Bosch Rextroth TSplus Installation instructions

1
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.
© 2003 Bosch Rexroth Corporation
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.

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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

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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

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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

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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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Linear Motion and Assembly Technologies
6. Peel the backing from the end of the new
abrasive cover and attach it to the edge of
the drum, then slowly turn the drum clockwise,
installing the abrasive in a spiral direction, until
the entire drum is covered.
IMPORTANT: Always install the new abrasive
cover in the same spiral as the old one! Failure to
do so could cause the abrasive to become loose
or cause poor results.
7. Once the drum is covered, trim any excess
abrasive paper that extends past the ends of
the drum.
8. Recheck the zero-point setting, following the
instructions on page 6, and adjust as needed.
9. Reinstall the aluminum guard and tighten the
nuts securely. NEVER operate the belt grinder
without all guards in place.

12 Bosch Rexroth Corporation
Publication No.:
8981 500 309 3/03
All rights are held by the Bosch Rexroth Corporation and ROBERT BOSCH GMBH, also regarding patent claims. We retain all powers of
disposition, such as for copying and/or for passing-on to third parties.
We reserve the right to make technical changes at any time without notice.
Errors and omissions excepted.
© 2003 Bosch Rexroth Corporation
Bosch Rexroth Corporation
Linear Motion and Assembly Technologies
816 E. Third Street
Buchanan, MI 49107
www.boschrexroth-us.com
Tel.: [phone]
Fax: [phone]