Bosch Rextroth TSplus Operating instructions

Modular Transfer Systems
TSplus Lift-Transfer Unit
Model EQ2/U3
Installation and Maintenance
Publication Number: 8981 500 299 7/02
Lift-Transfer Unit
2
Table of contents
IMPORTANT SAFETY INFORMATION .................. 3
For Lift And Lower Operation.................................. 14
Safety First ................................................................. 3
For Lift Only Operation ............................................. 14
Material Hazards: ...................................................... 3
Stop Rail Orientation ................................................. 16
Review All Safety Information: ............................... 3
Cushioned Stop Pneumatic Diagram .................... 16
IMPORTANT SAFETY INFORMATION .................. 4
Installing Optional Cushioned Stop
BWT = 480 and smaller ........................................... 17
SAVE THESE INSTRUCTIONS ............................... 4
Introduction .................................................................... 5
Installing Optional Cushioned Stop
BWT = 640 ................................................................. 17
About this manual ......................................................... 5
Operating Instructions .............................................. 18
Design and Detailed Description ............................. 6
Maintenance ................................................................ 19
Application and Function ............................................ 7
Repair ............................................................................ 20
Using T-Bolts and T-Nuts ........................................... 8
Replacing the Toothed Belt ..................................... 20
Attach LTU to Conveyor Section ............................. 9
Replacing Gear Box .................................................. 22
Installing Proximity Switch ........................................ 10
Installation of Protective Covers ............................. 25
Checking and Adjusting Toothed Belt Tension .. 11
Scope of Delivery ................................................... 25
Initial Start-up .............................................................. 12
Step by Step Assembly Instructions .................. 26
Connect the motor wiring ......................................... 12
Module Warranty ........................................................ 28
For CE Applications................................................... 13
Liability .......................................................................... 28
Terminal Block Assembly Instructions .................. 13
Environmental Protection ......................................... 28
Connect the Compressed Air Supply ................... 14
All rights are held by BOSCH AUTOMATION PRODUCTS and
ROBERT BOSCH GMBH, also regarding patent claims. We retain
all powers of disposition, such as for copying and/or for passing-on to
third parties.
We reserve the right to make technical changes at any time
without notice.
Errors and omissions excepted.
© 2002 Bosch Automation Products
3
IMPORTANT SAFETY INFORMATION
IMPORTANT: This operation and installation manual should be reviewed
with all equipment operators as part of your operator training program.
SAFETY FIRST!
Important safety information is contained throughout
this manual to alert you to potentially dangerous
situations and help prevent accidental injury and
property damage.
The safety warning symbol above has been included to
warn you of hazards that can hurt or kill you and
others, and/or cause serious damage to the equipment
and other property.
In addition, the following safety alert words are used:
DANGER!
Means that you or others will
be seriously or fatally injured if
instructions are not followed.
WARNING!
Means that you or others may
be seriously or fatally injured if
instructions are not followed.
CAUTION!
Means that you or others may
be injured if instructions are
not followed.
Material Hazards:
Some components, such as gearboxes, contain
lubricants or other materials that can represent a
potential health hazard if handled, stored, or disposed of improperly.
Please contact Bosch for copies of the Material
Safety Data Sheets (MSDS) for the lubricating oil
used in gearboxes and other potentially hazardous
materials.
Review All Safety Information:
Please review the safety information included on
page 4 and throughout this manual with all installers,
operators, and maintenance personnel of this equipment.
4
IMPORTANT SAFETY INFORMATION
WARNING!
Please read all assembly, and maintenance instructions
carefully before beginning set-up of the components in
this document.
Where appropriate, warning symbols
have been
included in this publication to alert you of potential or
impending danger.
• Be sure to read and observe all safety warnings in
this document as well as those attached to the
individual modules. Failure to do so could result in
potential risks to your health and safety as well as
those around you.
• Covers and guards have been designed to eliminate pinch points and exposure to moving chains
and gears. DO NOT operate the conveyor or any
of the other components in the system with the
guards removed. Serious injury may result!
• All set-up maintenance and repair work should
be performed only by properly trained, qualified
personnel. All operators must be properly trained
in the use of this equipment.
• A qualified electrician must make all electrical
connections when wiring the components installed in the TSplus system. Be sure to follow all
local, state and federal regulations when installing
electrical devices of any type. The customer assumes responsibility for the control system, and
must provide an EMERGENCY-OFF SWITCH or
switches for all workstation operators to meet all
applicable industry and OSHA requirements. In
general, emergency-off switches must be present
at easily accessible locations for all operators of
the installed TSplus conveyor system.
• All power supplies must be LOCKED OUT before
beginning maintenance or repair work of any type
on the conveyor system. Proper LOCK OUT
procedures include the identification of the locked
out power supply with a tag to prevent the accidental restoration of power.
• TSplus pneumatic components are designed to
operate in a range of 4–6 Bar (58–87 psi). It is the
users responsibility to install a filtered, regulated
air supply to limit the pressure to that recommended by the manufacturer. Before beginning
any maintenance or repair, bleed off the pressure
lines to all components to prevent unexpected or
accidental movement of a system component
which could result in personal injury.
• TSplus drives, returns and conveyor sections and
components are designed to transport Bosch
WT2, WT2/A, WT2/A-H workpiece pallets. Proper
usage is defined as the transport and positioning
of parts and assemblies via the workpiece pallet
and fixture during the assembly process. In no
instances should the pallet payload, the downward force applied to the pallet, or the total load
carrying capacity of the entire system be exceeded. Exceeding published specifications will
result in premature wear or system failure and may
cause damage to the motor, gearbox, roller chain,
seals and other components.
• CAUTION! Do not operate or work near mechanical equipment when wearing loose clothing. Moving components such as roller chain, drive belts,
drive shafts and pallets can snag long belts,
scarves, ties and other loose fitting garments, pull
the worker into the equipment and cause serious,
or in extreme cases, life threatening injury.
• CAUTION! Operators having long hair must wear
appropriate head protection (hair nets, hats, and
hair caps) to minimize the risk associated with
working near moving machinery. Hanging hair can
get caught in moving components such as roller
chain, drive belts, drive shafts and pallets, pull the
worker into the equipment and cause serious, or
in extreme cases, life threatening injury.
SAVE THESE INSTRUCTIONS!
5
Introduction
Like all Bosch flexible assembly systems, TSplus is
constructed solely from standardized modules that
are precisely matched to each other. One important
benefit of this modular design is that you can interlink
manual and automatic work stations freely, making
TSplus suitable for virtually any assembly task. The
EQ2/U3 Lift Transfer Unit (LTU) module allows you to
transfer pallets laterally off of the main conveyor line.
This manual describes the primary components
that make up the EQ2/U3 Lift Transfer Unit (refer to
page 6 for a description of primary components and
their functions).
Other TSplus modules are also available and vary
according to the configuration of the system. These
modules are described in separate manuals and include the following:
About this manual
The manual is divided into the following sections to
make it easier to use:
• Design and Detailed Description
Supplies an overview of the modules that make
up the EQ2/U3. This section will familiarize you
with the modules individual components.
• Drives, Returns, and Conveyor Sections
• Cushioned and Standard Stop Gates, Rockers
• Proximity Switch Mounting Kits
• Accumulation Control Kits
• Lift-Position Units
• Application and Function
Gives general information about the EQ2/U3
Tandem Lift Transfer Unit.
• Lift-Rotate Units
• Curve Modules
• Technical Data
Provides the most important technical specifications.
• Assembly
Lists step-by-step instruction for installing the
EQ2/U3 .
• Initial Start-up
Describes the final procedures for getting the
EQ2/U3 up and running.
• Maintenance
Provides information on preventive maintenance.
• Repair
Gives step-by-step procedures for replacing any
parts subjected to wear.
Contact Bosch for information on these and any other
modules for flexible assembly.
If this module was ordered as CE compliant, please
contact our applications engineering department for a
copy of the latest manufacturer's CE declaration.
6
Design and Detailed Description
The EQ2/U3 includes a drive motor to power the
toothed belts, two spring centered 3-position pneumatic cylinders, stop bar/guide bar, protective covers, pneumatic connections and mounting hardware.
A proximity switch mounting bracket is also included.
Due to the stroke, all three positions may not be
sensed, as three proximity switches will not fit into the
space available. It is recommended that the center
“pallet stop position” be sensed and the signal lost on
the up and down strokes. The proximity switch mounting kit can also be ordered separately under part
number: 3842 311 894.
In the EQ2/U3 (Fig. 1), the motor and gearbox power
the toothed belt conveyor via the belt drive gears.
Double acting pneumatic cylinders on the LTU may
be configured to lower the toothed belt conveyors
below the transport surface to allow pallet passthrough, or raise the pallet on the toothed belt conveyors above the transport surface. In the raised position, the toothed belts transfer the pallet across a
track roller section or transverse conveyor onto the
receiving LTU. The pneumatic cylinders on the receiving LTU then exhaust and lower the pallet to the
transport surface of the parallel line. A protective
cover protects the mechanism of the LTU from dirt
and damage and helps prevent accidental injury.
Proximity switches may be mounted to detect raised
or lowered status of the LTU.
CAUTION!
DO NOT operate the
EQ2/U3 with the protective cover removed!
Serious injury may result if the EQ2/U3 is
operated without guards!
3-Position
Pneumatic Cylinders
Stop Bar
Toothed Belt
Conveyor
T-Bolt
Muffler
Drive Motor
Protective
Cover
Fig. 1
7
Application and Function
The EQ2/U3 Lift Transfer Unit (LTU) is used
to transfer pallets perpendicularly off the conveyer. It is used primarily at “corners” and
“intersections”, but can also be used for pallet
routing changes.
“Corner Transfer” requires LTU operation in
the “Pallet Stop” and “Transfer” positions as
shown.
Optional
Cushioned
“Intersection Transfer” requires LTU operaStop
tions in the “Pallet Stop”, “Transfer” and
“Clear” positions as shown. Intersection Transfer permits the pallet to be directed off the
main line or allows the pallet to pass through
depending on the process requirement.
The LTU lift plate is powered up and down by
two pneumatic cylinders. In the spring centered, “Pallet Stop” position, the LTU belts
are located 1 mm below the bottom of the
pallet. A stop bar mounted to the lift plate may
be used to stop pallets on the LTU, or inverted
so pallets pass through freely. An optional
cushioned stop may be installed when pallet
payloads exceed 30 kg or with transport
speeds of 12 m/min or greater.
Rocker
Stop
“Corner Transfer”
“IntersectionTransfer”
1 mm
Centered “Pallet Stop” Position
10 mm
Raised “Transfer” Position
The LTU is raised to the “Transfer Position”
by applying air pressure to the bottom of the
cylinders. This lifts the LTU to a position 10
mm above the nominal conveyor height. As
the LTU rises, the LTU belts engage the pallet
and directs (or accepts) the pallet.
11 mm
The LTU is lowered to the “Clear Position” by
applying air pressure to the top of the cylinders. This pushes the LTU down to a position
11 mm below the nominal conveyor height.
Use the lowered position when it is required
to allow pallet pass through on the main
conveyor at spur lines and test stations for
example.
Lowered “Clear” Position
8
Operation (Fig. 2)
Pallet transfer from one parallel line to an adjacent line
requires the use of a sending EQ2/U3 and a receiving
EQ2/U3 located at each end of a set of track rollers
or a transverse conveyor.
The sending LTU waits in “Pallet Stop” mode below
the transport surface level until a pallet passes over
the LTU and is stopped by the stop rail or a cushioned
stop triggering a proximity sensor that activates the
LTU. The pneumatic cylinders in the LTU then energize, lifting the pallet perdendicularly off the main line,
across the non-powered track rollers or powered
transverse conveyor, and onto the waiting LTU. The
waiting LTU then lowers the pallet back to the transport surface of the parallel line.
Sending
Lift
Transfer
Unit
Receiving
Lift
Transfer
Unit
Pallet
Flow
Track
Rollers
or
Transverse
Conveyor
Fig. 2
Using T-Bolts and T-Nuts
A
The EQ2/U3, like virtually all Bosch conveyor modules, is connected to the transfer system using the Tslot principle (Fig. 3). Insert the T-bolt into slot (A), and
tighten down the hex nut. As it tightens, it will turn the
T-bolt 90° in the slot (B), creating a friction lock (C).
The same principle applies to T-nuts. The maximum
allowable torque is 25 Nm (18.5 ft-lbs).
B
ASSEMBLY TIP: T-Bolts also have a mark on the
end of the threaded shaft that will be perpendicular
to the T-slot when the T-Bolt is in its locked position.
C
Fig. 3
Mark
9
Attach LTU to Conveyor Section
(Fig. 4 and 5)
1 Mark the location on the conveyor line where the
LTU is to be installed.
conveyor section profile SP/2. Hand tighten the
M8 flange nut.
6 Attach supporting bar to mounting brackets
using hardware previously removed.
2 Remove middle guard cover.
3 Remove mounting brackets (2 per side) from
supporting bar on LTU and install in T-slot on
conveyor section profiles.
4 Lower EQ2/U3 from above onto conveyor
section profiles and set down on the four brackets. Adjust bracket position if necessary.
5 Manually insert four M8 T-bolts with the T-heads
through the oblong holes in the T-slot of the
7 Check alignment. (Fig. 5)
NOTE: Use a straightedge to be sure that the Lift
Transfer Units and track rollers are in perfect alignment from side-to-side, as shown in Fig. 5. This is
critical for pallet transfer.
8 Tighten the M8 flange nuts to 25 Nm (19 lb-ft).
Middle Guard
Cover
Sending
Lift
Transfer
Unit
Conveyor
Section
Profile
Supporting
Bar
Pallet
Flow
T-slot
M8 Flange
Nut
M8
T-bolt
Mounting
Brackets
Fig. 4
T-groove
Conveyor
Section
Profile
Fig. 5
Straight
Edge
Receiving
Lift
Transfer
Unit
Track
Rollers
or
Transverse
Conveyor
10
Installing Proximity Switch (Fig. 6)
1 Install the proximity switch in the mounting
bracket so that the sensing distance is approximately 2 mm (see inset).
NOTE: Due to the stroke, all three positions can not
be sensed, as three proximity switches will not fit
into the space available. It is recommended that the
center “Pallet Stop” position be sensed and the
signal lost on the up and down stroke.
Proximity Switch
Exciter
Proximity Switch
Mounting Bracket
2 mm
Proximity
Switch
Fig. 6
11
Checking and Adjusting Toothed Belt
Tension
NOTE: Incorrect toothed belt tension can lead to
premature belt failure! Always check toothed belt
tension prior to initial operation!
Using a moderate amount of pressure, press upward
on the belt for a deflection of approximately 10 mm
(see inset 2) .
To re-tension the toothed belt, loosen the 5 mm
socket head cap screw on the return roller (see inset
1). Then using a pry bar (screwdriver) move the return
roller upward until the belt can be deflected, using a
moderate amount of pressure, approximately 10 mm
(see inset 2). Retighten the socket head cap screw.
Recheck tension.
Toothed
Belt
Return
Roller
INSET #1
Pry Bar
5 mm
Socket Head
Cap Screw
"Z"
INSET #2
Fig. 7
12
Initial Start-up
For CE applications, refer to the next page for instructions on installing and connecting the terminal block.
Before starting up the Lift Transfer Unit for the first
time, recheck all mounting hardware for tightness.
Delta Connection
(Low Voltage)
L2
(Blk/Yel)T4 T2 (Blu)
NOTE: The customer assumes responsibility for the
control system, and must provide an EMERGENCYOFF SWITCH in the EQ2/U3.
T5(Blu/Yel)
(Blk) T1
T3 (Red)
(Red/Yel) T6
Connect the motor wiring
Grn/Yel TR (Gnd)
Make the motor electrical connections according to
the connection schematic as shown (see Fig. 8) . An
additional copy is also attached to the motor nameplate.
NOTE: All electrical wiring must be connected by a
qualified electrician.
“Y” Connection
(High Voltage)
T2
T5
T6
T4
T1
Blu
L2
Star Splice
(Blk/Yel, Blu/Yel
Red/Yel)
T3 Red
Blk
Grn/Yel TR (Gnd)
Fig. 8
L3
L1
L3
L1
13
For CE Applications
If a CE compliant module was ordered, an optional
terminal block (Fig. 9) was included. Refer to the
terminal box mounting instructions included with the
terminal box.
Blue
#4-40 Screw
Orange
#4-40 Screw
Terminal Block Assembly Instructions
1. Attach the terminal box to the motor according
to the mounting instructions included with the
terminal box. See Fig. 9.
2 Assemble the terminal block components to
produce an assembly having the following order:
support block, beige middle, blue middle block,
orange block and beige end block. See Fig. 9.
3 Secure the terminal block assembly to the
terminal box using two #4-40 screws in the
position shown. Tighten in the range 3 to 5 lb-in.
5 For a “DELTA” connection, terminate the motor
and line leads as follows:
Beige
Fig. 9
6 For a “Y” connection, terminate the motor and
line leads as follows:
a Insert the red-yellow motor lead, the black
motor lead and a line lead into the blue
middle block.
a Insert the black-yellow, and blue-yellow and
red-yellow motor leads into the beige middle
block opposite the motor lead exit.
b Insert the black-yellow motor lead, the blue
motor lead and a line lead into the orange
middle block.
b Insert the black motor lead and a line lead
into the blue middle block.
c Insert the blue-yellow motor lead, the red
motor lead and a line lead into the beige end
block near the motor lead exit.
c Insert the blue motor lead and a line lead into
the orange middle block.
d Insert the red motor lead and a line lead into
the beige end block near the motor lead exit.
14
Connect the Compressed Air Supply
(Fig.s 10, 11, and 12)
NOTE: Use a 5/3 way open center position control
valve (not included) to direct airflow to the module.
A 2-way valve will not work because the center
position is lost and the upward flow cannot be
controlled.
The EQ2/U3 Tandem Lift Transfer Unit must be
supplied with a filtered, regulated compressed air
supply of 4–6 bar (58–87 psi). The customer must
provide any necessary air preparation equipment.
All air connections should be made with 8 mm pushlock type fittings. If a different air line size is used, the
customer is responsible for installing the necessary
fittings. Connect the fittings for the lift cylinders to the
flow controls A and C.
2. Connect an 8 mm air line from a control valve
(not included) to the quick connect fitting on
flow control C. This connection will supply air
for LTU lowered operation, powering the unit
down, 11 mm below the transport surface to
allow pallet pass through.
3. Adjust flow controls A, B, and C as described in
Fig. 10 to regulate lift and lower operation.
NOTE: If as in the end of a rectangular line, pallets
do not need to pass through the LTU, the LTU can
be set up for Lift Only operation. The springs in the
cylinders will then return the LTU to the centered
(home) position.
For Lift Only Operation (Fig. 11 and 12)
The LTU can be plumbed for either lift and lowered
operation to allow pallet pass through or for lift only
operation. See Fig. 10
For Lift And Lower Operation (Fig. 11 and 12)
1. Connect and 8 mm air line from a control valve
(not included) to the quick connect fitting on
flow control A. This connection will supply air for
LTU lift operation.
Dual Cylinder Lift and Lower Operation
5/3 Way Open Center
Position Valve (Not Included)
C
D8
D8
A
A
B
C
1
2
1
2
B
1. Connect an 8 mm air line from a control valve
(not included) to flow control A. This connection
will supply air for LTU lift operation.
2. Remove the quick connect fitting on flow control
C and install the muffler.
3. Adjust flow controls A, B, and C as described in
Fig. 10 to regulate lift and lower operation.
Dual Cylinder Lift Only Operation
5/3 Way Open Center
C
Position Valve (Not Included)
Muffler
2
1
D8
2
1
A
B
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 playload.
Controls flow of air into cylinder for lift cylce. Increasing flow will cause the LTU to lift at a faster rate. Adjust as
needed for playload.
Controls the exhaust flow of air from cylinder as it is being lifted. Increasing air flow will cause the LTU to lift a faster
rate but also reduce end of stroke cushioning. Adjust as needed for playload.
Fig. 10
15
BWT=480 mm
For Lift Only Operation Remove
Quick Connect Fitting In Flow Control “C”
And Install a Muffler.
Quick
Connect
Fitting
Quick
Connect
Fitting
Flow
Muffler Control C
C
B
A
Flow
Control A
8 mm
Push Type
Fitting
Flow
Control B
Fig. 11
BWT=640 mm
For Lift Only Operation Remove
Quick Connect Fitting In Flow Control “C”
And Install a Muffler.
Quick
Connect
Fitting
C
B
A
Quick
Connect
Fitting
Flow
Control C
Muffler
Flow
Control A
Flow
Control B
Fig. 12
Push Type
Air Fitting
16
Stop Rail Orientation (see Fig. 13)
As delivered LTU stop rails are positioned so a pallet
will not stop on the LTU when it is in the centered or
home position. If your application requires, either
stop rail can be repositioned to stop a pallet entering
the LTU prior to lift and transfer. When total pallet
payload exceeds 30 kg or 12 m/min you must use a
cushioned stop to halt pallet travel.
1. To change stop rail orientation, remove the
socket head cap screws and turn the stop rail
180° and reattach it to the LTU.
BL=320, 400, 480 mm
Stop Plate
BL=640 mm
NOTE: Large LTUs have one stop rail on each side
and smaller LTUs have two stop blocks, one on
each end.
Stop Plate
Fig. 13
Cushioned Stop Pneumatic Diagram
(Fig. 14)
NOTE: Cushioning action can be adjusted to compensate for pallet payloads. Turning screw clockwise toward + will increase cushioning
Fig. 14
17
Installing Optional Cushioned Stop
BWT = 480 and smaller (Fig. 15)
Stop
Tab
1. On side you are mounting the stop, position
both stop blocks with the stop tab up.
Cushioned
Stop
2. Install stop bracket onto side of roller carrier as
shown using the screws, lockwasher and hex
nut included with cushioned stop. See Fig. 15.
Stop
Bracket
Guard
Plate
3. Attach guard plate to bottom of stop bracket as
shown.
4. Mount cushioned stop to stop bracket with
mounting hardware shown.
5. Connect compressed air supply to inlet port.
Fig. 15
Installing Optional Cushioned Stop
BWT = 640 (Fig. 16)
Cushioned
Stop
1. On side you are mounting the stop, position stop
rail with the notch up.
Stop Rail
Notch
2. Install stop bracket with screws included with
cushioned stop
Guard
Plate
3. Attach guard plate to bottom of stop bracket as
shown.
4. Mount cushioned stop to stop bracket with
mounting hardware shown.
5. Connect compressed air supply to inlet port.
NOTE: Cushioning action can be adjusted to compensate for pallet payloads. Turning screw clockwise
toward + will provide increased cushioning.
Stop
Bracket
Fig. 16
18
Operating Instructions
The TSplus conveyor is designed to transport Bosch
WT2 workpiece pallets or WT2 workpiece pallet
frames with integrated fixtures built into the pallet
design. Since the conveyor is modular in design and
part of a larger operating assembly system, it is the
WARNING!
• Use a qualified technician who is familiar with the
control system during the initial start-up.
• In case of control system failure, DO NOT attempt to catch or in any way prevent a pallet from
falling from the end of the conveyor. Use the
emergency stop switch to halt conveyor movement!
• KEEP HANDS CLEAR of moving conveyors and
pallets. Pallet accumulation creates a crush hazard between pallets, stop gates, and guide rails.
A crush and pinch hazard exists between Lift
Position Units, Lift Transfer Units, and Lift Rotate
Units. Assembly operations should be performed
ONLY when the workpiece pallet has come to a
complete stop.
• DO NOT perform pressing operations on a workpiece pallet without the use of a Lift Position Unit.
• DO NOT operate the conveyor or any other
components in the system with the guards removed. It is the operator’s responsibility to make
sure that all guards, covers, and other safety
equipment is in place before the system is put into
operation.
responsibility of the integrator or end user to provide
a control system and operating procedures. For your
safety, please observe the following guidelines when
operating the conveyor:
CAUTION!
• Do not operate or work near mechanical equipment when wearing loose clothing. Moving components such as roller chain, drive belts, drive
shafts and pallets can snag long belts, scarves,
ties and other loose fitting garments, pull the
worker into the equipment and cause serious, or in
extreme cases, life threatening injury.
• Operators having long hair must wear appropriate
head protection (hair nets, hats, and hair caps)
to minimize the risk associated with working near
moving machinery. Hanging hair can get caught in
moving components such as roller chain, drive
belts, drive shafts and pallets, pull the worker into
the equipment and cause serious, or in extreme
cases, life threatening injury.
19
Maintenance
WARNING!
LOCK OUT all power
supplies and release pressure from compressed air
lines before beginning maintenance work of any
type.
The gearbox and motor used in the TSplus conveyor
are maintenance-free. The following cleaning and
adjustment procedures, however, will help keep your
conveyor in almost new condition if performed on a
regular basis.
1 Remove all dirt & grease. Wipe the conveyor
clean of any excess grease, dirt or any foreign
substances every month, and at the same time
check the conveyor unit for wear. Replace any
parts showing signs of excess wear (see section
titled “Repair.”)
2 Re-tighten all fasteners. Check all fastening
elements for tightness, and re-tighten to 18 lb-ft
(25 Nm), if necessary.
3 Lubricate the toothed belts. If the application
permits, apply a thin coat of No. 10 machine oil
to the toothed belts on a monthly basis to help
prolong belt life.
4 Check adjacent components. Make sure that
idler rollers turn freely, that all components are
properly aligned and that there are no obstructions.
5 Check the toothed belts and guides for wear.
The toothed belts and guides should be
checked for excessive wear. If belts have
stretched or worn to the point where they do
not fit tightly to the pulleys, or show tears,
cracks, or other visible damage, they should be
replaced. If guides are worn or damaged, they
should be replaced. See page 11 to adjust
toothed belt tension.
20
Repair
Replacing the Toothed Belt
(Fig. 17 and 18)
WARNING! LOCK OUT all power supplies and release pressure from compressed air
lines before beginning maintenance work of any
type.
Toothed belts can be changed while the unit is installed! Always replace toothed belts in pairs to maintain smooth pallet flow. Always use genuine Bosch
replacement belts only.
3 Remove faulty toothed belt.
4 Apply a thin coat of No. 10 machine oil to the
new toothed belts.
5 Put toothed belt in place, with welds pointing in
direction of pallet flow. Always locate welds
adjacent to each other.
6 Attach stop plate (or two stops with BL 400 and
480).
Remove protective cover.
1 Relax toothed belt tension. (See page 11.)
2 Unscrew stop plate (always two stops with BL
400 and 480).
7 Tension the toothed belt. Follow the instructions
on page 11.
Replace protective case before restarting (not shown)!
21
BWT=480 mm
Weld
A
P
LL
E
T
F
W
LO
Apply Light Weight
Machine Oil
Stop
Plate
Toothed
Belt
Weld
Stop
Plate
Fig. 17
BWT=640 mm
Weld
T
E
LL
A
P
F
W
LO
Apply Light
Weight
Machine Oil
Toothed
Belt
Weld
Stop
Plate
Fig. 18
22
Replacing Gear Box (Fig. 19)
WARNING!
LOCK OUT all power supplies and release pressure from compressed air lines
before beginning maintenance work of any type.
1 Remove protective case (not shown).
2 Relax tension on toothed belt and move belt out of
way. (See page 11)
3 Remove the C-clip from the hex shaft on the inside
of the bearing block.
NOTE: The Hex shaft subassembly is shown with the
parts exploded for clarity in Fig. 19. It is not necessary,
however, to remove the components when replacing
the gearbox.
4 Slide the hex shaft subassembly out in the direction shown taking care to not damage the short
cover tube on male/female coupling. Set all the
parts aside for reinstallation.
5 Remove motor mounting bolts and lower motor
from gearbox and position it so that there is no
strain on the wiring.
6 Remove flange mounting screw and slide gearbox
off hex shaft noting orientation of gearbox on other
end of LTU. Be careful not to damage the male/
female coupling.
7 Remove gearbox mounting screws from old
gearbox and install mounting flange on new
gearbox.
8 Reverse steps 2-6 to reinstall new gearbox. Apply
anti-seize compound to motor shaft before
installing motor.
NOTE: New gearboxes are shipped with oil in the
gearbox. Do not add additional lubricant.
Male/Female
Coupling
Gearbox
Mounting
Screw
C-Clip
Short
Cover Tube
Hex-Shaft
Sub Assembly
Note orientation of gearbox when
removing and reinstalling gearbox.
Hex-Shaft
Fig. 19
Flange
Mounting
Screw
23
Replacing Motor (Fig. 20)
1 Remove protective case (not shown)
2 Be sure electric power supply is locked out and
disconnect motor wiring.
3 Remove motor mounting bolts and lower motor
from gearbox.
4 Apply anti-seize compound to new motor shaft
and attach new motor to gearbox with the
hardware you removed earlier.
5 Reconnect electrical wiring.
CAUTION!
Check motor for correct
rotation before putting conveyor system back
into operation.
Gearbox
Apply
Anti-Seize
Compound
Motor
Bolts (4)
Lower
Motor
Fig. 20
24
Application Notes:
25
Installation of Protective Covers
The protective cover assembly for the lift transfer unit
with bottom mounted motor/gearbox is shown in Fig.
21. Note the orientation of the assembly. The cutout
in sheet 1 is a clearance hole for the motor and must
be oriented properly.
3 Side aluminum cover sheet
Scope of Delivery:
6 Corner Bracket, RH (Qty. 2)
1 Bottom aluminum cover sheet with motor
clearance hole
7 M6x20 Cap screw, lock washer, flat washer,
M6x10mm T-nut (Qty. 4)
2 End aluminum cover sheet, lower (with two
tapped holes) (Qty. 2)
8 Side corner rail profile (Qty. 2)
4 Side aluminum cover sheet
5 Corner Bracket, LH (Qty. 2)
9 End corner rail profile (Qty. 2)
2a End aluminum cover sheet, upper (Qty. 2)
10Flange screw (Qty. 4)
2c End aluminum cover sheet, upper with stop
clearance notch
7
2c
5
10
2a
2
3
7
9
1
8
6
7
4
6
2a
8
10
2
7
9
Fig. 21
5
26
Step by Step Assembly Instructions (Fig. 22)
Note: All of the corner rail profiles (8 and 9) must be
installed with the longer side on the bottom as shown
in the inset. Make sure any protective film is removed
from the aluminum sheets prior to assembly.
Assembly hint: The four corner brackets hold the cover
assembly firmly together, and the aluminum sheets fit
snugly into them. To hold the corner rail profiles in
place during assembly, slightly bend each aluminum
sheet before sliding it into the corner rail profile.
Refer to Fig. 22 for the following steps.
1 Slide one end sheet (2) into the end corner rail
profile (9).
2 Slide one LH and one RH corner bracket (5 & 6)
onto the end sheet (2). Make sure they are
oriented with the screw hole for the T-bolt and
alignment nub as shown in Fig. 21.
3 Repeat steps 1 and 2 for the other end.
4 Slide the bottom sheet (1) into the two side
corner rail profiles (8). Make sure to orient sheet
1 so the motor clearance hole will match the
location of the motor on the module this cover
will guard.
5 Slide the two side cover sheets (3 & 4) into the
side corner rail profiles (8).
6 Slide the two end assemblies, created in steps
1-3, onto either end of the bottom and side
sheets.
7 Pre-assemble four M6x20 socket head cap
screws, four ribbed lock washers, four flat
washers and the four T-nuts into the holes on
each corner bracket as shown in Fig. 22.
8 Install end sheets (2a), using two M6x12 flange
head screws. For modules mounted to 80mm
conveyor profile, use the upper holes, for
100mm conveyor profiles use the lower holes.
Note: if a cushioned stop will be mounted on
the module, sheet 2a must be replaced with
sheet 2c to provide clearance for the stop.
9 Install the Protective Cover onto the bottom of the
LTU by insetting the four T-nuts (7) into the bottom
T-slots of the conveyor rails. Tighten the four
socket head cap screws to 25 Nm (18 lb-ft).
27
10
3
INSET
2a or 2c
1
8
8
2
3
1
4
8
2
2a
10
7
5
2
7
8
Flat Washer
9
3
Motor Clearance
Hole
1
Alignment
Nub
6
4
7
8
6
2
Flat Washer
Lockwasher
9
7
M6 x 20 SHCS
Fig. 22
5
28
Module Warranty
BOSCH AUTOMATION PRODUCTS warrants to the original purchaser the modules manufactured by us to
be free from defects in materials and workmanship under normal use and service. Our obligation under this
warranty shall be limited to the repair or exchange of any part or parts which may thus prove defective under
normal use and service within one (1) year from date of installation by the original purchaser. THIS WARRANTY
IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING THE
WARRANTY OF MERCHANTABILITY OR FITNESS FOR USE, AND WE NEITHER MAKE NOR AUTHORIZE
ANY OTHER PERSON TO MAKE FOR US, ANY WARRANTY IN CONNECTION WITH THE SALE.
This warranty shall not apply to the modules or any part thereof that has 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 to whom the modules were originally sold.
Our obligation under this warranty is limited to the modules only, and excludes wear items, such as belts, etc.,
and we may not be responsible for system concept, design, engineering, or function beyond this.
For further information, contact:
BOSCH AUTOMATION PRODUCTS
816 East Third Street
Buchanan, MI 49107
Tel: 616-695-0151
Fax: 616-695-5363
Liability:
Environmental Protection:
In no event can the manufacturer accept warranty
claims or liability claims for damages resulting from
improper use of the equipment or as a result of
changes made to the equipment other than those
specified in this instruction manual.
Always dispose of worn, damaged or obsolete parts
in a responsible manner. Some components, such as
gearboxes, contain lubricating oil which can pollute
the environment. It is the user’s responsibility to
dispose of all hazardous material within the components following all local, state and federal guidelines.
The manufacturer will accept no claims in which nonoriginal spare parts have been used. For information
on spare parts and replacement parts, refer to publication no. 8981 500 281 TSplus Spare Parts List or
8981 500 170 TS2 and TS2/C Spare Parts List.
Please contact Bosch for copies of the Material
Safety Data Sheets (MSDS) for the lubricating oil
used in gearboxes.
Publication No.: 8981 500 299 7/02