mounted motor). Tools Allen key 5 mm Retaining ring plier Instruction 1 Disconnect all electrical wiring from the motor. Release the chain from the drive wheel on the lain furthest away from the motor, see “Replace chain on XT conveyor module – End drive unit” on page 16. 2 Loosen the screws (2×M8) on the side plate furthest away from the motor. Use the 5 mm Allen key. Remove the side plate.
4 Adjust the keyway on the shaft so it fits the keyway of the motor gearbox. Make sure the key is correctly fitted in keyway. 5 Mount the motor on to the short shaft. The torque arm should be placed on the rubber tube. CAUTION! Make sure that the torque arm fork has entered the cage in a correct way. An unlocked rotating motor can cause personal injury. 6 Insert the long shaft through the inner side plate (furthest away from the motor).
Replace chain on XT Compact conveyor module Introduction Valid for XT Compact conveyor only. Tools Screwdriver Allen key 3 mm Allen key 2,5 mm Instruction 1 Use a screwdriver to remove the plastic cover on the idler end. 1 Use the 3 mm Allen key to loosen the screws on the idler end.
2 Carefully remove the plastic guides. First push it forward (1) and then pull the end out (2). 2 3 Remove the plastic guide on the other side. 4 Remove a pin (holding the chain together) in the idler end by pressing it through the chain. Use the 2,5 mm Allen key. 5 Remove the wheel.
6 Carefully pull the chain out. CAUTION! Make sure that the chain runs smoothly through the drive end. Risk for the chain to brake. 7 Note that the chain can be mounted one way only, even if it is bidirectional. The chain shall always be mounted in the direction according to the picture, on top of the beam from the idler end to the drive end. Mo un tin 8 Feed the chain to the drive end and if necessary help feeding it by pulling the other chain. If the other chain is removed turn the drive wheel.
10 Fit the pin into the chain, use the 2,5 mm Allen key. 11 Make sure that the pin snaps in to the correct position (centred). 12 Fit the plastic guide. 13 Carefully fit the other plastic guide. First push in the end (1) and then push it backward (2).
1 Fit the screws on the idler end, use the 3 mm Allen key. 2 Fit the plastic cover.
Replace driving belt on XT Compact conveyor module Introduction Valid for XT Compact conveyor only. Tools Box wrench 8 mm Allen key 3 mm Instruction 1 Remove the screws on the belt cover, use the 8 mm box wrench. 2 Remove the belt cover. Remove the chains according to instruction “Replace chain on XT Compact conveyor module” on page 35 3 Use the 3 mm Allen key to loosen the screws holding the drive unit cover, Remove the drive unit cover and the two distance washers.
4 Loosen the screws on the outer side of the drive unit, use the 3 mm Allen key. 5 Remove the screws (4×) on the inner side of the drive unit, use the 8 mm box wrench. 6 Carefully remove the end drive unit and unhook the driving belt from the motor. 7 Replace the old belt.
8 Hook the driving belt on the motor and carefully assemble the end drive unit back on the conveyor. 9 Fit and tighten the screws on the inner side of the drive unit, use the 8 mm box wrench. 10 Tighten the screws on the outer side of the drive unit, use the 3 mm Allen key.
12 Fit and tighten the screws holding the drive unit cover, use the 3 mm Allen key. Mount the chains according to instruction “Replace chain on XT Compact conveyor module” on page 35. 13 Assemble the belt cover. 1 Fit and tighten the screws on the belt cover, use the 8 mm box wrench.
Replace motor on XT Compact conveyor module Introduction Valid for XT Compact conveyor only. Tools Box wrench 10 mm Box wrench 8 mm Allen key 5 mm Instruction 1 Remove the screws on the driving belt cover. Use the 8 mm box wrench. 2 Remove the driving belt cover.
3 Loosen the screws holding the motor, use the 5 mm Allen key and 10 mm box wrench. 4 Remove the screws holding the motor. Remove the old motor and fit the new motor. 5 Fit the screws holding the motor. 6 Tighten the screws holding the motor, use the 5 mm Allen key and 10 mm box wrench.
7 Fit the driving belt cover. 1 Fit and tighten the screws holding the driving belt cover. Use the 8 mm box wrench.
Replace motor on XT transfer unit XTPT M1 Introduction Valid for XT transfer unit type M1. Tools Phillips screwdriver Allen key 5 mm Box wrench 10 mm Instruction 1 Remove the screws (8×) on the transfer unit covers on both sides. Use the Phillips screwdriver. Remove the covers. 2 Remove the screws (2x) holding the motor, use the 5 mm Allen key and the 10 mm box wrench. Replace the old motor and fasten the screws using the 5 mm Allen key and the 10 mm box wrench.
Replace motor on XT transfer unit XTPT M2 Introduction Valid for XT transfer unit type M2. Tools Allen key 3 mm Allen key 5 mm Box wrench 10 mm Instruction 1 Remove the screws (4×) on the transfer unit cover. Use the 3 mm Allen key. Remove the cover. 2 Remove the screws (2×) on the transfer unit bracket. Use the 5 mm Allen key.
3 Carefully lift upp the transfer unit. 4 Remove the screws (2×) which hold the motor, use the 5 mm Allen key and the 10 mm box wrench. Replace the old motor and fasten the screws using the 5 mm Allen key and the 10 mm box wrench. Make sure to hook the driving belt to the new motor. 5 When re-installing the transfer drive unit, make sure that the electric cable (A) does not get stuck between any moving parts. A 6 Carefully fit the transfer drive unit.
7 Fit and tighten the screws (2×) on the transfer unit bracket. Use the 5 mm Allen key. 8 Fit the cover Fit the screws (4×) holding the transfer unit cover. Use the 3 mm Allen key.
Replace driving belt on XT transfer unit XTPT M1 Introduction Valid for XT transfer unit type M1. Tools Phillips screwdriver Allen key 3 mm Allen key 5 mm Box wrench 10 mm Instruction 1 Remove the screws (8x) on the transfer unit covers on both sides. Use the Phillips screwdriver. Remove the covers. 2 Loosen the screws holding the transfer unit cover, use the 3 mm Allen key. Remove the transfer unit cover.
3 Remove the screws (2×) holding the conveyor unit. Use the 5 mm Allen key. 4 Carefully lean the conveyor unit forward. 5 Gently push the driving belt of the driving wheel. 6 Lift out the conveyor unit.
7 Loosen two screws holding the side cover (one side only), use a 10 mm box wrench. Remove the side cover. 8 Remove the screw holding the beam using a 5 mm Allen key. Remove the two screws holding the beam on the other side using the 8 mm box wrench. 9 Rotate the beam 90º around the shaft and replace the driving belt. Rotate the beam back 90º. 10 Fit the screw holding the beam using a 5 mm Allen key. Fit the two screws holding the beam on the other side using the 8 mm box wrench.
11 Fit the side cover and the two screws holding the side cover, use a 10 mm box wrench. 12 Put the conveyor unit back. 13 Carefully lean the conveyor unit forward. 14 Gently push the driving belt back on the driving wheel.
15 Fit the screws (2×) holding the conveyor unit. Use the 5 mm Allen key. 16 Fit the transfer unit cover and the screws holding the transfer unit cover. Use the 3 mm Allen key. 1 Fit the transfer unit covers and the screws (8×) on both sides. Use the Phillips screwdriver.
Replace driving belt on XT transfer unit XTPT M2 Introduction Valid for XT transfer unit. Tools Allen key 3 mm Allen key 5 mm Box wrench 10 mm Instruction 1 Remove the screws (4×) on the transfer unit cover. Use the 3 mm Allen key. Remove the cover 2 Remove the screws (2×) on the transfer unit bracket. Use the 5 mm Allen key.
3 Carefully lift upp the transfer unit. 4 Replace the old driving belt according to instruction “Replace driving belt on XT Compact conveyor module” on page 40. 5 When re-installing the transfer drive unit, make sure that the electric cable (A) does not get stuck between any moving parts. A 6 Carefully fit the transfer drive unit.
7 Fit and tighten the screws (2×) on the transfer unit bracket. Use the 5 mm Allen key. 8 Fit the cover Fit the screws (4×) holding the transfer unit cover. Use the 3 mm Allen key.
Mounting guide pins to locating, lift-and-rotate and lift-and-locate station Introduction Valid for all locating stations. Tools Allen key 4 mm Soft faced hammer Box wrench 10 mm Instruction 1 You need the following equipment to change guide pins. A A: Screw MC6S M5×25 B: Pipe Ø18×2×28 C: Washer Ø19 Ø6 t=4 D: Washer Ø25 Ø8 t=5 2 Place the piece of pipe (B) over the pin.
3 Place washer (C) on the pipe and tighten the screw (A) until it has reached the bottom of the thread on the guide pin. Use the 4 mm Allen key. 4 Remove the screw (A) and washer (C). 5 Place washer (D) on the pipe (B) and fit the screw (A) and washer (C). 6 Tighten the screw (A) until the guide pin is loose. Use the 4 mm Allen key.
7 Fit a new guide pin in the hole and use a soft faced hammer to fit it in place. 8 Turn the non cylindrical guide pin in position (see next picture). Use the 10 mm box wrench. 9 Locating pin position.
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XT Compact conveyor XTUC S11 Symptom Possible cause Action Reference Worn or damaged conveyor links Replace links or chain “Check wear or damage of conveyor chain” on page 6 Conveyor chain too loose Shorten conveyor chain “Check elongation of conveyor chain (only valid for conveyor > 1500 mm)” on page 6 Damaged or deformed slide rail Replace slide rail “Check the slide rails” on page 6 Worn driving belt Replace driving belt “Replace driving belt on XT Compact conveyor module” on page 40 Overl
XT Conveyor XTUC _51/52 Symptom Jerky movment Noisy Possible cause Action Reference Worn or damaged conveyor links Replace links or chain “Check wear or damage of conveyor chain” on page 8 Conveyor chain too loose Shorten conveyor chain “Check tension of conveyor chain” on page 8 Damaged or deformed slide rail Replace slide rail “Check the slide rails” on page 9 Worn infeed guides Replace infeed guides “Check wear or damage of guides in drive unit” on page 9 Overloaded conveyor Remove load
XT Transfer unit XTPT PWxPL Symptom Possible cause Action Reference Worn or damaged conveyor links Replace links or chain “Check wear or damage of conveyor chain” on page 10 Conveyor chain too loose Shorten conveyor chain Compare “Check elongation of conveyor chain (only valid for conveyor > 1500 mm)” on page 6 Damaged or deformed slide rail Replace slide rail Compare “Check the slide rails” on page 6 Wrong driving belt Replace driving belt “Replace driving belt on XT transfer unit XTPT M1” on
XT Locating station XTPX P11 A Symptom Possible cause Action Reference Worn guide pins Replace guide pins “Check wear of guide pins” on page 11 If fault remains Incorrect orientation Rotate pin to correct “Assembly manual of non-cylindric orientation XT modules” guide pin Incorrect position of Jam and noise when lift units lifting, lowering the pallet Incorrect position of stop Correct distance between units to fit the pallet bushings “Check docking of pallet” on page 11 Adjust placement of stop
XT Lift & Rotate station XTPR Symptom Possible cause Action Reference Worn guide pins Replace guide pins “Check wear of guide pins” on page 13 If fault remains Incorrect orientation Rotate pin to correct “Assembly manual of non-cylindric orientation XT modules” guide pin Incorrect position of Adjust placement of stop stop to fit the locating unit Jam and noise when “Check speed of lifting, lowering the Incorrect position of Adjust the end guide pins position of the rotate rotating movement” pallet
