0852 Drive-In 4P With PLC: Assembly and Operating Instructions E-Rtg / RTG Electrification System

Assembly and Operating Instructions
E-RTGTM / RTG electrification system

0852 Drive-In 4P with PLC
8.2.16 Replacing the tooth belt of the vertical unit
Risk of injury!
→ Read and observe the safety instructions in Chapters 8.1 and 8.2.4.
→ Secure the drive-in unit against unexpected activation.
CAUTION!
→ Safety systems that have been removed must be replaced and checked immediately after work is
completed.
→ After work, recollect the measuring tools used and check the inventory.
On the DIU-variants T2 and T4 (option winter and option winter/summer), there are additional covers
provided. Eventually, these must be removed.
ADVICE!
Tools required:
Allen wrench Crescent wrench

Size 5 Size 7
Size 8 Size 8
Size 10
Size 13
Size 17
Size 24
Starting situation:
• Current collector trolley in lowest position (2) (final stop on rubber buffer),
• linear extension on final stop (1),
• extension locked (3).
Figure 90: Starting situation for tooth belt replacement procedure
MAL0852-0001e-EN
www.conductix.com translated document page 109 of 150

8.2.16.1 Removing the current collector trolley
Steps:
4
→ Remove the hexagon bolt M8 x 25 and locking nut M8 (4)
of the PE cable.
→ Remove the hexagon bolt M5 x 30 and locking nut M5 (5)
of the shackle for the safety rope.
5
→ Repeat the procedure on the opposite side.
Figure 91: Removing the PE-cable
→ Cut all cable straps on the current collector trolley (except

those on the current collectors).
→ Remove all 4 hexagon bolts M4 x 16 that are used to
6
fasten the magnetic switches, complete with washers and
locking nuts (6).
Figure 92: Removing magnetic switches
→ Remove the cables of the initiators by loosening the fit

nuts (7).
Figure 93: Separating cables from initiators
→ Unscrew the connecting piece (8) on the cable of the

sensor bearing.
Figure 94: Disconnecting the connecting piece of the cable of the

sensor bearing
MAL0852-0001e-EN

→ Remove hexagon bolts M6 x 25 including washer and

locking nut M6 (9) of the energy guiding chain plate (10).
→ Repeat the procedure on the opposite side. 9
10
Figure 95: Removing the fastening of the energy guiding chain
→ Secure the current collectors (11) against falling down.

→ Remove cylinder bolts M10x280 (12).
11
12
Figure 96: Removing current collectors
→ Put the current collectors (11) aside (on a table, a trolley,

etc.), without straining the cables.
11
Figure 97: Removing current collectors
→ Unscrew locking nut M10 (13).

→ Repeat the procedure at the other 3 screw connections.
→ Remove current collector trolley. 13
Figure 98: Removing the current collector trolley
MAL0852-0001e-EN

8.2.16.2 Removing the tooth belt of the vertical unit
→ Loosen Nuts M6 and hexagon bolts M6 x 25 and washers

(15) of the safety plate (14), remove safety plate.
14
15
Figure 99: Removing the safety plate
On the DIU-variants T2 and T4 (option winter and option winter/summer), first remove the top cover of the
vertical unit. To remove the cover, unscrew the 4 lateral bolts.
ADVICE!
→ Remove counter nuts M16 (16) on both sides.
16
Figure 100: Removing the counter nut
→ Loosen nut M16 and hexagon bolts M16 x 150 (18) until 17
the tooth belt (17) slackens.
18
Figure 101: Reducing the tooth belt tension
→ Remove hexagon bolts M10 x 65 and washers (21) of the

clamping plate (19/20).
19
20
21
Figure 102: Removing the clamping plate
MAL0852-0001e-EN

→ Remove the defective tooth belt (17).

→ Replace all loosened locking nuts.
17
Figure 103: Removing the tooth belt
8.2.16.3 Mounting the tooth belt of the vertical unit
→ Lay the tooth belt on the tooth belt pulleys (22).
17
Figure 104: Laying on the tooth belt
→ Fixing the tooth belt (17): Mount the clamping plate (19 / 17
20) with hexagon bolts M10 x 65 and washers (21).
19
20
21
Figure 105: Mounting the clamping plate
→ Tightening the tooth belt (17): Tighten the hexagon bolts

und Nuts (18) that are located to the right and to the left 17
side of the lower tooth belt pulley in an alternating manner.
Pay attention to keep the axle of the tooth belt pulley
oriented perpendicular relative to the tooth belt. 18
→ Check the belt tension with a Tensiometer
(WF - Tensiometer made by Walther Flender, e. g.).
→ 36 Hz ± 1 Hz measured at the back.
Figure 106: Tightening the tooth belt
MAL0852-0001e-EN

→ Lock the screw connection with counter nuts M16 (16) on

both sides.
→ Make sure that the clamping plate (19 / 20) rests on the
16
rubber buffers (see starting situation).
Figure 107: Locking the screw connection with counter nut
→ Fix the safety plate (14) with hexagon bolts M6 x 25 and

new locking nuts M6 including washers (15).
→ Drill a hole Ø7 mm into the tooth belt. 14
→ Additionally, fix the safety plate with hexagon bolt M6 x 25
including locking nut and washer. 15
Figure 108: Mounting the safety plate
On the DIU-variants T2 and T4 (option winter and option winter/summer), reinstall the top cover of the
vertical unit. To reinstall the cover, mount the 4 lateral bolts.
ADVICE!
8.2.16.4 Mount the current collector trolley
→ Fix the current collector trolley with locking nut M10

including washer and hexagon bolt M10 x 65 (13).
13
Figure 109: Mounting the current collector trolley
→ Lift the current collectors (11) into the current collector

trolley from below.
11
Figure 110: Mounting the current collectors
MAL0852-0001e-EN

→ Fix the current collectors with

cylinder bolts M10 x 280 (12).
12
Figure 111: Fixing the current collectors
→ Mount the energy guiding chain plates (10) with hexagon 26

bolts M6 x 25 including washers und locking nuts M6 (9) to
9
the plate (26).
10
Figure 112: Fixing the energy guiding chain
→ Mount hexagon bolt M8 x 25, washer and locking nut (4) of 4

the PE-cable.
→ Mount hexagon bolt M5 x 30 and locking nut (5) of the 5
shackle for the safety rope.
Figure 113: Fixing the PE-cable
→ Connect the connection piece of the sensor bearing (8).
Figure 114: Connection piece of the sensor bearing
MAL0852-0001e-EN

→ Connect the cables to the initiators (7) and tighten the

screw connectors.
Figure 115: Connecting the cables to the initiators
→ Mount the magnetic switches with 4 hexagon bolts M4 x 16

including washers and locking nuts (6).
6
Figure 116: Mounting magnetic witches
22
→ Fix the cables for the initiator and the magnetic switch on
the rear side shield (23) with cable straps (22).
22
23
Figure 117: Fixing cables
22
→ Fix the plug of the sensor bearing with cable straps to the
support plate.
22
→ Fix the cables for the sensor bearing and the magnetic
switch with cable straps (22) to the front side shield (24) 24
and to the hexagon rod (25). 25
22
Figure 118: Fixing cables
MAL0852-0001e-EN

8.2.17 Replacing the tooth belt on the linear extension
Risk of Injury!
→ Read and observe the safety instructions in Chapters 8.1 and 8.2.4.
→ Secure the drive-in unit against unexpected activation.
CAUTION!
→ Safety systems that have been removed must be replaced and checked immediately after work is
completed.
→ After work, recollect the measuring tools used and check the inventory.
On the DIU-variants T2 and T4 (option winter and option winter/summer), there are additional covers
provided. Eventually, these must be removed.
ADVICE!
Tools required:
Crescent wrench size 13.
Starting situation:
• Current collector trolley in lowest position (2) (final stop on rubber buffer),
• linear extension on final stop (1),
• extension locked (3).
Figure 119: Starting situation for tooth belt replacement
MAL0852-0001e-EN

0852 Drive-In 4P With PLC: Assembly and Operating Instructions E-Rtg / RTG Electrification System

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0852 Drive-In 4P With PLC: Assembly and Operating Instructions E-Rtg / RTG Electrification System

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Assembly and Operating Instructions

E-RTGTM / RTG electrification system

Allen wrench Crescent wrench

Figure 90: Starting situation for tooth belt replacement procedure

E-RTGTM / RTG electrification system

Figure 91: Removing the PE-cable

→ Cut all cable straps on the current collector trolley (except

Figure 92: Removing magnetic switches

→ Remove the cables of the initiators by loosening the fit

Figure 93: Separating cables from initiators

→ Unscrew the connecting piece (8) on the cable of the

Figure 94: Disconnecting the connecting piece of the cable of the

E-RTGTM / RTG electrification system

→ Remove hexagon bolts M6 x 25 including washer and

Figure 95: Removing the fastening of the energy guiding chain

→ Secure the current collectors (11) against falling down.

Figure 96: Removing current collectors

→ Put the current collectors (11) aside (on a table, a trolley,

Figure 97: Removing current collectors

→ Unscrew locking nut M10 (13).

Figure 98: Removing the current collector trolley

E-RTGTM / RTG electrification system

→ Loosen Nuts M6 and hexagon bolts M6 x 25 and washers

Figure 99: Removing the safety plate

→ Remove counter nuts M16 (16) on both sides.

Figure 100: Removing the counter nut

Figure 101: Reducing the tooth belt tension

→ Remove hexagon bolts M10 x 65 and washers (21) of the

Figure 102: Removing the clamping plate

E-RTGTM / RTG electrification system

→ Remove the defective tooth belt (17).

Figure 103: Removing the tooth belt

8.2.16.3 Mounting the tooth belt of the vertical unit

→ Lay the tooth belt on the tooth belt pulleys (22).

Figure 104: Laying on the tooth belt

Figure 105: Mounting the clamping plate

→ Tightening the tooth belt (17): Tighten the hexagon bolts

E-RTGTM / RTG electrification system

→ Lock the screw connection with counter nuts M16 (16) on

Figure 107: Locking the screw connection with counter nut

→ Fix the safety plate (14) with hexagon bolts M6 x 25 and

Figure 108: Mounting the safety plate

8.2.16.4 Mount the current collector trolley

→ Fix the current collector trolley with locking nut M10

Figure 109: Mounting the current collector trolley

→ Lift the current collectors (11) into the current collector

Figure 110: Mounting the current collectors

E-RTGTM / RTG electrification system

→ Fix the current collectors with

Figure 111: Fixing the current collectors

→ Mount the energy guiding chain plates (10) with hexagon 26

Figure 112: Fixing the energy guiding chain

→ Mount hexagon bolt M8 x 25, washer and locking nut (4) of 4

Figure 113: Fixing the PE-cable

→ Connect the connection piece of the sensor bearing (8).

Figure 114: Connection piece of the sensor bearing

E-RTGTM / RTG electrification system

→ Connect the cables to the initiators (7) and tighten the

Figure 115: Connecting the cables to the initiators

→ Mount the magnetic switches with 4 hexagon bolts M4 x 16

Figure 116: Mounting magnetic witches

Figure 117: Fixing cables

Figure 118: Fixing cables