Bosch 3 842 999 904 RV 1 User Manual Download

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Assembly instructions

3 842 358 724/2013-04

Replaces: –

English

BS 2/C-100

BS 2/C-H

BS 2/R-700
BS 4/R-700

BS 2/R-300
BS 4/R-300

BS 2/R-H
BS 2/R-V-1200

BS 2/C-250

BS 2/C-…, BS 2/R-…

Belt sections

Applies to the following types:

3 842 998 096 , BS 2/R-700

3 842 998 097 , BS 4/R-300

3 842 998 238 , BS 2/R-H

3 842 998 239 , BS 2/C-H

3 842 998 492 , BS 2/R-V-1200

3 842 999 901 , BS 4/R-700

3 842 999 904 , BS 2/R-300

3 842 999 917 , BS 2/C-100

3 842 999 985 , BS 2/C-250

GLISH

358724_2013_04_EN.indd 1

27.05.2013 13:07:31

Summary of Contents for 3 842 999 904 RV 1

Page 1: ...2 R Belt sections Applies to the following types 3 842 998 096 BS 2 R 700 3 842 998 097 BS 4 R 300 3 842 998 238 BS 2 R H 3 842 998 239 BS 2 C H 3 842 998 492 BS 2 R V 1200 3 842 999 901 BS 4 R 700 3 842 999 904 BS 2 R 300 3 842 999 917 BS 2 C 100 3 842 999 985 BS 2 C 250 ENGLISH 358724_2013_04_EN indd 1 358724_2013_04_EN indd 1 27 05 2013 13 07 31 27 05 2013 13 07 31 ...

Page 2: ...media directory www boschrexroth com mediadirectory 1 Nella maschera di ricerca in alto a destra sotto Search immettere 3 842 358 726 2 Fate clic su Search ES Este manual de instrucciones está disponible en los idiomas aquí indicados como versión impresa o archivo PDF para descarga desde el directorio de medios www boschrexroth com mediadirectory 1 Indique en el cuadro de búsqueda parte superior d...

Page 3: ...ormance description 13 5 1 1 BS 2 belt section application 13 5 1 2 BS 2 belt section version 13 5 2 Product description 14 5 3 Product identiﬁcation 15 6 Transport and Storage 15 6 1 Transporting the product 15 6 2 Storing the product 15 7 Assembly 16 7 1 Unpacking 16 7 2 Installation requirements 16 7 2 1 Mounting orientation 16 7 2 2 Mounting with T bolts 16 7 3 Required tools 16 7 4 Required a...

Page 4: ... 36 9 1 4 Ambient inﬂuences 36 10 Maintenance and Repair 37 10 1 Cleaning and care 38 10 2 Inspection 38 10 2 1 Conveyor chain ﬂat top chain accumulation roller chain 38 10 3 Maintenance 38 10 3 1 Bearings 38 10 3 2 Gears 38 10 3 3 Motor 38 10 3 4 Conveyor chain ﬂat top chain accumulation roller chain 39 10 3 5 Options to lubricate the conveyor chain manually 40 10 3 6 LU 2 automatic lubrication u...

Page 5: ...conveyor chain BS 2 C H BS 2 R H BS 2 R V 1200 motor mounting MA R L 62 10 4 19 Exchanging the conveyor chain BS 2 R H reversible BS 2 R V reversible motor mounting MA R L 65 10 4 20 Exchanging the relief roller connection roller toothed belt BS 2 C H BS 2 R H BS 2 R V 1200 motor mounting MA R L 67 10 4 21 Exchanging the motor and or gear BS 2 C 100 BS 2 R 300 BS 4 R 300 motor mounting MA R L 68 1...

Page 6: ...ed and supplementary documentation Only commission the product once you have obtained the system documentation that is marked with a book symbol and understood and complied with its contents Table 1 Required and supplementary documentation Title Document number Document type Instructions for Employees on Safety 3 842 527 147 MTparts 3 842 529 770 Spare parts list on CD 1 3 Presentation of informat...

Page 7: ...oided will certainly result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury NOTICE Damage to equipment The product or surrounding equipment may be damaged 1 3 2 Symbols The following symbols ide...

Page 8: ... the following abbreviations Table 5 Abbreviations Abbreviation Meaning Chain Conveyor chain with conveyor medium Flat top chain C Accumulation roller chain R Accumulation roller chain Vplus R V 2 Notes on Safety 2 1 About this chapter The product has been manufactured according to the accepted rules of current technology Even so there is a risk of injury or damage if this chapter and the safety i...

Page 9: ...al terms Additional knowledge of the lifting device s usage and of the associated lifting equipment are necessary to transport and handle the product In order to ensure operating safety these activities may therefore only be carried out by qualiﬁed technical personnel or an instructed person under the direction and supervision of qualiﬁed personnel Qualiﬁed personnel are those who can recognize po...

Page 10: ...lines and norms 2 6 Product speciﬁc safety instructions The following safety instructions apply to chapters 6 to 14 Do not modify or convert the product Do not expose the product to any mechanical loads under any circumstances Never use the product as a handle or step Do not place any objects on the product Always secure the product to prevent toppling Observe the transport instructions on the pac...

Page 11: ...ion only switch on the system once the cause of the fault has been determined and the error resolved Make sure that there are no obstacles blocking access to maintenance and inspection points Perform the prescribed maintenance work at the intervals speciﬁed in section 10 3 Maintenance Make sure that no lines connectors or components are disconnected as long as the system is under pressure and volt...

Page 12: ...m the conveyor chain Deformations such as folds and or the chain twisting e g due to the chain coil tipping while the chain is being mounted cause the conveyor chain to fail and can lead to a crash Ensure that the chain is lying evenly and that it runs smoothly from the chain coil during mounting Ensure that the chain coil does not tip over during assembly If the chain coil has tipped over during ...

Page 13: ...tudinal conveyor for WT 2 workpiece pallets on conveyor sections of up to 6000 mm Transverse conveyor for WT 2 workpiece pallets between parallel conveyor sections in conjunction with two HQ 2 lift transverse units 5 1 2 BS 2 belt section version Ready for operation conveyor section Section load see Technical data on page 75 Conveyor medium BS 2 C Polyamide ﬂat top chain BS 2 R Accumulation roller...

Page 14: ... D C E E G E F C H B A Belt sections BS 2 C BS 2 R A Gear B Motor C Gear motor D Flat top chains E Accumulation roller chain F Vplus accumulation roller chain G Only with BS 2 R H reversible H Accelerating element for BS 2 R 300 700 BS 4 R 300 700 For safe bridging of the conveyor trench without accumulation operation Only for lWT 160 lWT 240 358724_2013_04_EN indd 14 358724_2013_04_EN indd 14 27 ...

Page 15: ... documents for product weight Before lifting the product make sure that the lifting equipment is correctly fastened Secure the product to prevent toppling while lifting Make sure that no one is in the danger area when raising and lowering with the exception of the operator 6 2 Storing the product Only store the product on a ﬁrm ﬂat surface Protect the product against mechanical inﬂuences Protect t...

Page 16: ...nctioning and prevents premature wear 7 2 2 Mounting with T bolts Mount the transfer systems TS 1 TS 2plus TS 2pv TS 4plus TS 5 and chain conveyor systems VarioFlow and VarioFlow S with T bolts and ﬂange nuts Make sure the T bolt is in the correct position when inserting and tightening in the slot The notch at the end of the bolt indicates the T bolt orientation 1 T bolt insertion orientation in t...

Page 17: ...g the belt section in lateral transverse transport drive head to section BS 2 C 100 BS 2 C 250 BS 2 R 300 BS 4 R 300 BS 2 R 700 BS 4 R 700 with ST 2 B ST 2 B 100 ST 2 C 100 ST 2 R 100 3 842 528 192 BS 2 C 400 BS 2 C 700 BS 2 R 1200 BS 2 R 2200 with ST 2 B ST 2 B 100 ST 2 C 100 ST 2 R 100 3 842 518 828 BS 2 C H BS 2 R H BS 2 R V with ST 2 C H ST 2 R H ST 2 R V 3 842 530 868 Connection kits for the ...

Page 18: ...ssed head size Lubricate with Structovis GHD 0 842 904 229 gleitmo585K Anti Seize Grease grease with speciﬁed lubricant gleitmo 585 K gleitmo 585 K www fuchs lubritech com Anti Seize Food Grade Anti Seize Loctite 8014 www henkel com Loctite 243 Loctite 601 Secure the screws with Loctite 243 medium strength adhesive detachable www loctite de Loctite 601 high strength adhesive permanent www loctite ...

Page 19: ...Z 2 Assembling the belt section on leg sets 1 2 1 Assemble the belt section on 2 to 4 leg sets Note Assemble one leg set each in the direct vicinity of the drive and return unit Assemble the leg sets under the cross connectors of the belt section Maximum distance between 2 leg sets 2000 mm ENGLISH 358724_2013_04_EN indd 19 358724_2013_04_EN indd 19 27 05 2013 13 07 55 27 05 2013 13 07 55 ...

Page 20: ...547 601 03 Assembling the belt section on leg sets 2 2 2 Align the belt section at the same height and level as the adjacent components 3 Bolt the belt section to the ﬂoor The following is required per connection 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 358724_2013_04_EN indd 20 358724_2013_04_EN indd 20 27 05 2013 13 07 56 27 ...

Page 21: ...D 8 Nm 90 90 90 90 90 90 90 SW8 2x MD 6 Nm A A A A A A A A A A Swiveling the motor gear combination or the gear motor around the drive axle 1 Disassemble the screws A B 2 Swivel the motor gear combination or the gear motor in 90 increments around the drive axle 3 Assemble the screws A B ENGLISH 358724_2013_04_EN indd 21 358724_2013_04_EN indd 21 27 05 2013 13 07 56 27 05 2013 13 07 56 ...

Page 22: ...13 M 10 Nm D B A D C 547 601 04 BS 2 C 100 Assembling the belt section between two sections Required accessories Connection kit 3 842 528 192 1x Note Support the belt section with leg sets if necessary see page 19 1 Disassemble the external housing element halves 2 Break off an opening for the connection kit corresponding to your application type on all housing element halves at the perforated are...

Page 23: ... 828 M8x50 4x M8x25 4x SW13 MD 25 Nm SW13 MD 25 Nm BS 2 C H Assembling the belt section between two sections Required accessories Connection kit 3 842 518 828 0 5x Connection kit 3 842 530 868 0 5x Note Support the belt section with leg sets if necessary see page 19 1 Dismount the gear motor 2 Disassemble the side cover plates 3 Mount the connection kit 3 842 518 828 2x 4 Mount the connection kit ...

Page 24: ...s Required accessories Connection kit 3 842 518 828 0 5x Connection kit 3 842 528 192 0 5x 1 Dismount the gear motor 2 Disassemble the side cover plates 3 Mount the connection kit 3 842 518 828 2x 4 Disassemble the external housing element halves 5 Break off an opening for the connection kit corresponding to your application type on all housing element halves on the perforated area X 6 Smooth the ...

Page 25: ...t Required accessories Connection kit 3 842 529 881 1x 1 Disassemble the external housing element halves 2 Slide the connection kit into the T slot on the drive head 3 Position the return unit of the connecting belt section without gap at the same height and level as the drive head 4 Mount the connection kit in the center between the drive head and the return unit 5 Mount the external housing elem...

Page 26: ...belt sections drive head to return unit Required accessories Connection kit 3 842 530 871 1x 1 Dismount the gear motor 2 Disassemble the side cover plates 3 Mount the connection kit on the drive head 4 Position the return unit of the connecting belt section without gap at the same height and level as the drive head Mount the connection kit on the return unit 5 Mount the side cover plates 6 Mount t...

Page 27: ...o bottom elongated chain The chain must be shortened once the lever in the slot is no longer visible As an alternative mount a proximity switch E ø8 mm max length incl the turn radius of the cable 45 mm in the fastening clip Switch distance 1 5 0 5 mm The tab C activates the proximity switch when the max admissible chain elongation is reached Note Always observe the switch distance otherwise the p...

Page 28: ...f the tension lever X of the chain tensioner The tension lever X moves down as the chain length increases from top new short chain to bottom elongated chain The chain must be shortened once the tension lever X is in the lowest position As an alternative mount a proximity switch to query the lowest position of the tension lever X SH 2 UV switch bracket 3 842 168 600 Proximity switch 3 842 537 995 3...

Page 29: ...ve the external housing element halves 3 Turn the drive shaft with the help of a wrench in the transport direction until the master link appears on the chain tensioner The master link of the accumulation roller chain can be recognized through the galvanized link plate 2 4 Pull the chain tensioner upwards3 and secure it in its ﬁnal position with a pin or a screwdriver 3 BS reversible unlatch the ch...

Page 30: ... drive wheel Turn the drive wheels in the transport direction until the chain appears on the chain tensioner 11 Close the chain 12 Release the chain tensioner Check the tension of the chain 13 Mount the external housing element halves 14 Assemble the gear motor Note Avoid accumulation over the acceleration element Accumulation over the acceleration element causes heavy wear on the rollers and shor...

Page 31: ...or as a Y connection or a delta connection in accordance with the connection plans see Fig 16 on page 32 and the connection plan in the terminal box The motor is equipped with a bi metal switch potential free thermal contact 230 V AC 300 mA to monitor the temperature Connect the motor in such a manner that it becomes currentless when the switch is actuated Select a cable entry that prevents damage...

Page 32: ...nnection Fig 17 Connection cable option Installation_A TW1 TW2 PE T1 T2 1U2 1V2 1W2 1U2 1V2 1W2 1U1 1V1 1W1 1U1 1V1 1W1 2U1 2V1 2W1 2U1 2V1 2W1 PE U1 V1 W1 TW1 TW2 PE T1 T2 PE U1 V1 W1 Installation_DY 3 842 409 645 Installation_C 3 842 409 645 L 400 mm L 400 mm 358724_2013_04_EN indd 32 358724_2013_04_EN indd 32 27 05 2013 13 08 01 27 05 2013 13 08 01 ...

Page 33: ...r recommissioning of a conveyor system According to EU Machinery Directive 2006 42 EC you must provide the transfer system with an EMERGENCY STOP command device The surfaces of motors and gears can reach temperatures of over 65 C under certain load and operating conditions In such cases the valid accident prevention regulations in Germany UVV must be met by corresponding constructive measures safe...

Page 34: ...min e g a protective fence 3 Conveyor medium Between running conveyor medium and standing workpiece pallet e g during separation Catching of body parts Crushing Do not reach into the system during operation 4 Between workpiece pallet and workpiece pallet Crushing of body parts Crushing Do not reach into the system during operation Design solutions are necessary in the service area and at transport...

Page 35: ... C H R H R V leads to increased wear on the workpiece pallet There is a danger of damage to property Avoid accumulation on the connection roller 9 1 Notes on operation 9 1 1 Wear Wear is caused by the basic principle of this system and cannot be avoided on individual components By taking constructive measures and selecting proper materials we strive to ensure that functional safety lasts for the l...

Page 36: ...Avoid long term contact with strong acidic or basic reacting materials Wear may increase dramatically if the system is contaminated due to environmental factors particularly with abrasive media such as sand and silicates but also due to processes running on the transfer system e g welding beads pumice dust glass shards shavings or lost parts In such cases maintenance intervals should be substantia...

Page 37: ...TION Hot electric motor surfaces during operation Possible burns if the hot surfaces over 65 C are touched Provide appropriate safety devices to seal off the motors Let the system cool off for at least 30 min before performing any maintenance or repair work Continuous conveyors that are in motion or operation may only be inspected or adjusted if protective devices are present and correctly positio...

Page 38: ... damage to property Always comply with the maintenance intervals Maintain a maintenance schedule Keep grease dissolving or aggressive cleaning agents away from the conveyor chain Only use a slightly damp cloth to clean the product 10 2 Inspection 10 2 1 Conveyor chain ﬂat top chain accumulation roller chain Conduct regular visual inspections of the conveyor chain for wear and sufﬁcient lubrication...

Page 39: ...cation will result in operational disruptions due to a chain malfunction up to a system crash with substantial damage to property Maintain a maintenance schedule The running times during set up and commissioning of the system count as a part of the ﬁrst maintenance interval If you do not know how long the system ran during set up and commissioning lubricate the conveyor chain before starting produ...

Page 40: ... 2 C 100 C 250 BS 2 R 300 R 700 MD 7 Nm SW4 MD 7 Nm SW4 BS 2 C 400 C H BS 2 R H R V 1200 Fig 19 Lubricating the conveyor chain in the drive module MD 5 Nm SW4 MD 5 Nm SW4 ST 2 C W ST 2 R W Fig 20 Lubricating the conveyor chain in the maintenance section 358724_2013_04_EN indd 40 358724_2013_04_EN indd 40 27 05 2013 13 08 02 27 05 2013 13 08 02 ...

Page 41: ...ter set 3 842 543 486 AS 2 R V 1200 adapter set 3 842 543 487 1 An additional LU 2 retroﬁt kit 3 842 546 725 is required for retroﬁtting older transfer systems without lube hole LU 2 AS 2 C 100 AS 2 C 250 AS 2 C 400 AS 2 C 700 LU 2 LC 2 Set AS 3 842 543 482 LU 2 3 842 543 469 LC 2 3 842 543 483 AS 2 C 100 250 set 3 842 543 484 AS 2 C 400 700 set AS 2 R 300 AS 2 R 700 AS 2 R 1200 AS 2 R 2200 AS 2 R...

Page 42: ... socket wrenches WS4 Water level Combination pliers 10 4 3 Required accessories For the ﬂat top chain Disassembly tool 3 842 010 510 Master link 3 842 535 333 For the accumulation roller chain Disassembly tool 3 842 010 511 Master link 3 842 530 417 For the Vplus accumulation roller chain Disassembly tool 3 842 539 357 Master link 3 842 538 872 8 981 010 510 3 842 535 333 8 981 010 511 3 842 530 4...

Page 43: ...1 On the side without the motor either remove the external housing element half BS 2 C 100 250 BS 2 R 300 700 BS 4 R 300 700 or unscrew the cover plate on the side BS 2 C H BS 2 R H BS 2 R V 1200 2 Use the hold to run control to run the belt section until the master link appears in the chain tensioner The master link can be recognized through The gray ﬂat plate with hole on the gray ﬂat top chain ...

Page 44: ...3 Fig 25 Securing the chain tensioner large drive head BS 2 C BS 2 R Pull the chain tensioner upwards and secure it in its ﬁnal position with a pin or a screwdriver BS 2 R reversible Unlatch the chain tensioner by lifting the latches Fig 24 Pull the chain tensioner upwards and secure it in its ﬁnal position with a pin or a screwdriver Pull the chain tensioner X upwards and secure it in its ﬁnal po...

Page 45: ...e chain length increases from top new short chain to bottom elongated chain The chain must be shortened once the lever in the slot is no longer visible Exchange the chain if the admissible elongation of the chain 3 of the original length is exceeded You can check the elongation of the chain based on the state of the tension lever X of the chain tensioner The tension lever X moves down as the chain...

Page 46: ...g the conveyor chain BS 2 C 100 250 BS 2 R 300 700 MA R L 1 2 Note Perform the work steps on both sides at the same time 1 Dismount the gear motor 2 Disassemble the external housing element halves 3 Turn the drive shaft with the help of a wrench in the transport direction until the master link appears on the chain tensioner The master link can be recognized through The gray ﬂat plate with hole on ...

Page 47: ... be able to close the chain as tightly as possible at the tension wheel 3 Disassembly tool For the ﬂat top chain 3 842 010 510 For the accumulation roller chain 3 842 010 511 Note Remove the same number of chain links from both chains Note the number of chain links removed in the service plan Exchange the chain if the admissible elongation of the chain 3 of the original length is exceeded 7 Close ...

Page 48: ...al master link is required for each chain4 4 Master link For the ﬂat top chain 3 842 535 333 For the accumulation roller chain 3 842 530 417 Perform the work steps on both sides at the same time 1 Disassemble the external housing element halves 2 Secure the chain tensioner 3 Open the chain with the disassembly tool3 3 Disassembly tool For the ﬂat top chain 3 842 010 510 For the accumulation roller...

Page 49: ...ly as possible at the tension wheel Note Remove the same number of chain links from both chains Note the number of chain links removed in the service plan Exchange the chain if the admissible elongation of the chain 3 of the original length is exceeded 5 Lubricate the master link and close the chain 6 Release the chain tensioner Check the tension of the chain 7 Mount the external housing element h...

Page 50: ...H BS 2 R V 1200 MA R L 1 2 Note Perform the work steps on both sides at the same time 1 Dismount the gear motor 2 Disassemble the side cover plates remove the bottom cover sheets 3 Turn the drive shaft with the help of a wrench in the transport direction until the master link appears on the chain tensioner The master link can be recognized through The gray ﬂat plate with hole on the gray ﬂat top c...

Page 51: ... to be able to close the chain as tightly as possible at the chain tensioner 3 Disassembly tool For the ﬂat top chain 3 842 010 510 For the accumulation roller chain 3 842 010 511 Note Remove the same number of chain links from both chains Note the number of chain links removed in the service plan Exchange the chain if the admissible elongation of the chain 3 of the original length is exceeded 7 C...

Page 52: ... work steps on both sides at the same time 1 Dismount the gear motor 2 Disassemble the side cover plates remove the bottom cover sheets 3 Disassemble the external housing element halves 4 Turn the drive shaft with the help of a wrench in the transport direction until the master link appears on the return unit s chain tensioner The master link can be recognized through The galvanized link plate on ...

Page 53: ...isassembly tool For the accumulation roller chain 3 842 010 511 For Vplus accumulation roller chain 3 842 539 357 Note Remove the same number of chain links from both chains Note the number of chain links removed in the service plan Exchange the chain if the admissible elongation of the chain 3 of the original length is exceeded 8 Close the chain 9 Release the chain tensioner Check the tension of ...

Page 54: ...While doing this check the chain wheels1 the glide proﬁles the guide elements2 in the drive and return unit the chain tensioner3 the connection roller4 and the corresponding toothed belt for wear Exchange the worn out parts Fig 36 547 601 63 2 2 3 1 2 3 3 4 Wear parts We recommend When exchanging the ﬂat top chain always exchange the glide proﬁles at the same time 358724_2013_04_EN indd 54 358724_...

Page 55: ...lfunctions and can lead to a crash There is a danger of damage to property Ensure that the chain is lying evenly and that it runs smothly from the chain coil Ensure that the chain coil does not tip over during assembly If the chain coil has tipped over during assembly and the chain is deformed Use the disassembly tool to remove all of the affected area 547 601 39 Fig 37 Uncoiling the chain from th...

Page 56: ...tion points NOTICE Conveyor chain malfunction ﬂat top chain accumulation roller chain Lack of lubrication on the conveyor chain will lead to conveyor chain malfunctions and can lead to a crash There is a danger of damage to property The conveyor chain used in this product has already been lubricated at the factory before delivery Before commissioning lubricate the conveyor chain with 1 to 2 g oil ...

Page 57: ... sides at the same time Dismount the chain 1 Dismount the gear motor 2 Disassemble the external housing element halves 3 Secure the chain tensioner 4 Open the chain with the disassembly tool3 3 Disassembly tool For the ﬂat top chain 3 842 010 510 For the accumulation roller chain 3 842 010 511 5 Disassemble the covers on the drive and return head 6 Pull the used chain downwards from the BS 2 7 Rem...

Page 58: ...the chain in the top guide proﬁle up to the drive head 11 Position the chain on the drive wheel 12 Turn the drive wheels in the transport direction until the chain appears on the chain tensioner 13 Mount the covers on the drive and return heads 14 With the disassembly tool remove enough excess chain links to be able to close the chain as tightly as possible at the tension wheel 15 Lubricate the ma...

Page 59: ... the chain 1 Disassemble the external housing element halves 2 Secure the chain tensioner 3 Open the chain with the disassembly tool3 3 Disassembly tool For the ﬂat top chain 3 842 010 510 For the accumulation roller chain 3 842 010 511 4 Disassemble the covers on the drive and return heads 5 Pull the chain back until the drive head is exposed 6 Remove the slider 7 Dismount the drive train 8 Pull ...

Page 60: ...hain 10 Pull the new chain5 up to the return head with a pulling aid 5 BS 2 C BS 2 R Note the direction of movement of the chain Fig 38 page 56 11 Hold the chain up perpendicularly and insert the slider into the return head Note For the next assembly step you will need a helper or a lift aid 358724_2013_04_EN indd 60 358724_2013_04_EN indd 60 27 05 2013 13 08 12 27 05 2013 13 08 12 ...

Page 61: ...through the drive head downwards to the chain tensioner 15 Insert the drive train into the drive heads 16 Lift the chain up slightly and place the slider into the drive heads 17 Mount the covers on the drive and return head 18 With the disassembly tool remove enough excess chain links to be able to close the chain as tightly as possible at the tension wheel 19 Lubricate the master link and close t...

Page 62: ...ps on both sides at the same time Dismount the chain 1 Dismount the gear motor 2 Disassemble the side cover plates remove the bottom cover sheets 3 Secure the chain tensioner 4 Open the chain with the disassembly tool3 3 Disassembly tool For the ﬂat top chain 3 842 010 510 For the accumulation roller chain 3 842 010 511 For Vplus accumulation roller chain 3 842 539 357 5 Dismount the cover of the ...

Page 63: ... 2 R H BS 2 R V 1200 MA R L 2 3 Mounting the chain 9 Pull the new chain5 up to the return head with a pulling aid 5 BS 2 C BS 2 R Note the direction of movement of the chain Fig 38 page 56 10 Lay the chain around the return wheel in the return head 11 Mount the slider into the return head ENGLISH 358724_2013_04_EN indd 63 358724_2013_04_EN indd 63 27 05 2013 13 08 14 27 05 2013 13 08 14 ...

Page 64: ...p to the drive head 13 Position the chain on the drive wheel 14 Turn the drive wheels in the transport direction until the chain appears on the chain tensioner 15 With the disassembly tool remove enough excess chain links to be able to close the chain as tightly as possible at the chain tensioner 16 Lubricate the master link and close the chain 17 Release the chain tensioner Check the tension of t...

Page 65: ...me Dismount the chain 1 Dismount the gear motor 2 Disassemble the side cover plates remove the bottom cover sheets 3 Disassemble the external housing element halves 4 Secure the chain tensioners to the drive and the return unit 5 Open the chain with the disassembly tool3 on the return unit 3 Disassembly tool For the accumulation roller chain 3 842 010 511 For Vplus accumulation roller chain 3 842 ...

Page 66: ... direction of movement of the chain Fig 38 page 56 10 Lay the chain around the chain tensioner and the drive wheel and pull it in the top guide proﬁle up to the return head 11 With the disassembly tool remove enough chain links to be able to close the chain as tightly as possible at the tension wheel 12 Lubricate the master link and close the chain 13 Release the chain tensioner Check the tension ...

Page 67: ... Dismount the gear motor 2 Disassemble the side cover plates 3 Disassemble the toothed belt Check the connection roller for wear and exchange if necessary Pull the connection roller off the axle ﬁrst insert the new contact plate then the new connection roller on the axle 4 Position the new toothed belt over the toothed belt wheel 5 Turn the drive wheels in the transport direction at the same time ...

Page 68: ...osition the motor correctly terminal box and mount the motor in the gear If the motor is not properly positioned do NOT turn it Disconnect the motor from the gear and assemble it again If only the motor is to be exchanged begin with step 4 1 Loosen the hexagonal screws on the ﬂange 2 Remove the motor gear combination from the hexagonal shaft 3 Remove the cover plugs from the faulty gear and ﬁt ont...

Page 69: ...not properly positioned do NOT turn it Disconnect the motor from the gear and assemble it again For dismounting the drive train see Exchanging the conveyor chain page 59 step 1 to step 7 The drive train does not have to be dismounted if only the motor has to be replaced In that case begin with step 4 1 Loosen the hexagonal screws on the ﬂange 2 Disconnect the motor gear combination from the drive ...

Page 70: ...tor motor mounting MA R L Note The gear motor can only be exchanged completely Separating the motor from the gear is not permitted 1 Dismount the gear motor 2 Disassemble the ﬂange from the gear motor 3 Disassemble the blanking plug 4 Assemble the blanking plug on the new gear motor 5 Assemble the ﬂange on the new gear motor 6 Mount the gear motor 358724_2013_04_EN indd 70 358724_2013_04_EN indd 7...

Page 71: ... 1 Disassemble the side cover plates 2 Remove the retainer rings from the hexagonal shaft 3 Push the hexagonal shaft out of the drive Keep the sheath tube for reusing 4 Disassemble the ﬂange from the gear motor 5 Assemble the ﬂange on the new gear motor 6 Assemble the gear motor and tighten the screws by hand 7 Push the hexagonal shaft into the drive Attach the sheath tube Secure the hexagonal sha...

Page 72: ... T 40 2 7 3 5 Exchanging glide proﬁles BS 2 C 100 BS 2 C 250 BS 2 C H 1 Dismount the chain see pages 57 59 62 2 Dismount the return head 3 Disassemble the locking bolts 4 Exchange the glide proﬁles 5 Fix the glide proﬁles and drill them open 6 Assemble the locking bolts 7 Mount the return head 8 Mount the chain see pages 58 61 64 358724_2013_04_EN indd 72 358724_2013_04_EN indd 72 27 05 2013 13 08...

Page 73: ...tem against being switched on Lifted loads may fall Falling objects may result in severe injuries or even death Always use lifting equipment with a sufﬁciently high load bearing capacity see the shipping documents for product weight Before lifting the product make sure that the carrying straps are correctly fastened Secure the product to prevent toppling while lifting Make sure that no one is in t...

Page 74: ... currently applicable national regulations in your country 14 Extension and Conversion Do not convert the product The Bosch Rexroth warranty only applies to the delivered conﬁguration and extensions taken into account in the conﬁguration The manufacturer can accept no warranty claims if the system is converted or extended in a manner not listed in these instructions 15 Troubleshooting and Resoluti...

Page 75: ...nary use in a location that is protected from the elements Operating temperature 5 C to 40 C 5 C to 60 C with 20 reduced load Storage temperature 25 C to 70 C Relative humidity 5 to 85 Air pressure 84 kPa appropriate height 1400 m above sea level Permissible ﬂoor load 1000 kg m2 The load values of the electrical drives are reduced by 15 when the system is set up in a location with an altitude 1400...

Page 76: ...0 02 07 D 70442 Stuttgart Germany Fax 49 711 811 7777 info boschrexroth de www boschrexroth com Subject to changes 3 842 358 724 2013 04 358724_2013_04_EN indd 76 358724_2013_04_EN indd 76 27 05 2013 13 08 20 27 05 2013 13 08 20 ...

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