Bosch Rextroth TSplus Installation instructions

Linear Motion and Assembly Technologies

Modular Transfer Systems

Belt Grinder

Assembly and Operation Guide

Publication Number: 8981 500 309 3/03

TSplus Belt Grinder

2Bosch Rexroth Corporation

All rights are held by BOSCH REXROTH CORPORATION or

ROBERT BOSCH GMBH, also regarding patent claims. We retain all

powers of disposition, such as for copying and/or for passing-on to

third parties.

We reserve the right to make technical changes at any time

without notice.

Errors and omissions excepted.

Table of contents Page

• Important Safety Information ........................................................................................................................ 3

• Introduction ........................................................................................................................................................ 4

• Shipping Information ....................................................................................................................................... 4

• Assembly ............................................................................................................................................................. 5

• Preliminary Adjustments ................................................................................................................................ 5

• Operating Instructions ..................................................................................................................................... 8

• Maintenance ..................................................................................................................................................... 10

Liability:

In no event can the manufacturer accept warranty

claims or liability claims for damages resulting from

improper use of the equipment or as a result of

changes made to the equipment other than those

specified in this instruction manual.

Guarantee:

The manufacturer will accept no claims in which non-

original spare parts have been used. For information

on spare parts and replacement parts, contact Bosch

Rexroth Corporation.

Environmental Protection:

Always dispose of worn, damaged or obsolete parts

in a responsible manner. It is the user’s responsibility

to dispose of all hazardous material such as adhesives

and cleaning solutions in accordance with all local,

state and federal guidelines.

Linear Motion and Assembly Technologies

WARNING!

Please read all assembly and maintenance instruc-

tions carefully before beginning set-up and operation

of the belt grinder.

Where appropriate, warning symbols have been

included in this publication to alert you of potential or

impending danger.

•Be sure to read and observe all safety warnings in

this document. Failure to do so could result in

potential risks to your health and safety as well as

those around you.

•Covers and guards have been designed to elimi-

nate pinch points and exposure to moving belts

and pulleys. DO NOT operate the belt grinder with

the guards removed. Serious injury may result!

•All set-up, maintenance, and repair work should

be performed only by properly trained, qualified

personnel. All operators must be properly trained

in the use of this equipment.

•Always make sure that the switch is in the OFF

position and the power cord is unplugged before

adjusting or servicing.

•Always be sure that the switch is in the OFF

position before plugging in the belt grinder.

•To prevent serious injury, never wear loose-fitting

clothing while operating the belt grinder. Long hair

MUST be tied back.

SAVE THESE INSTRUCTIONS!

IMPORTANT SAFETY INFORMATION

4Bosch Rexroth Corporation

Introduction

Prior to welding the transport belts for TSplus

conveyors, the ends must be tapered to provide

the proper overlap. The belt grinder is designed

to grind the belt ends to the proper taper in a

single pass.

The belt grinder's 1/3 HP, 120 VAC/60 Hz motor

operates at 1,750 RPM to drive the V-belt that

powers the grinding mechanism. The grinding

mechanism features a round grinding drum with

a replaceable abrasive covering. An adjustable

clamping and feed mechanism holds the belt

securely and helps ensure the correct taper.

Important components are shown in Figure 1.

Shipping Information

The belt grinder is shipped completely assembled,

except for the table hand crank, which must be

installed prior to use.

The belt grinder has been adjusted to the

correct settings before leaving the factory;

however, it is highly recommended that you test

grind two scrap pieces of belt to ensure that the

belt lap length and zero-height adjustment have not

changed during shipping. See the “Preliminary

Adjustments” section for details.

Clamp Handle

Aluminum Guard/

Grinding Drum Motor

On/Off

Switch

Movable Table

Table Hand Crank

Fig. 1

Linear Motion and Assembly Technologies

Motor Mounting

olts

Tighten elt

Loosen elt

Hand Crank

Setscrew

Table Hand Crank

Fig. 2

Assembly

The table hand crank must be installed prior to use.

To install the hand crank:

1. Slide the hand crank onto the shaft in the table

base, as shown in Figure 2.

2. Use a 1/8″hex key to securely tighten the

setscrew in the hand crank.

Preliminary Adjustments

Prior to leaving the factory, the belt grinder was

checked and set for the correct adjustments.

However, all settings should be rechecked prior

to use, to be sure that nothing has changed during

shipping. These settings should also be checked

before each use, especially after any type of

maintenance work is performed, such as replacing

the grinding drum abrasive.

Before using the belt grinder, check the following:

1. Drive belt tension (Figure 3)

Make sure that the V-belt on the motor drive

pulley is tensioned against the grinding drum

pulley (it may necessary to remove the guard).

If it is too loose, it could slip during operation.

To adjust the belt tension, or when replacing a

worn belt, loosen the motor mounting bolts with a

1/2″wrench and slide the motor base away from

the grinding drum to tighten the belt, or towards

it to loosen it.

IMPORTANT: Always be sure that the motor

base is straight after making any adjustments.

If it is not straight, excess belt wear could result.

Fig. 3

6Bosch Rexroth Corporation

Preliminary Adjustments (continued)

2. Clamp Handle Rotary Cam (Figure 4)

The clamp must hold two belts securely to the

table. Check it with two pieces of the type of belt

that you will be grinding, making sure that it

applies an equal amount of pressure to each

piece (the gap should be equal on both ends),

and that both belts are held securely in place.

If adjustment is needed, use a 1/8″hex key to

loosen the two clamp handle setscrews and

rotate the brass cam bearings on each end to

increase or decrease the tension on the clamp

handle. Retighten the setscrews securely after

adjusting.

Fig. 4

3. Zero Point Adjustment (Figure 5)

Turn the hand crank until the end of the table is

directly under the grinding drum. Look under the

aluminum guard and check the gap between the

abrasive surface of the grinding drum and the

table. The edge of the table should just barely

touch the abrasive drum, and the two surfaces

should be perfectly parallel to each other.

If adjustment is needed, remove the 7/16″nuts

holding the aluminum guard, and lift off the

guard. Then loosen the 7/16″jam-nuts on the

grinding drum setscrews, and back out the

setscrews slightly using a 1/8″hex key, until the

drum nuts can be turned. Turn the large drum

nuts counterclockwise to lower the drum or

clockwise to raise it. Once the drum height is

properly adjusted, tighten the setscrews and

jam-nuts, and reinstall the guard.

Clamp Handle

Setscrews

rass Cam

earing

e sure both ends

provide equal tension

Fig. 5

Grinding Drum

Jam-nuts and Setscrews

(shown with guard removed)

Grinding Drum

Adjustment Nuts

Front Edge

of Table

Linear Motion and Assembly Technologies

evel Length = 60mm

evel Length

Adjusting Stud

and Jam-Nut

4. Bevel Length Adjustment (Figures 6 and 7)

The belt grinder is preset to provide the correct

bevel length for TSplus conveyor transport belts,

which is 60mm (Figure 6).

If adjustment is needed, the slope of the table

can be increased or decreased to provide the

proper bevel length. Loosen the 7/16″jam-nut

on the bevel length adjustment setscrew under

the rear edge of the table. Then use a 1/8″hex

key to turn the setscrew. Turn it clockwise to

decrease the bevel length, counterclockwise to

lengthen the bevel length. Once the bevel length

is set to the correct 60mm length, hold the

setscrew in place with the hex key and tighten

the jam-nut securely.

5. Final check

Make sure that all guards are in place and all

fasteners are tightened securely before using the

belt grinder. Be certain the power switch is in the

OFF position before plugging in the cord.

The belt grinder should be securely clamped

or fastened to a solid, stable worksurface that

is clean and free of items that could present

a hazard.

Fig. 6

Fig. 7

8Bosch Rexroth Corporation

Operating Instructions

The belt grinder will grind two belts at once, in a

single pass. The proper bevel is absolutely

critical when welding TSplus transport belts.

To ensure proper operation, it is important that all

settings outlined on pages 5–7 are checked before

grinding belts, and that the following steps are

followed carefully.

WARNING!

To prevent serious injury, always observe the

following safety warnings:

• Make sure all guards are securely in place

and all fasteners are tight.

• NEVER wear loose-fitting clothing or

jewelry that could be pulled into the

grinding drum.

• Long-hair MUST be tied back.

• Because of the fine dust generated in the

grinding process, ALWAYS wear safety

glasses and a dust mask.

Preparing to grind the belts:

1. Turn the crank handle counterclockwise, moving

the table as far forward (toward the motor) as it

will go.

2. Raise the belt clamp handle and feed two belts

under the clamping bar and grinding drum, until

the ends of the belt are even with the front edge

of the table. Make sure the belts are straight and

parallel to the sides of the table and each other,

and that the ends of the belt are square with the

front edge of the table. See Figure 8.

IMPORTANT: Make sure that you grind the

bottom of the belt coming from the drive and

the top of the belt coming from the return. This

ensures smooth pallet transfer over the belt joint.

See Figure 9.

Fig. 9

Fig. 8

elt Ends Even with

Edge of Table

elts Straight and

Parallel to Each Other

and Sides of Table

Linear Motion and Assembly Technologies

Grinding the belts:

1. Once the belts have been properly positioned,

push down on the clamping lever to lock it.

Make sure the belts are held securely.

2. Make sure that the power switch is in the OFF

position, then plug the belt grinder cord into a

3-prong grounded outlet.

3. Perform a final visual check to make sure that

all guards are in place and that the belts are

properly aligned and securely clamped in place.

4. Turn ON the motor using the switch on the

power cord.

5. Turn the crank handle clockwise to feed the

belts against the grinding drum. Once the belts

contact the grinding drum, maintain a slow and

steady pace while turning the hand crank. It may

be necessary to slow down as you approach the

ends of the belts, as the grinder removes more

material from the belts.

CAUTION! Do NOT try to force the feed rate

too quickly! Feeding the belt too quickly may

overheat or damage the belt, resulting in an

unusable bevel.

6. Once the belt has fed completely through and

the grinder has reached the end of the table,

slowly crank the table back in the reverse

direction by turning the crank handle counter-

clockwise. This will ensure a clean bevel.

7. Once the table has returned to the starting

position, turn the power switch to OFF and

unplug the grinder. Raise the belt clamp handle

and remove the belts. Make sure the ends are

properly feathered and free of burrs, as shown in

Figure 6 on page 7. Remove any burrs by lightly

sanding with 80 grit sandpaper.

IMPORTANT: Protect the beveled surfaces on

the belts from oil, dust, moisture, fingerprints, etc.

Any contamination could result in a defective

weld and create a safety hazard.

The belts are now ready for welding. Refer to

the belt welding section of the TSplus Basic

Equipment manual for instructions.

elt Clamp

Handle

elts even with

edge of table

Moves Table

Away from

Motor

Fig. 10

10 Bosch Rexroth Corporation

Maintenance

Other than replacing the abrasive on the grinding

drum as needed, the belt grinder is maintenance-

free. Following the checklist and steps below will

help ensure safe operation and superior results.

WARNING! Make sure the

unit is unplugged before performing any

maintenance or repair work!

• After belt grinding is complete, vacuum any

dust and particulate from the unit.

• Before each use, check that all guards are in

place and all fasteners are tight.

• Regularly check the power cord and plug for

damage or wear, and replace it, if necessary.

• Regularly check the drive belt for looseness or

wear, and adjust or replace as needed.

Replacing the abrasive cover:

The grinding drum uses a self-adhesive abrasive

cover. This should be replaced when the abrasive

surface becomes worn or clogged with belt

particulate. Failure to do so could result in difficulty

grinding and poor results.

1. Make sure the unit is unplugged.

2. Using a 7/16″wrench, remove the nuts that

secure the aluminum guard in place and remove

the guard.

3. Using a utility knife, carefully pry up the end of

the abrasive cover along the edge of the drum.

4. Carefully peel off the abrasive by slowly turning

the grinding drum as shown in Figure 11.

5. Remove any adhesive residue from the grinding

drum with a lint-free cloth and lacquer thinner.

Allow the drum to dry completely.

Pry up corner of old abrasive

cover and remove it as you

slowly rotate grinding drum

Fig. 11

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