Bosch BS 2/R Assembly Instructions Manual Download

Page: 37 / 84

Life stages of the machine according to EN 12100 Sect. 5.4 a /b (No. 1- 27), Sect. 5.4 a

Transport, assembly and installation

Commissioning

Use

Disassembly, decommissioning and disposal

Setting up

Verifying

Teaching/programming

Changeover

Startup

All operating modes

Feeding the machine

Removing product from the machine

Shutting the machine down

Shutting the machine down in the case of an emergency

Restoring operation after a bottleneck or blockage

Restarting after unscheduled shutdown

Troubleshooting and remedial action (intervention by operating personnel)

Cleaning and keeping clean

Preventive maintenance

Corrective maintenance

Operating states of the machine, Sect. 5.4 b

Normal operation

Modiﬁ cation of a property or a dimension of the material or workpiece to be processed

Failure of one (or more) of its components or supply devices

External disturbances (e.g. impact, vibration, electromagnetic interference)

Design faults or defects (e.g. software errors)

Disruption in the power supply

Ambient conditions (e.g. damaged ﬂ oors)

Commissioning 37/84

3 842 563 834/2022-08, MIT: BS 2/C-…, BS 2/R-…,

Bosch Rexroth AG

GLISH

Summary of Contents for BS 2/R

Page 1: ...y instructions 3 842 563 834 2022 08 Replaces ENGLISH BS 2 C BS 2 R Belt section Valid for the following types 3842 998 933 BS 2 C 100 3842 998 934 BS 2 C 250 3842 998 935 BS 2 C H 3842 998 937 BS 2 R 300 3842 998 938 BS 2 R 700 3842 998 939 BS 2 R H 3842 998 941 BS 2 R V 1200 ENGLISH ...

Page 2: ...ior derecha en Search introduzca 3 842 563 837 a continuación haga clic en Search PT O presente manual de montagem está disponível nos idiomas aqui indicados Demais idiomas sob consulta Como versão impressa ou o arquivo PDF para download no diretório de mídias www boschrexroth com mediadirectory Insira a máscara de pesquisa parte superior direita em Search 3 842 563 838 e clique em Search ZH 本安装说明...

Page 3: ...sporting the product 15 6 2 Storing the product 15 7 Assembly 16 7 1 Unpacking 16 7 2 Installation requirements 16 7 2 1 Installation position 16 7 3 Required tools 16 7 4 Required accessories 17 7 5 Symbols used 18 7 6 Assembling the product 19 7 6 1 Installing the belt section on leg sets 19 7 6 2 Modifying the mounting position of the motor gear combination or the gear motor 21 7 6 3 BS 2 C 100...

Page 4: ...eyor chain manually 44 10 3 6 LU 2 automatic lubrication unit 45 10 4 Replacing wear parts 46 10 4 1 Designations 46 10 4 2 Required tools 46 10 4 3 Required accessories 46 10 4 4 BS 2 C 100 250 BS 2 R 300 700 Disassembling the protective case 47 10 4 5 Assembly instructions Finding a chain lock with an operable chain 48 10 4 6 Assembly instructions Fixing the chain tensioner at BS 2 C 100 250 BS ...

Page 5: ...1200 motor mounting MA R L 72 10 4 22 Replacing the motor and or gear BS 2 C 100 BS 2 R 300 Motor mounting MA R L 73 10 4 23 Replacing the motor and or gear BS 2 C 100 BS 2 R 300 Motor mounting MA M 74 10 4 24 Replacing the gear motor BS 2 C H BS 2 R H BS 2 R V 1200 Motor mounting MA R L 75 10 4 25 Replacing the gear motor BS 2 C H BS 2 R H BS 2 R V 1200 motor mounting MA M 76 10 4 26 Changing the...

Page 6: ... followed the instructions in it Table 1 Required and supplementary documentation Title Document number Document type Employee safety training 3 842 527 147 Declaration of incorporation 3 842 358 415 MTpro 1 3 842 539 057 With spare parts list 1 Download at www boschrexroth com mtpro 2 All documents are also available for download from the media directory www boschrexroth com mediadirectory 1 3 Pr...

Page 7: ...icates a hazardous situation that may result in serious injury or death if not avoided CAUTION Indicates a hazardous situation that may result in minor to moderate injury if not avoided NOTICE Property damage The product or the surrounding area could get damaged 1 3 2 Symbols The following symbols indicate important information that is not safety relevant but increases the comprehensibility of the...

Page 8: ...KT Chain type accumulation roller chain with PA accumulation rollers KT 1 Steel accumulation rollers KT 2 PA accumulation rollers and small parts protection KT 3 Steel accumulation rollers and small parts protection KT 4 2 Safety instructions 2 1 About this chapter The product has been manufactured in accordance with the generally accepted rules of current technology Nevertheless there is a risk o...

Page 9: ...ted person acting under the direction of such a person Qualiﬁed personnel refers to those who can recognize potential hazards and take appropriate safety measures based on their technical training knowledge experience and understanding of the relevant regulations pertaining to the work being performed Qualiﬁed personnel must comply with the relevant technical regulations and have the necessary exp...

Page 10: ...is depressurized and de energized before assembling the product or inserting or removing plugs Ensure that the system component cannot be switched back on Before commissioning make sure that all seals and plugs for the plug connectors are correctly installed and not damaged to prevent liquids and foreign bodies from entering the product Allow the product to acclimatize for a few hours prior to com...

Page 11: ...ir net for long loose hair As the system owner or operator you are personally responsible for ensuring the use of appropriate protective equipment when the product is being used All component parts of the personal protective equipment must be free of damage 2 8 Owner responsibilities Before the initial commissioning or re commissioning of a conveyor system carry out a risk assessment in accordance...

Page 12: ...all over during installation If the chain reel has fallen over during installation and the chain is deformed Use the disassembly tool to remove the affected area with a generous margin on either end Prevent cleaning agents from getting into the system Never use solvents or corrosive cleaning agents Do not use a pressure washer for cleaning During servicing and repair During cleaning 12 84 General ...

Page 13: ...on BS 2 Longitudinal conveying of the WT 2 workpiece pallet on conveyor sections of up to 6000 mm Transverse conveying of the WT 2 workpiece pallet between parallel conveyor sections in connection with two HQ 2 lift transverse units 5 1 2 Design of belt section BS 2 Ready to use conveyor section Section load see Technical Data on page 83 Conveyor medium BS 2 C Plastic ﬂat top chain BS 2 R Accumula...

Page 14: ...Gear B Motor C Gear motor D Flat top chain E Accumulation roller chain F Accumulation roller chain Vplus G Only for BS 2 R H reversible H Acceleration element for BS 2 R 300 700 BS 2 R 300 DE 2 BS 4 R 300 700 To safely overcome the conveyor trench without accumulation operation Only for lWT 160 lWT 240 14 84 About this product Bosch Rexroth AG MIT BS 2 C BS 2 R 3 842 563 834 2022 08 ...

Page 15: ... is correctly fastened before lifting the product Secure the product against tipping over when lifting Make sure that no one but the operator is in the danger zone during lifting and lowering 6 2 Storing the product Only set the product down on a ﬂat stable surface Protect the product from mechanical stress Protect the product from environmental inﬂuences such as dirt and moisture Observe the ambi...

Page 16: ...the ambient conditions speciﬁed in the technical data see page 83 7 2 1 Installation position Install the product level and plumb at right angles and axially parallel This ensures proper functioning and prevents premature wear 7 3 Required tools Hex wrench open end SW8 SW10 SW13 SW19 SW24 Hex socket wrench SW4 Spirit level Combination pliers Flat smooth ﬁle 16 84 Assembly Bosch Rexroth AG MIT BS 2...

Page 17: ... the belt section in lateral transverse conveying drive head at 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 3 842 528 192 Connection kit for longit...

Page 18: ...e Food Grade Anti Seize Loctite 8014 www henkel com GHD V 68 Oil Oil Oil Lubricate lubricate with speciﬁc mineral oil GHD Structovis GHD www klueber com V 68 Mineral oil with a viscosity of 68 Loctite 243 Loctite 601 Secure the screws with Loctite 243 Medium strength detachable www loctite de Loctite 601 High strength screw retention non detachable www loctite de The marked parts are not required ...

Page 19: ...on leg sets 1 2 1 Install the belt section on 2 to 4 leg sets Please note Install one leg set each in the immediate vicinity of the drive and return unit Install the leg sets under each of the cross connectors of the belt section Max distance between 2 leg sets 2000 mm Assembly 19 84 3 842 563 834 2022 08 MIT BS 2 C BS 2 R Bosch Rexroth AG ENGLISH ...

Page 20: ... Installing the belt section on leg sets 2 2 2 Align the belt section ﬂush horizontally and by height 3 Screw the belt section to the ﬂoor For each connection you will need 1x foundation bracket 3 842 146 815 1x dowel 3 842 526 560 2x T bolt 3 842 528 718 2x ﬂange nut 3 842 345 081 20 84 Assembly Bosch Rexroth AG MIT BS 2 C BS 2 R 3 842 563 834 2022 08 ...

Page 21: ...90 90 90 SW8 2x MD 6 Nm A A A A B B B B B B Swiveling the motor gear combination or gear motor around the drive axle 1 Remove the screws A B 2 Pivot the motor gear combination or the gear motor around the drive axis in 90 intervals 3 Install the screws A B Assembly 21 84 3 842 563 834 2022 08 MIT BS 2 C BS 2 R Bosch Rexroth AG ENGLISH ...

Page 22: ... C 4 1 BS 2 C 100 250 BS 2 R 300 700 Disassembling the protective case 1 Open the latches using two slotted screwdrivers 2 Remove the front half of the protective case 3 Remove the drip tray 4 If necessary remove the other part of the protective case Mount the protective case in reverse order 22 84 Assembly Bosch Rexroth AG MIT BS 2 C BS 2 R 3 842 563 834 2022 08 ...

Page 23: ...00 Installing the belt section between two sections Required accessories Connection kit 3 842 528 192 1x Please note Support the belt section if necessary with section supports see page 19 1 Disassemble the outer protective case halves 2 At all halves of the protective case break out a gap for the connection kit at the perforated location X according to your application case 3 Smooth the resulting...

Page 24: ...MD 25 Nm SW13 MD 25 Nm BS 2 C H Installing the belt section between two sections Required accessories Connection kit 3 842 518 828 0 5x Connection kit 3 842 530 868 0 5x Please note Support the belt section if necessary with section supports see page 19 1 Remove the gear motor 2 Remove the side cover plates 3 Install the connection kit 3 842 518 828 2x 4 Install the connection kit 3 842 530 868 2x...

Page 25: ...sories Connection kit 3 842 518 828 0 5x Connection kit 3 842 528 192 0 5x 1 Remove the gear motor 2 Remove the side cover plates 3 Install the connection kit 3 842 518 828 2x 4 Disassemble the outer protective case halves 5 At all halves of the protective case break out a gap for the connection kit at the perforated location X according to your application case 6 Smooth the resulting burr 7 Insta...

Page 26: ...ories Connection kit 3 842 529 881 1x 1 Disassemble the outer protective case halves 2 Slide the connection kit into the T groove at the drive head 3 Align the return unit of the adjacent belt section and position it without a gap at the height of the drive head 4 Install the connection kit centrally between drive head and return unit 5 Mount the outer halves of the protective case 26 84 Assembly ...

Page 27: ...o return unit Required accessories Connection kit 3 842 530 871 1x 1 Remove the gear motor 2 Remove the side cover plates 3 Install the connection kit at the drive head 4 Align the return unit of the adjacent belt section and position it without a gap at the height of the drive head Mount the connection kit to the return unit 5 Mount the side cover plates 6 Mount the gear motor Assembly 27 84 3 84...

Page 28: ...creases If the lever is no longer visible in the slot the chain must be shortened Alternatively install a sensor E 3 842 551 761 ø8 mm max length incl bending radius of the cable 45 mm in the attachment tab Switching distance 1 5 0 5mm The vane C damps the sensor when the maximum permissible chain length is reached Please note Be sure to comply with the switching distance otherwise the sensor will...

Page 29: ...chain at the level of the tensioning lever X of the chain tensioner The tensioning lever X moves from the top new shortened chain downwards elongated chain as the chain length increases When the tensioning lever X is in the lowest position the chain must be shortened Alternatively mount a sensor to indicate the lowest position of the clamping lever X Sensor support SH 2 UV 3 842 557 600 1 Sensor 3...

Page 30: ... Scanning the chain length with sensor large drive head 2 2 1 Adjust the stop of the sensor support 2 Install the sensor support with the provided screws 1 Scope of delivery 2 Not included in the scope of delivery Please note Fully slide the sensor into the sensor support 30 84 Assembly Bosch Rexroth AG MIT BS 2 C BS 2 R 3 842 563 834 2022 08 ...

Page 31: ...tective case halves 3 Using a wrench turn the drive shaft in the conveying direction until the chain lock appears on the chain tensioner You can recognize the chain lock of the accumulation roller chain by the galvanized tab 2 4 Pull the chain tensioner up 3 and ﬁx it in its end position with a pin or screwdriver 3 BS reversible unlock the chain tensioner by lifting the latch Fig 14 item 4 5 Open ...

Page 32: ...on until the chain appears on the chain tensioner 11 Close the chain 4 Chain lock for accumulation roller chain 3 842 530 417 12 Loosen the mount of the chain tensioner Check the tension of the chain 13 Mount the outer halves of the protective case 14 Install the gear motor Please note Avoid accumulation above the acceleration element Accumulation above the acceleration element causes severe rolle...

Page 33: ...ect the motor in either a wye or a delta conﬁguration in accordance with the wiring diagrams see Fig 17 on page 34 and the wiring diagram in the terminal box The motor is ﬁtted with a bimetal temperature monitoring switch potential free thermal contact 230 V AC 300 mA Wire the motor so that it is de energized when the switch is triggered Insert the cable so that it cannot get damaged during operat...

Page 34: ...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 Delta wye connection diagrams Fig 19 Installation_IEC Optional motor connection with plug AT S 34 84 Assembly Bosch Rexroth AG MIT BS 2 C BS 2 R 3 842 563 834 2022 08 ...

Page 35: ... B Motor side The push in ﬁtting consists of UL components Fig 21 Installation_Stecker PE A B 1 3 4 5 2 PE 2 5 4 3 1 Motor connection with plug AT 1 push in ﬁtting A Connection cable side B Motor side Connection list Connection terminals motor 3 Pin no Code U1 1 L1 V1 2 L2 W1 3 L3 TW1 4 Th1 TW2 5 Th2 PE PE Assembly 35 84 3 842 563 834 2022 08 MIT BS 2 C BS 2 R Bosch Rexroth AG ENGLISH ...

Page 36: ...2006 42 EC you must equip the transfer system with EMERGENCY STOP control devices The surfaces of motors and gears can reach temperatures of over 65 C under certain load and operating conditions In these cases you must comply with the respective applicable accident prevention regulations UVV by taking appropriate constructive measures safety guards or by afﬁxing displaying appropriate warning sign...

Page 37: ...arting after unscheduled shutdown 17 Troubleshooting and remedial action intervention by operating personnel 18 Cleaning and keeping clean 19 Preventive maintenance 20 Corrective maintenance Operating states of the machine Sect 5 4 b 21 Normal operation 22 Modiﬁcation of a property or a dimension of the material or workpiece to be processed 23 Failure of one or more of its components or supply dev...

Page 38: ...static force for stopping the load is less than 150 N 3 Conveyor medium between running conveyor and stationary workpiece pallet e g during separation Trapping of limbs Crushing Do not reach into the system while it is running 4 Between workpiece pallets Trapping of limbs Crushing Shearing Do not reach into the system while it is running At workspaces relative movements of loads e g at accumulatin...

Page 39: ...on belt roller BS 2 C H R H R V leads to increased wear at the workpiece pallet There is a risk of damage to property Avoid congestion on the connection belt roller 9 1 Information on operation 9 1 1 Wear Individual components are subject to unavoidable wear by their very nature Constructive measures and the selection of materials help ensure functional safety over the full service life However we...

Page 40: ... well as machining processes in the transfer system e g welding beads pumice dust glass shards chips waste parts etc Maintenance intervals should be signiﬁcantly shortened under these circumstances Resistance to media and contamination does not mean that functional safety is guaranteed in every case Liquids that thicken as they evaporate and become highly viscous or adhesive sticky can lead to mal...

Page 41: ...s that are in motion or operation when the protective equipment is in place Observe DIN EN ISO 13857 when you remove or replace safety guards and or bypass protective equipment Test runs with open paneling should only be performed by a person with appropriate knowledge and experience using tip switches and if there is no possibility of interference from other switching devices Maintenance and repa...

Page 42: ...e intervals Keep a maintenance schedule Keep degreasers or aggressive cleaning agents away from the conveyor chain Only clean the product with a damp cloth 10 2 Inspection 10 2 1 Conveyor chain ﬂat top chain accumulation roller chain Check the conveyor chain regularly for wear and sufﬁcient lubrication by visual inspection 10 3 Maintenance 10 3 1 Bearings The bearings have lifelong lubrication and...

Page 43: ...alfunctions due to chain failure or even crash the system causing considerable property damage Keep a maintenance schedule The running times during the system s set up and start up count towards the ﬁrst maintenance interval If you do not know the running times during the system s set up and start up lubricate the conveyor chain at the start of production Lubricate the chain after downtimes 6 mont...

Page 44: ... MD 7 Nm SW4 MD 7 Nm SW4 BS 2 C H BS 2 R H R V 1200 Fig 23 Greasing the conveyor chain in the drive module MD 5 Nm SW4 MD 5 Nm SW4 ST 2 C W ST 2 R W Fig 24 Greasing the conveyor chain in the maintenance section 44 84 Maintenance and repair Bosch Rexroth AG MIT BS 2 C BS 2 R 3 842 563 834 2022 08 ...

Page 45: ...42 543 486 Adapter set AS 2 R V 1200 3 842 543 487 1 For retroﬁtting older transfer systems without a lubrication hole you also need a retroﬁt kit LU 2 3 842 546 725 LU 2 BS 2 C 100 BS 2 C 250 BS 2 C H LU 2 LC 2 Set AS 3 842 543 482 LU 2 3 842 543 469 LC 2 3 842 543 483 set AS 2 C 100 250 3 842 543 484 set AS 2 C 400 700 BS 2 R 300 BS 2 R 700 BS 2 R 1200 BS 2 R V 1200 3 842 543 485 set AS 2 R 300 ...

Page 46: ...equired tools Hex wrench open end SW8 SW10 SW13 SW19 SW27 Hex socket wrench SW4 Two slotted screwdrivers Spirit level Combination pliers 10 4 3 Required accessories For ﬂat top chain Disassembly tool 3 842 010 510 Chain lock 3 842 535 333 For accumulation roller chain Disassembly tool 3 842 010 511 Chain lock 3 842 530 417 For accumulation roller chain Vplus Disassembly tool 3 842 539 357 Chain lo...

Page 47: ...2 C 100 250 BS 2 R 300 700 Disassembling the protective case 1 Open the latches using two slotted screwdrivers 2 Remove the front half of the protective case 3 Remove the drip tray 4 If necessary remove the back half of the protective case Mount the protective case in reverse order Maintenance and repair 47 84 3 842 563 834 2022 08 MIT BS 2 C BS 2 R Bosch Rexroth AG ENGLISH ...

Page 48: ... side without motor either remove the outer protective case half BS 2 C 100 250 BS 2 R 300 700 BS 4 R 300 700 or remove the side cover plate BS 2 C H BS 2 R H BS 2 R V 1200 5 Start the belt section with the jog switch until the chain lock appears on the chain tensioner You recognize the chain lock of the ﬂat top chain by the gray ﬂat chain with hole 1 of the accumulation roller chain by the galvan...

Page 49: ...ive head BS 2 C BS 2 R Pull the chain tensioner up and ﬁx it in its end position with a pin or screwdriver BS 2 R reversible Unlock the chain tensioner by lifting the latch Fig 28 Pull the chain tensioner up and ﬁx it in its end position with a pin or screwdriver Pull the chain tensioner X up and ﬁx it in its end position by turning it 90 clockwise Fig 29 item 2 Loosen the chain tensioner by turni...

Page 50: ...in length increases If the lever is no longer visible in the slot the chain must be shortened Replace the chain if the permissible elongation of the chain 3 of the original length is exceeded You can see the length of the chain at the level of the tensioning lever X of the chain tensioner The tensioning lever X moves from the top new shortened chain downwards elongated chain as the chain length in...

Page 51: ... R 300 700 MA R L 1 2 Please note Perform the steps on both sides in parallel 1 Remove the gear motor 2 Disassemble the outer protective case halves 3 Using a wrench turn the drive shaft in the conveying direction until the chain lock appears on the chain tensioner You recognize the chain lock of the ﬂat top chain by the gray ﬂat chain with hole 1 of the accumulation roller chain by the galvanized...

Page 52: ...for ﬂat top chain 3 842 010 510 for accumulation roller chain 3 842 010 511 4 Chain lock for ﬂat top chain 3 842 535 333 for accumulation roller chain 3 842 530 417 Please note Remove the same number of chain links for both chains Note in the maintenance plan how many chain links you have removed Replace the chain if the permissible elongation of the chain 3 of the original length is exceeded 7 Cl...

Page 53: ...ck 4 per chain 4 Chain lock for ﬂat top chain 3 842 535 333 for accumulation roller chain 3 842 530 417 Perform the steps on both sides in parallel 1 Disassemble the outer protective case halves 2 Fix the chain tensioner 3 Open the chain with the disassembly tool 3 3 Disassembly tool for ﬂat top chain 3 842 010 510 for accumulation roller chain 3 842 010 511 Maintenance and repair 53 84 3 842 563 ...

Page 54: ...Remove the same number of chain links for both chains Note in the maintenance plan how many chain links you have removed Replace the chain if the permissible elongation of the chain 3 of the original length is exceeded 5 Grease the new chain lock and close the chain 6 Loosen the mount of the chain tensioner Check the tension of the chain 7 Mount the outer halves of the protective case 54 84 Mainte...

Page 55: ... in parallel 1 Remove the gear motor 2 Remove the side cover plates remove the bottom cover sheets 3 Using a wrench turn the drive shaft in the conveying direction until the chain lock appears on the chain tensioner You recognize the chain lock of the ﬂat top chain by the gray ﬂat chain with hole 1 of the accumulation roller chain by the galvanized tab 2 3 Disassembly tool for ﬂat top chain 3 842 ...

Page 56: ...accumulation roller chain 3 842 010 511 for accumulation roller chain Vplus 3 842 539 537 4 Chain lock for ﬂat top chain 3 842 535 333 for accumulation roller chain 3 842 530 417 for accumulation roller chain Vplus 3 842 538 872 Please note Remove the same number of chain links for both chains Note in the maintenance plan how many chain links you have removed Replace the chain if the permissible e...

Page 57: ...ssemble the outer protective case halves 4 Using a wrench turn the drive shaft in the conveying direction until the chain lock appears on the chain tensioner of the return unit You recognize the chain lock 4 of the accumulation roller chain by the galvanized tab 3 5 Secure the chain tensioners at drive and return unit 6 Open the chain at the chain lock 4 3 Disassembly tool for accumulation roller ...

Page 58: ... 3 842 539 537 4 Chain lock for accumulation roller chain 3 842 530 417 for accumulation roller chain Vplus 3 842 538 872 Please note Remove the same number of chain links for both chains Note in the maintenance plan how many chain links you have removed Replace the chain if the permissible elongation of the chain 3 of the original length is exceeded 8 Close the chain 9 Loosen the chain tensioners...

Page 59: ...pieces 2 in the drive and return unit the chain tensioners 3 the connection belt roller 4 and the associated toothed belt for wear Replace the worn parts Fig 41 563 833 63 2 2 3 1 2 3 3 4 MD 2 5 Nm SW4 MD 2 5 Nm SW4 MD 2 5 Nm SW4 Wear parts We recommend When replacing the ﬂat top chain always replace the glide proﬁles as well Maintenance and repair 59 84 3 842 563 834 2022 08 MIT BS 2 C BS 2 R Bos...

Page 60: ...property Make sure the chain remains straight and can leave the chain reel smoothly during installation Make sure the chain reel cannot tilt during installation If the chain reel does tilt during installation and the chain is deformed Use the disassembly tool to remove the affected area with a generous margin on either end 563 833 39 Fig 42 Unwinding of the chain from the chain reel 60 84 Maintena...

Page 61: ... Failure of the conveyor chain ﬂat top chain accumulation roller chain Inadequate lubrication of the conveyor chain can result in conveyor chain failure or even crashing There is a risk of damage to property The conveyor chain used in this product comes lubricated Lubricate the conveyor chain before the commissioning with Structovis GHD 0 842 904 229 using 1 2 g oil m of chain then every 1 000 hrs...

Page 62: ...in 1 Remove the gear motor 2 Disassemble the outer protective case halves 3 Fix the chain tensioner 4 Open the chain with the disassembly tool 3 3 Disassembly tool for ﬂat top chain 3 842 010 510 for accumulation roller chain 3 842 010 511 5 Remove the drive and return head covers 6 Pull the used chain down from the BS 2 7 Remove the sliding piece from the return head Assembling the chain 8 Drag t...

Page 63: ...n the drive wheel 12 Rotate the drive wheels in the conveying direction until the chain appears on the chain tensioner 13 Install the drive and return head covers 14 Use the disassembly tool to remove so many excessive chain links that you can close the chain as closely as possible to the tensioning wheel 15 Grease the new chain lock 4 and close the chain 4 Chain lock for accumulation roller chain...

Page 64: ...ssemble the outer protective case halves 2 Fix the chain tensioner 3 Open the chain with the disassembly tool 3 3 Disassembly tool for ﬂat top chain 3 842 010 510 for accumulation roller chain 3 842 010 511 4 Remove the drive and return head covers 5 Pull the chain back until the drive head is exposed 6 Remove the sliding piece 7 Remove the drive train 8 Pull the used chain down from the BS 2 9 Re...

Page 65: ...d with a pull in aid 5 BS 2 C BS 2 R Observe the running direction of the chain Fig 42 page 61 11 Hold the end of the chain vertically and insert the sliding piece into the return head Please note For the next assembly step you need a helper or a lift aid Maintenance and repair 65 84 3 842 563 834 2022 08 MIT BS 2 C BS 2 R Bosch Rexroth AG ENGLISH ...

Page 66: ...ect the drive train in the drive heads 16 Lift the chain slightly and insert the sliding piece into the drive head 17 Install the drive and return head covers 18 Use the disassembly tool to remove so many excessive chain links that you can close the chain as closely as possible to the tensioning wheel 19 Grease the new chain lock 4 and close the chain 4 Chain lock for accumulation roller chain 3 8...

Page 67: ...l Disassembling the chain 1 Remove the gear motor 2 Remove the side cover plates remove the bottom cover sheets 3 Fix the chain tensioner 4 Open the chain with the disassembly tool 3 3 Disassembly tool for ﬂat top chain 3 842 010 510 for accumulation roller chain 3 842 010 511 for accumulation roller chain Vplus 3 842 539 357 5 Remove the cover of the return head 6 Pull the used chain down from th...

Page 68: ... Drag the new chain 5 to the return head with a pull in aid 5 BS 2 C BS 2 R Observe the running direction of the chain Fig 42 page 61 10 Place the chain around the return wheel and place the return wheel in the return head 11 Mount the sliding piece into the return head 68 84 Maintenance and repair Bosch Rexroth AG MIT BS 2 C BS 2 R 3 842 563 834 2022 08 ...

Page 69: ...ain appears on the chain tensioner 15 Use the disassembly tool to remove so many excessive chain links that you can close the chain as closely as possible to the chain tensioner 16 Grease the new chain lock 4 and close the chain 4 Chain lock for ﬂat top chain 3 842 535 333 for accumulation roller chain 3 842 530 417 for accumulation roller chain Vplus 3 842 538 872 17 Loosen the mount of the chain...

Page 70: ...Remove the gear motor 2 Remove the side cover plates remove the bottom cover sheets 3 Disassemble the outer protective case halves 4 Secure the chain tensioners at drive and return unit 5 Use the disassembly tool 3 to open the chain at the return unit 3 Disassembly tool for accumulation roller chain 3 842 010 511 for accumulation roller chain Vplus 3 842 539 357 6 Remove the cover of the return he...

Page 71: ...the drive wheel and pull in the upper guide proﬁle to the return head 11 With the disassembly tool remove so many chain links that you can close the chain as closely at the tensioning wheel as possible 12 Grease the new chain lock 4 and close the chain 4 Chain lock for accumulation roller chain 3 842 530 417 for accumulation roller chain Vplus 3 842 538 872 13 Loosen the mount of the chain tension...

Page 72: ...over plates 3 Remove the toothed belt Check the connection belt roller for wear and replace if necessary Remove the connection belt roller from the axis place the starting disk on the axis ﬁrst then the new connection belt roller 4 Place the new toothed belt around the toothed belt wheel 5 Rotate the drive wheels in the conveying direction simultaneously place the toothed belt around the pinion of...

Page 73: ... to the gear If the motor is not in the proper position Do NOT rotate the motor Disconnect the motor from the gear and reconnect it If only the motor is to be replaced start with item 4 1 Loosen the hexagon screws on the ﬂange 2 Remove the motor gear combination from the hexagonal shaft 3 Remove the cover plug from the defective gear and insert it at the new gear 4 Loosen the hexagon screws on the...

Page 74: ...osition terminal box and connect it to the gear If the motor is not in the proper position Do NOT rotate the motor Disconnect the motor from the gear and reconnect it Disassembling the drive train see Changing the conveyor chain page 64 item 1 to item 7 If only the motor is to be changed the drive train does not have to be removed Then start with item 4 1 Loosen the hexagon screws on the ﬂange 2 D...

Page 75: ...63 833 65 SW10 MD 8 Nm 3 4 2 5 1 6 Replacing the gear motor motor mounting MA R L Please note The gear motor can only be exchanged completely A separation of motor and gear is not permitted 1 Remove the gear motor 2 Remove the ﬂange from the gear motor 3 Remove the plug 4 Mount the plug at the new gear motor 5 Mount the ﬂange at the new gear motor 6 Install the gear motor ENGLISH ...

Page 76: ...etely A separation of motor and gear is not permitted 1 Remove the side cover plates 2 Remove the locking rings from the hexagonal shaft 3 Slide the hexagonal shaft out of the drive Store the protective tube for reuse 4 Remove the ﬂange from the gear motor 5 Mount the ﬂange at the new gear motor 6 Assemble the gear motor and tighten the screws by hand 7 Push the hexagonal shaft into the drive Whil...

Page 77: ...GP 2 H KS 2 24 x L 6000 mm 3 842 564 314 Guide proﬁle D FP 2 C R 2 12 x L 6000 mm 3 842 567 261 Glide proﬁle E GP 2 2 24 x L 6000 mm 3 842 567 260 1 ST steel 2 KS plastic 1 Remove the chain see chapter Changing the conveyor chain 2 Clean the interior X of the section proﬁle thoroughly Please note Before removing the glide proﬁles thoroughly clean the interior X of the section proﬁle of grease dirt...

Page 78: ...C H C C 3a 4a 3c 4c Changing the glide proﬁles BS 2 C 100 250 BS 2 C H 2 2 3 Remove the worn glide proﬁles 4 Install the new glide proﬁles Attach the glide proﬁle vertically at the groove Swivel the glide proﬁle into the groove Press the glide proﬁle into the end position 5 Install the chain see chapter Changing the conveyor chain ...

Page 79: ...ing the glide proﬁle into the section proﬁle ST 2 R V set 5 pieces 3 842 564 984 Glide proﬁle C GP 2 H ST 3 48 x L 3000 mm 3 842 564 315 GP 2 H KS 4 24 x L 6000 mm 3 842 564 314 Guide proﬁle D FP 2 C R 4 12 x L 6000 mm 3 842 567 261 Glide proﬁle E GP 2 4 24 x L 6000 mm 3 842 567 260 1 yellow 2 red 3 ST steel 4 KS plastic 1 Remove the chain see chapter Changing the conveyor chain 2 Clean the interi...

Page 80: ...300 700 BS 2 R H BS 2 R V 1200 2 2 3 Remove the worn glide proﬁles 4 Install the new glide proﬁles Insert the assembly aids A B onto the glide proﬁle R A yellow R H A yellow R V B red Attach the glide proﬁle vertically at the groove Swivel the glide proﬁle into the groove Remove the assembly aids and press the glide proﬁle into the end position 5 Install the chain see chapter Changing the conveyor...

Page 81: ...ent before performing any maintenance or repair work Secure the system against being unintentionally switched on again Suspended loads may fall Falling objects can result in severe injury or even death Use only slings with sufﬁciently high bearing loads for product weight see delivery documents Make sure the lifting straps are correctly fastened before lifting the product Secure the product agains...

Page 82: ... Careless disposal may lead to environmental contamination Dispose of the product in accordance with the regulations in your country 14 Upgrading and modiﬁcation Do not modify the product The Bosch Rexroth warranty only applies to the conﬁguration as delivered and to approved upgrades The manufacturer will not accept any warranty claims for systems with unapproved modiﬁcations or upgrades 15 Troub...

Page 83: ... C 5 C to 60 C at 20 reduced load Storage temperature 25 C to 70 C Relative humidity 5 to 85 Air pressure 84 kPa corresponds to an installation altitude 1400 m above sea level Max load capacity of ﬂoor 1000 kg m2 At installation altitudes 1400 m the load values of the electric drives are reduced by 15 The area should be kept free of mold fungus rodents and other vermin Do not install or operate in...

Page 84: ...Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax 49 711 811 7777 info boschrexroth de www boschrexroth com Subject to change 3 842 563 834 2022 08 ...

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Bosch BS 2/R, Assembly Instructions Manual

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