Modular Transfer Systems

Lift-Transfer Unit

Model EQ2/U3Installation and MaintenancePublication Number: 8981 500 299 7/02

TSplus Lift-Transfer Unit

2

All rights are held by BOSCH AUTOMATION PRODUCTS andROBERT BOSCH GMBH, also regarding patent claims. We retainall powers of disposition, such as for copying and/or for passing-on tothird parties.

We reserve the right to make technical changes at any timewithout notice.Errors and omissions excepted.© 2002 Bosch Automation Products

Table of contents

IMPORTANT SAFETY INFORMATION .................. 3

Safety First ................................................................. 3

Material Hazards: ...................................................... 3

Review All Safety Information: ............................... 3

IMPORTANT SAFETY INFORMATION .................. 4

SAVE THESE INSTRUCTIONS ............................... 4

Introduction .................................................................... 5

About this manual ......................................................... 5

Design and Detailed Description ............................. 6

Application and Function ............................................ 7

Using T-Bolts and T-Nuts ........................................... 8

Attach LTU to Conveyor Section ............................. 9

Installing Proximity Switch ........................................ 10

Checking and Adjusting Toothed Belt Tension .. 11

Initial Start-up .............................................................. 12

Connect the motor wiring......................................... 12

For CE Applications................................................... 13

Terminal Block Assembly Instructions .................. 13

Connect the Compressed Air Supply ................... 14

For Lift And Lower Operation.................................. 14

For Lift Only Operation ............................................. 14

Stop Rail Orientation ................................................. 16

Cushioned Stop Pneumatic Diagram .................... 16

Installing Optional Cushioned StopBWT = 480 and smaller ........................................... 17

Installing Optional Cushioned StopBWT = 640 ................................................................. 17

Operating Instructions .............................................. 18

Maintenance ................................................................ 19

Repair ............................................................................ 20

Replacing the Toothed Belt ..................................... 20

Replacing Gear Box .................................................. 22

Installation of Protective Covers ............................. 25

Scope of Delivery ................................................... 25

Step by Step Assembly Instructions .................. 26

Module Warranty ........................................................ 28

Liability .......................................................................... 28

Environmental Protection ......................................... 28

3

IMPORTANT SAFETY INFORMATIONIMPORTANT: This operation and installation manual should be reviewedwith all equipment operators as part of your operator training program.

SAFETY FIRST!

Important safety information is contained throughoutthis manual to alert you to potentially dangeroussituations and help prevent accidental injury andproperty damage.

The safety warning symbol above has been included towarn you of hazards that can hurt or kill you andothers, and/or cause serious damage to the equipmentand other property.

In addition, the following safety alert words are used:

DANGER! Means that you or others willbe seriously or fatally injured ifinstructions are not followed.

WARNING! Means that you or others maybe seriously or fatally injured ifinstructions are not followed.

CAUTION! Means that you or others maybe injured if instructions arenot followed.

Material Hazards:

Some components, such as gearboxes, containlubricants or other materials that can represent apotential health hazard if handled, stored, or dis-posed of improperly.

Please contact Bosch for copies of the MaterialSafety Data Sheets (MSDS) for the lubricating oilused in gearboxes and other potentially hazardousmaterials.

Review All Safety Information:

Please review the safety information included onpage 4 and throughout this manual with all installers,operators, and maintenance personnel of this equip-ment.

4

WARNING!Please read all assembly, and maintenance instructionscarefully before beginning set-up of the components inthis document.

Where appropriate, warning symbols have beenincluded in this publication to alert you of potential orimpending danger.

• Be sure to read and observe all safety warnings inthis document as well as those attached to theindividual modules. Failure to do so could result inpotential risks to your health and safety as well asthose around you.

• Covers and guards have been designed to elimi-nate pinch points and exposure to moving chainsand gears. DO NOT operate the conveyor or anyof the other components in the system with theguards removed. Serious injury may result!

• All set-up maintenance and repair work shouldbe performed only by properly trained, qualifiedpersonnel. All operators must be properly trainedin the use of this equipment.

• A qualified electrician must make all electricalconnections when wiring the components in-stalled in the TSplus system. Be sure to follow alllocal, state and federal regulations when installingelectrical devices of any type. The customer as-sumes responsibility for the control system, andmust provide an EMERGENCY-OFF SWITCH orswitches for all workstation operators to meet allapplicable industry and OSHA requirements. Ingeneral, emergency-off switches must be presentat easily accessible locations for all operators ofthe installed TSplus conveyor system.

• All power supplies must be LOCKED OUT beforebeginning maintenance or repair work of any typeon the conveyor system. Proper LOCK OUTprocedures include the identification of the lockedout power supply with a tag to prevent the acci-dental restoration of power.

• TSplus pneumatic components are designed tooperate in a range of 4–6 Bar (58–87 psi). It is theusers responsibility to install a filtered, regulatedair supply to limit the pressure to that recom-mended by the manufacturer. Before beginningany maintenance or repair, bleed off the pressurelines to all components to prevent unexpected oraccidental movement of a system componentwhich could result in personal injury.

• TSplus drives, returns and conveyor sections andcomponents are designed to transport BoschWT2, WT2/A, WT2/A-H workpiece pallets. Properusage is defined as the transport and positioningof parts and assemblies via the workpiece palletand fixture during the assembly process. In noinstances should the pallet payload, the down-ward force applied to the pallet, or the total loadcarrying capacity of the entire system be ex-ceeded. Exceeding published specifications willresult in premature wear or system failure and maycause damage to the motor, gearbox, roller chain,seals and other components.

• CAUTION! Do not operate or work near mechani-cal equipment when wearing loose clothing. Mov-ing components such as roller chain, drive belts,drive shafts and pallets can snag long belts,scarves, ties and other loose fitting garments, pullthe worker into the equipment and cause serious,or in extreme cases, life threatening injury.

• CAUTION! Operators having long hair must wearappropriate head protection (hair nets, hats, andhair caps) to minimize the risk associated withworking near moving machinery. Hanging hair canget caught in moving components such as rollerchain, drive belts, drive shafts and pallets, pull theworker into the equipment and cause serious, orin extreme cases, life threatening injury.

SAVE THESE INSTRUCTIONS!

IMPORTANT SAFETY INFORMATION

5

Introduction

Like all Bosch flexible assembly systems, TSplus isconstructed solely from standardized modules thatare precisely matched to each other. One importantbenefit of this modular design is that you can interlinkmanual and automatic work stations freely, makingTSplus suitable for virtually any assembly task. TheEQ2/U3 Lift Transfer Unit (LTU) module allows you totransfer pallets laterally off of the main conveyor line.

About this manual

The manual is divided into the following sections tomake it easier to use:

• Design and Detailed DescriptionSupplies an overview of the modules that makeup the EQ2/U3. This section will familiarize youwith the modules individual components.

• Application and FunctionGives general information about the EQ2/U3Tandem Lift Transfer Unit.

• Technical DataProvides the most important technical specifica-tions.

• AssemblyLists step-by-step instruction for installing theEQ2/U3 .

• Initial Start-upDescribes the final procedures for getting theEQ2/U3 up and running.

• MaintenanceProvides information on preventive maintenance.

• RepairGives step-by-step procedures for replacing anyparts subjected to wear.

This manual describes the primary componentsthat make up the EQ2/U3 Lift Transfer Unit (refer topage 6 for a description of primary components andtheir functions).

Other TSplus modules are also available and varyaccording to the configuration of the system. Thesemodules are described in separate manuals and in-clude the following:

• Drives, Returns, and Conveyor Sections

• Cushioned and Standard Stop Gates, Rockers

• Proximity Switch Mounting Kits

• Accumulation Control Kits

• Lift-Position Units

• Lift-Rotate Units

• Curve Modules

Contact Bosch for information on these and any othermodules for flexible assembly.

If this module was ordered as CE compliant, pleasecontact our applications engineering department for acopy of the latest manufacturer's CE declaration.

6

Design and Detailed Description

The EQ2/U3 includes a drive motor to power thetoothed belts, two spring centered 3-position pneu-matic cylinders, stop bar/guide bar, protective cov-ers, pneumatic connections and mounting hardware.

A proximity switch mounting bracket is also included.Due to the stroke, all three positions may not besensed, as three proximity switches will not fit into thespace available. It is recommended that the center“pallet stop position” be sensed and the signal lost onthe up and down strokes. The proximity switch mount-ing kit can also be ordered separately under partnumber: 3842 311 894.

In the EQ2/U3 (Fig. 1), the motor and gearbox powerthe toothed belt conveyor via the belt drive gears.Double acting pneumatic cylinders on the LTU maybe configured to lower the toothed belt conveyors

below the transport surface to allow pallet pass-through, or raise the pallet on the toothed belt convey-ors above the transport surface. In the raised posi-tion, the toothed belts transfer the pallet across atrack roller section or transverse conveyor onto thereceiving LTU. The pneumatic cylinders on the receiv-ing LTU then exhaust and lower the pallet to thetransport surface of the parallel line. A protectivecover protects the mechanism of the LTU from dirtand damage and helps prevent accidental injury.Proximity switches may be mounted to detect raisedor lowered status of the LTU.

CAUTION! DO NOT operate theEQ2/U3 with the protective cover removed!Serious injury may result if the EQ2/U3 isoperated without guards!

Fig. 1

3-PositionPneumatic Cylinders

Muffler

ProtectiveCover

T-BoltStop Bar

Toothed BeltConveyor

Drive Motor

7

Application and Function

The EQ2/U3 Lift Transfer Unit (LTU) is usedto transfer pallets perpendicularly off the con-veyer. It is used primarily at “corners” and“intersections”, but can also be used for palletrouting changes.

“Corner Transfer” requires LTU operation inthe “Pallet Stop” and “Transfer” positions asshown.

“Intersection Transfer” requires LTU opera-tions in the “Pallet Stop”, “Transfer” and“Clear” positions as shown. Intersection Trans-fer permits the pallet to be directed off themain line or allows the pallet to pass throughdepending on the process requirement.

11 mm

Lowered “Clear” Position

Centered “Pallet Stop” Position1 mm

Raised “Transfer” Position10 mm

The LTU lift plate is powered up and down bytwo pneumatic cylinders. In the spring cen-tered, “Pallet Stop” position, the LTU beltsare located 1 mm below the bottom of thepallet. A stop bar mounted to the lift plate maybe used to stop pallets on the LTU, or invertedso pallets pass through freely. An optionalcushioned stop may be installed when palletpayloads exceed 30 kg or with transportspeeds of 12 m/min or greater.

The LTU is raised to the “Transfer Position”by applying air pressure to the bottom of thecylinders. This lifts the LTU to a position 10mm above the nominal conveyor height. Asthe LTU rises, the LTU belts engage the palletand directs (or accepts) the pallet.

The LTU is lowered to the “Clear Position” byapplying air pressure to the top of the cylin-ders. This pushes the LTU down to a position11 mm below the nominal conveyor height.Use the lowered position when it is requiredto allow pallet pass through on the mainconveyor at spur lines and test stations forexample.

“Corner Transfer”

OptionalCushioned

Stop

RockerStop

“IntersectionTransfer”

8

Fig. 3

A

B

C

Mark

TrackRollers

orTransverseConveyor

PalletFlow

ReceivingLift

TransferUnit

SendingLift

TransferUnit

Fig. 2

Using T-Bolts and T-Nuts

The EQ2/U3, like virtually all Bosch conveyor mod-ules, is connected to the transfer system using the T-slot principle (Fig. 3). Insert the T-bolt into slot (A), andtighten down the hex nut. As it tightens, it will turn theT-bolt 90° in the slot (B), creating a friction lock (C).The same principle applies to T-nuts. The maximumallowable torque is 25 Nm (18.5 ft-lbs).

ASSEMBLY TIP: T-Bolts also have a mark on theend of the threaded shaft that will be perpendicularto the T-slot when the T-Bolt is in its locked position.

Operation (Fig. 2)

Pallet transfer from one parallel line to an adjacent linerequires the use of a sending EQ2/U3 and a receivingEQ2/U3 located at each end of a set of track rollersor a transverse conveyor.

The sending LTU waits in “Pallet Stop” mode belowthe transport surface level until a pallet passes overthe LTU and is stopped by the stop rail or a cushionedstop triggering a proximity sensor that activates theLTU. The pneumatic cylinders in the LTU then ener-gize, lifting the pallet perdendicularly off the main line,across the non-powered track rollers or poweredtransverse conveyor, and onto the waiting LTU. Thewaiting LTU then lowers the pallet back to the trans-port surface of the parallel line.

9

Attach LTU to Conveyor Section(Fig. 4 and 5)

1 Mark the location on the conveyor line where theLTU is to be installed.

2 Remove middle guard cover.

3 Remove mounting brackets (2 per side) fromsupporting bar on LTU and install in T-slot onconveyor section profiles.

4 Lower EQ2/U3 from above onto conveyorsection profiles and set down on the four brack-ets. Adjust bracket position if necessary.

5 Manually insert four M8 T-bolts with the T-headsthrough the oblong holes in the T-slot of the

conveyor section profile SP/2. Hand tighten theM8 flange nut.

6 Attach supporting bar to mounting bracketsusing hardware previously removed.

7 Check alignment. (Fig. 5)

NOTE: Use a straightedge to be sure that the LiftTransfer Units and track rollers are in perfect align-ment from side-to-side, as shown in Fig. 5. This iscritical for pallet transfer.

8 Tighten the M8 flange nuts to 25 Nm (19 lb-ft).

Fig. 4

Middle GuardCover

MountingBrackets

M8 FlangeNut

SupportingBar

M8T-bolt

T-slot

ConveyorSectionProfile

ConveyorSectionProfile

T-groove

TrackRollers

orTransverseConveyor

PalletFlow

StraightEdge

ReceivingLift

TransferUnit

SendingLift

TransferUnit

Fig. 5

10

Installing Proximity Switch (Fig. 6)

1 Install the proximity switch in the mountingbracket so that the sensing distance is approxi-mately 2 mm (see inset).

NOTE: Due to the stroke, all three positions can notbe sensed, as three proximity switches will not fitinto the space available. It is recommended that thecenter “Pallet Stop” position be sensed and thesignal lost on the up and down stroke.

Fig. 6

2 mm

Proximity SwitchExciter

Proximity SwitchMounting Bracket

ProximitySwitch

11

Checking and Adjusting Toothed BeltTension

NOTE: Incorrect toothed belt tension can lead topremature belt failure! Always check toothed belttension prior to initial operation!

Using a moderate amount of pressure, press upwardon the belt for a deflection of approximately 10 mm(see inset 2) .

To re-tension the toothed belt, loosen the 5 mmsocket head cap screw on the return roller (see inset1). Then using a pry bar (screwdriver) move the returnroller upward until the belt can be deflected, using amoderate amount of pressure, approximately 10 mm(see inset 2). Retighten the socket head cap screw.Recheck tension.

"Z"5 mmSocket HeadCap Screw

Pry Bar

ReturnRoller

ToothedBelt

INSET #2

INSET #1

Fig. 7

12

Initial Start-up

For CE applications, refer to the next page for instruc-tions on installing and connecting the terminal block.Before starting up the Lift Transfer Unit for the firsttime, recheck all mounting hardware for tightness.

NOTE: The customer assumes responsibility for thecontrol system, and must provide an EMERGENCY-OFF SWITCH in the EQ2/U3.

Connect the motor wiring

Make the motor electrical connections according tothe connection schematic as shown (see Fig. 8) . Anadditional copy is also attached to the motor name-plate.

NOTE: All electrical wiring must be connected by aqualified electrician.

(Blk/Yel)T4

(Blk) T1

(Red/Yel) T6 T3 (Red)

T5 (Blu/Yel)

T2 (Blu)

Grn/Yel TR (Gnd)

L2

L3

L1

Delta Connection(Low Voltage)

T4

T1

T6T3

T5

T2

Grn/Yel TR (Gnd)

L2

L3

L1

“Y” Connection(High Voltage)

Blu

Red

Blk

Star Splice(Blk/Yel, Blu/YelRed/Yel)

Fig. 8

13

For CE Applications

If a CE compliant module was ordered, an optionalterminal block (Fig. 9) was included. Refer to theterminal box mounting instructions included with theterminal box.

Terminal Block Assembly Instructions

1. Attach the terminal box to the motor accordingto the mounting instructions included with theterminal box. See Fig. 9.

2 Assemble the terminal block components toproduce 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 theterminal box using two #4-40 screws in theposition shown. Tighten in the range 3 to 5 lb-in.

5 For a “DELTA” connection, terminate the motorand line leads as follows:

a Insert the red-yellow motor lead, the blackmotor lead and a line lead into the bluemiddle block.

b Insert the black-yellow motor lead, the bluemotor lead and a line lead into the orangemiddle block.

c Insert the blue-yellow motor lead, the redmotor lead and a line lead into the beige endblock near the motor lead exit.

6 For a “Y” connection, terminate the motor andline leads as follows:

a Insert the black-yellow, and blue-yellow andred-yellow motor leads into the beige middleblock opposite the motor lead exit.

b Insert the black motor lead and a line leadinto the blue middle block.

c Insert the blue motor lead and a line lead intothe orange middle block.

d Insert the red motor lead and a line lead intothe beige end block near the motor lead exit.

Fig. 9

Beige

Blue Orange#4-40 Screw#4-40 Screw

14

Connect the Compressed Air Supply(Fig.s 10, 11, and 12)

NOTE: Use a 5/3 way open center position controlvalve (not included) to direct airflow to the module.A 2-way valve will not work because the centerposition is lost and the upward flow cannot becontrolled.

The EQ2/U3 Tandem Lift Transfer Unit must besupplied with a filtered, regulated compressed airsupply of 4–6 bar (58–87 psi). The customer mustprovide any necessary air preparation equipment.

All air connections should be made with 8 mm push-lock type fittings. If a different air line size is used, thecustomer is responsible for installing the necessaryfittings. Connect the fittings for the lift cylinders to theflow controls A and C.

The LTU can be plumbed for either lift and loweredoperation to allow pallet pass through or for lift onlyoperation. 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 onflow control A. This connection will supply air forLTU lift operation.

5/3 Way Open CenterPosition Valve (Not Included)

D8

A B

1 2

Dual Cylinder Lift Only Operation

Muffler

1 2

C5/3 Way Open CenterPosition Valve (Not Included)

D8

D8

A B

1 2

1 2

C

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.

Dual Cylinder Lift and Lower Operation

A

B

C

Fig. 10

2. Connect an 8 mm air line from a control valve(not included) to the quick connect fitting onflow control C. This connection will supply airfor LTU lowered operation, powering the unitdown, 11 mm below the transport surface toallow pallet pass through.

3. Adjust flow controls A, B, and C as described inFig. 10 to regulate lift and lower operation.

NOTE: If as in the end of a rectangular line, palletsdo not need to pass through the LTU, the LTU canbe set up for Lift Only operation. The springs in thecylinders will then return the LTU to the centered(home) position.

For Lift Only Operation (Fig. 11 and 12)

1. Connect an 8 mm air line from a control valve(not included) to flow control A. This connectionwill supply air for LTU lift operation.

2. Remove the quick connect fitting on flow controlC and install the muffler.

3. Adjust flow controls A, B, and C as described inFig. 10 to regulate lift and lower operation.

15

Fig. 12

Fig. 11

BWT=640 mmFor Lift Only Operation Remove Quick Connect Fitting In Flow Control “C” And Install a Muffler.

FlowControl B

FlowControl A

FlowControl C

Push TypeAir Fitting

QuickConnectFitting

QuickConnectFitting

Muffler

B

A

C

BWT=480 mm

FlowControl B

Flow Control C

FlowControl A

8 mmPush Type

Fitting

Quick ConnectFitting

Quick ConnectFitting

For Lift Only Operation Remove Quick Connect Fitting In Flow Control “C” And Install a Muffler.

Muffler

B

C

A

16

Stop Rail Orientation (see Fig. 13)

As delivered LTU stop rails are positioned so a palletwill not stop on the LTU when it is in the centered orhome position. If your application requires, eitherstop rail can be repositioned to stop a pallet enteringthe LTU prior to lift and transfer. When total palletpayload exceeds 30 kg or 12 m/min you must use acushioned stop to halt pallet travel.

1. To change stop rail orientation, remove thesocket head cap screws and turn the stop rail180° and reattach it to the LTU.

NOTE: Large LTUs have one stop rail on each sideand smaller LTUs have two stop blocks, one oneach end.

BL=320, 400, 480 mm

Stop Plate

BL=640 mm

Stop Plate

Fig. 13

Fig. 14

Cushioned Stop Pneumatic Diagram(Fig. 14)

NOTE: Cushioning action can be adjusted to com-pensate for pallet payloads. Turning screw clock-wise toward + will increase cushioning

17

Installing Optional Cushioned StopBWT = 480 and smaller (Fig. 15)

1. On side you are mounting the stop, positionboth stop blocks with the stop tab up.

2. Install stop bracket onto side of roller carrier asshown using the screws, lockwasher and hexnut included with cushioned stop. See Fig. 15.

3. Attach guard plate to bottom of stop bracket asshown.

4. Mount cushioned stop to stop bracket withmounting hardware shown.

5. Connect compressed air supply to inlet port.

Installing Optional Cushioned StopBWT = 640 (Fig. 16)

1. On side you are mounting the stop, position stoprail with the notch up.

2. Install stop bracket with screws included withcushioned stop

3. Attach guard plate to bottom of stop bracket asshown.

4. Mount cushioned stop to stop bracket withmounting hardware shown.

5. Connect compressed air supply to inlet port.

NOTE: Cushioning action can be adjusted to com-pensate for pallet payloads. Turning screw clockwisetoward + will provide increased cushioning.

CushionedStop

Stop RailNotch

StopBracket

GuardPlate

CushionedStop

StopBracket

StopTab

GuardPlate

Fig. 15

Fig. 16

18

WARNING!

• Use a qualified technician who is familiar with thecontrol system during the initial start-up.

• In case of control system failure, DO NOT at-tempt to catch or in any way prevent a pallet fromfalling from the end of the conveyor. Use theemergency stop switch to halt conveyor move-ment!

• KEEP HANDS CLEAR of moving conveyors andpallets. Pallet accumulation creates a crush haz-ard between pallets, stop gates, and guide rails.A crush and pinch hazard exists between LiftPosition Units, Lift Transfer Units, and Lift RotateUnits. Assembly operations should be performedONLY when the workpiece pallet has come to acomplete stop.

• DO NOT perform pressing operations on a work-piece pallet without the use of a Lift Position Unit.

• DO NOT operate the conveyor or any othercomponents in the system with the guards re-moved. It is the operator’s responsibility to makesure that all guards, covers, and other safetyequipment is in place before the system is put intooperation.

CAUTION!• Do not operate or work near mechanical equip-

ment when wearing loose clothing. Moving com-ponents such as roller chain, drive belts, driveshafts and pallets can snag long belts, scarves,ties and other loose fitting garments, pull theworker into the equipment and cause serious, or inextreme cases, life threatening injury.

• Operators having long hair must wear appropriatehead protection (hair nets, hats, and hair caps)to minimize the risk associated with working nearmoving machinery. Hanging hair can get caught inmoving components such as roller chain, drivebelts, drive shafts and pallets, pull the worker intothe equipment and cause serious, or in extremecases, life threatening injury.

Operating Instructions

The TSplus conveyor is designed to transport BoschWT2 workpiece pallets or WT2 workpiece palletframes with integrated fixtures built into the palletdesign. Since the conveyor is modular in design andpart of a larger operating assembly system, it is the

responsibility of the integrator or end user to providea control system and operating procedures. For yoursafety, please observe the following guidelines whenoperating the conveyor:

19

Maintenance

WARNING! LOCK OUT all powersupplies and release pressure from compressed airlines before beginning maintenance work of anytype.

The gearbox and motor used in the TSplus conveyorare maintenance-free. The following cleaning andadjustment procedures, however, will help keep yourconveyor in almost new condition if performed on aregular basis.

1 Remove all dirt & grease. Wipe the conveyorclean of any excess grease, dirt or any foreignsubstances every month, and at the same timecheck the conveyor unit for wear. Replace anyparts showing signs of excess wear (see sectiontitled “Repair.”)

2 Re-tighten all fasteners. Check all fasteningelements for tightness, and re-tighten to 18 lb-ft(25 Nm), if necessary.

3 Lubricate the toothed belts. If the applicationpermits, apply a thin coat of No. 10 machine oilto the toothed belts on a monthly basis to helpprolong belt life.

4 Check adjacent components. Make sure thatidler rollers turn freely, that all components areproperly aligned and that there are no obstruc-tions.

5 Check the toothed belts and guides for wear.The toothed belts and guides should bechecked for excessive wear. If belts havestretched or worn to the point where they donot fit tightly to the pulleys, or show tears,cracks, or other visible damage, they should bereplaced. If guides are worn or damaged, theyshould be replaced. See page 11 to adjusttoothed belt tension.

20

Repair

Replacing the Toothed Belt(Fig. 17 and 18)

WARNING! LOCK OUT all power sup-plies and release pressure from compressed airlines before beginning maintenance work of anytype.

Toothed belts can be changed while the unit is in-stalled! Always replace toothed belts in pairs to main-tain smooth pallet flow. Always use genuine Boschreplacement belts only.

Remove protective cover.

1 Relax toothed belt tension. (See page 11.)

2 Unscrew stop plate (always two stops with BL400 and 480).

3 Remove faulty toothed belt.

4 Apply a thin coat of No. 10 machine oil to thenew toothed belts.

5 Put toothed belt in place, with welds pointing indirection of pallet flow. Always locate weldsadjacent to each other.

6 Attach stop plate (or two stops with BL 400 and480).

7 Tension the toothed belt. Follow the instructionson page 11.

Replace protective case before restarting (not shown)!

21

StopPlate

ToothedBelt

BWT=640 mm

Apply LightWeight

Machine Oil

Weld

WeldPALLET FLOW

PALLET FLOW

StopPlate

ToothedBelt

Weld

Weld

BWT=480 mm

Apply Light WeightMachine Oil

StopPlate

Fig. 17

Fig. 18

22

Replacing Gear Box (Fig. 19)

WARNING! LOCK OUT all power sup-plies and release pressure from compressed air linesbefore beginning maintenance work of any type.

1 Remove protective case (not shown).

2 Relax tension on toothed belt and move belt out ofway. (See page 11)

3 Remove the C-clip from the hex shaft on the insideof the bearing block.

NOTE: The Hex shaft subassembly is shown with theparts exploded for clarity in Fig. 19. It is not necessary,however, to remove the components when replacingthe gearbox.

4 Slide the hex shaft subassembly out in the direc-tion shown taking care to not damage the shortcover tube on male/female coupling. Set all theparts aside for reinstallation.

Fig. 19

5 Remove motor mounting bolts and lower motorfrom gearbox and position it so that there is nostrain on the wiring.

6 Remove flange mounting screw and slide gearboxoff hex shaft noting orientation of gearbox on otherend of LTU. Be careful not to damage the male/female coupling.

7 Remove gearbox mounting screws from oldgearbox and install mounting flange on newgearbox.

8 Reverse steps 2-6 to reinstall new gearbox. Applyanti-seize compound to motor shaft beforeinstalling motor.

NOTE: New gearboxes are shipped with oil in thegearbox. Do not add additional lubricant.

Male/FemaleCoupling

C-Clip

ShortCover Tube

FlangeMounting

Screw

Hex-Shaft

GearboxMounting

Screw

Hex-ShaftSub Assembly

Note orientation of gearbox whenremoving and reinstalling gearbox.

23

Replacing Motor (Fig. 20)

1 Remove protective case (not shown)

2 Be sure electric power supply is locked out anddisconnect motor wiring.

3 Remove motor mounting bolts and lower motorfrom gearbox.

4 Apply anti-seize compound to new motor shaftand attach new motor to gearbox with thehardware you removed earlier.

5 Reconnect electrical wiring.

CAUTION! Check motor for correctrotation before putting conveyor system backinto operation.

MotorBolts (4)

LowerMotor

ApplyAnti-SeizeCompound

Gearbox

Fig. 20

24

Application Notes:

25

Installation of Protective Covers

The protective cover assembly for the lift transfer unitwith bottom mounted motor/gearbox is shown in Fig.21. Note the orientation of the assembly. The cutoutin sheet 1 is a clearance hole for the motor and mustbe oriented properly.

Scope of Delivery:

1 Bottom aluminum cover sheet with motorclearance hole

2 End aluminum cover sheet, lower (with twotapped holes) (Qty. 2)

2a End aluminum cover sheet, upper (Qty. 2)

2cEnd aluminum cover sheet, upper with stopclearance notch

3 Side aluminum cover sheet

4 Side aluminum cover sheet

5 Corner Bracket, LH (Qty. 2)

6 Corner Bracket, RH (Qty. 2)

7 M6x20 Cap screw, lock washer, flat washer,M6x10mm T-nut (Qty. 4)

8 Side corner rail profile (Qty. 2)

9 End corner rail profile (Qty. 2)

10Flange screw (Qty. 4)

Fig. 21

2c

2a

2

2

9

1

4

3 7

6

10

5

5

7

7

9

8

8

2a

10

6

7

26

Step by Step Assembly Instructions (Fig. 22)

Note: All of the corner rail profiles (8 and 9) must beinstalled with the longer side on the bottom as shownin the inset. Make sure any protective film is removedfrom the aluminum sheets prior to assembly.

Assembly hint: The four corner brackets hold the coverassembly firmly together, and the aluminum sheets fitsnugly into them. To hold the corner rail profiles inplace during assembly, slightly bend each aluminumsheet 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 railprofile (9).

2 Slide one LH and one RH corner bracket (5 & 6)onto the end sheet (2). Make sure they areoriented with the screw hole for the T-bolt andalignment 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 sidecorner rail profiles (8). Make sure to orient sheet1 so the motor clearance hole will match thelocation of the motor on the module this coverwill guard.

5 Slide the two side cover sheets (3 & 4) into theside corner rail profiles (8).

6 Slide the two end assemblies, created in steps1-3, onto either end of the bottom and sidesheets.

7 Pre-assemble four M6x20 socket head capscrews, four ribbed lock washers, four flatwashers and the four T-nuts into the holes oneach corner bracket as shown in Fig. 22.

8 Install end sheets (2a), using two M6x12 flangehead screws. For modules mounted to 80mmconveyor profile, use the upper holes, for100mm conveyor profiles use the lower holes.Note: if a cushioned stop will be mounted onthe module, sheet 2a must be replaced withsheet 2c to provide clearance for the stop.

9 Install the Protective Cover onto the bottom of theLTU by insetting the four T-nuts (7) into the bottomT-slots of the conveyor rails. Tighten the foursocket head cap screws to 25 Nm (18 lb-ft).

27

3

18 8

3

10 2a

2a or 2c

2

2

2

2

1

4

8

10

8 3 9

4

1

7

6

Flat Washer

Flat WasherAlignment

Nub

Lockwasher

M6 x 20 SHCS9

8

5

7

7

6

5

7

INSET

Motor ClearanceHole

Fig. 22

28

Publication No.: 8981 500 299 7/02

Module Warranty

BOSCH AUTOMATION PRODUCTS warrants to the original purchaser the modules manufactured by us tobe free from defects in materials and workmanship under normal use and service. Our obligation under thiswarranty shall be limited to the repair or exchange of any part or parts which may thus prove defective undernormal use and service within one (1) year from date of installation by the original purchaser. THIS WARRANTYIS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING THEWARRANTY OF MERCHANTABILITY OR FITNESS FOR USE, AND WE NEITHER MAKE NOR AUTHORIZEANY 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 thiswarranty, 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 PRODUCTS816 East Third StreetBuchanan, MI 49107Tel: 616-695-0151Fax: 616-695-5363

Liability:

In no event can the manufacturer accept warrantyclaims or liability claims for damages resulting fromimproper use of the equipment or as a result ofchanges made to the equipment other than thosespecified in this instruction manual.

The manufacturer will accept no claims in which non-original spare parts have been used. For informationon spare parts and replacement parts, refer to publi-cation no. 8981 500 281 TSplus Spare Parts List or8981 500 170 TS2 and TS2/C Spare Parts List.

Environmental Protection:

Always dispose of worn, damaged or obsolete partsin a responsible manner. Some components, such asgearboxes, contain lubricating oil which can pollutethe environment. It is the user’s responsibility todispose of all hazardous material within the compo-nents following all local, state and federal guidelines.

Please contact Bosch for copies of the MaterialSafety Data Sheets (MSDS) for the lubricating oilused in gearboxes.