What are Bosch Rexroth case lifting devices and which industries use them?

Bosch Rexroth case lifting devices (Kistenhubgeräte) are ergonomic material handling systems designed to mechanically lift and position heavy containers, boxes, and cases in industrial production environments. These pneumatic or electric lifting solutions reduce manual handling strain and improve workplace safety in automotive manufacturing, electronics assembly, packaging operations, and general manufacturing facilities. The systems integrate sensor units like the Comfort series (3842547200) with various fork configurations including 400mm and 600mm sets for different container sizes, enabling precise height adjustment and positioning control throughout the production workflow.

What are the key technical selection criteria for Bosch Rexroth case lifters?

Selection of Bosch Rexroth case lifting devices depends primarily on container dimensions, weight capacity, and control complexity requirements. Fork width options include 400mm sets (3842549435) and 600mm sets (3842549442) to accommodate different case sizes, while mounting plate variants B400 (3842549427) and B600 (3842549428) provide corresponding base dimensions. Control systems range from Basic hand switches (3842546998) for simple up-down operation to Comfort hand switches (3842546999) with enhanced functionality, with sensor units (3842547200) enabling automatic height detection and positioning feedback for precise material handling applications.

Which safety standards and certifications apply to industrial case lifting equipment?

Industrial case lifting devices must comply with EN ISO 12100 machinery safety standards and DIN EN 1005-2 for manual handling ergonomics to ensure operator protection during material transport operations. Equipment used in potentially explosive atmospheres requires ATEX certification according to Directive 2014/34/EU, while electrical components must meet IEC 60204-1 safety requirements for industrial machinery. Pneumatic systems typically conform to ISO 4414 compressed air safety standards, and lifting mechanisms exceeding certain weight capacities may require CE marking under the Machinery Directive 2006/42/EC with appropriate risk assessment documentation and operating instructions.

What are the differences between Basic and Comfort variants of Bosch Rexroth case lifters?

The Basic variant (3842546998) provides essential manual lifting control with simple up-down hand switch operation for straightforward case positioning applications. The Comfort series includes enhanced sensor units (3842547200) with automatic height detection, position feedback, and programmable lifting sequences for improved precision and operator convenience. Comfort systems feature advanced hand switches (3842546999) with additional control functions, integrated safety features, and compatibility with factory automation systems, making them suitable for high-volume production environments requiring consistent positioning accuracy and reduced operator fatigue.

What installation requirements and system compatibility apply to case lifting devices?

Bosch Rexroth case lifting devices require compressed air supply at 6 bar operating pressure for pneumatic variants, with electrical connections conforming to 24V DC control voltage standards for integrated sensor and control systems. Mounting hardware includes specific attachment plates (B400/B600) that integrate with standard aluminum profile systems and industrial workstation frameworks. Installation requires adequate overhead clearance for full lifting stroke, typically 800-1200mm depending on case height requirements, with hanging brackets (3842549449) providing flexible positioning options and hand switch holders (3842548038) ensuring ergonomic operator access within the working envelope.

What safety ratings and operating conditions do case lifting systems meet?

Bosch Rexroth case lifting systems operate within temperature ranges of -10°C to +60°C for standard industrial environments, with electrical components rated to IP54 protection class for dust and moisture resistance. Maximum lifting capacities typically range from 10kg to 50kg depending on configuration, with safety factors of 4:1 built into mechanical components according to EN ISO 4413 fluid power safety standards. Pneumatic operating pressure maintains 6 bar nominal with emergency stop functionality integrated into control circuits, while sensor systems provide position feedback accuracy within ±2mm for precise material positioning and overload protection.

What maintenance schedules and service intervals are required for case lifting equipment?

Bosch Rexroth case lifting devices require weekly visual inspections of pneumatic connections, monthly lubrication of mechanical guides and bearings, and quarterly replacement of compressed air filter elements to maintain optimal performance. Annual comprehensive inspections must verify lifting capacity, safety system functionality, and sensor calibration according to manufacturer specifications and local machinery safety regulations. Pneumatic seals and wear components typically require replacement every 500,000 cycles or 18 months under normal industrial usage, with complete system overhaul recommended after 5 years of continuous operation to ensure compliance with workplace safety standards and maintain lifting precision within specified tolerances.

Case Lifters Bosch Rexroth

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Bosch Rexroth 3842547200. Comfort sensor unit
€646.62
Excl. 19% VAT , excl. Shipping Cost
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Bosch Rexroth 3842546999. Comfort hand switch
€367.69
Excl. 19% VAT , excl. Shipping Cost
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Bosch Rexroth 3842549442. Forks, 600
€256.06
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Bosch Rexroth 3842549435. Forks, 400
€242.61
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Bosch Rexroth 3842546998. Basic hand switch
€240.90
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Bosch Rexroth 3842549449. Suspension strap
€106.73
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Bosch Rexroth 3842549427. Attachment plate, 450/400
€63.38
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Bosch Rexroth 3842549428. Attachment plate, 650/600
€63.38
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Bosch Rexroth 3842548038. Holder for hand switch
€36.77
Excl. 19% VAT , excl. Shipping Cost

Bosch Rexroth Kistenhubgeräte are precision-engineered manual lifting devices designed for ergonomic handling of bins, crates, and containers in assembly and production environments. Built around the Bosch Rexroth modular production system, these units deliver controlled vertical travel with load capacities up to 50 kg per unit, maintaining compatibility with standard KLT and VDA containers (VDA 4500 series). The robust steel frame construction and integrated overload protection ensure reliable operation in line with DIN EN ISO 11228-2 ergonomic handling requirements.

As an authorized Bosch Rexroth distributor, esd.equipment supplies 9 Kistenhubgeräte variants directly from stock, all fully compatible with the Bosch Rexroth TS 2plus and TS 5 transfer system profiles. Each unit is designed for seamless integration into manual production lines and lean manufacturing cells, complying with EU Machinery Directive 2006/42/EC and workplace ergonomic standards.

Key technical advantages - Bosch Rexroth Kistenhubgeräte at a glance

⚡ Up to 50 kg load capacity - robust steel frame with integrated overload protection

↕ Ergonomic vertical travel - reduces operator strain per DIN EN ISO 11228-2

🛠 Modular system compatibility - fits Bosch Rexroth TS 2plus and TS 5 profiles

⚙ VDA 4500 container support - compatible with standard KLT and VDA bins

🛡 EU Machinery Directive 2006/42/EC - CE-compliant design and construction

✓ 9 variants in stock - direct availability for lean and manual production lines

Typical areas of application: Manual assembly lines (DIN EN ISO 11228-2), automotive production logistics (VDA 4500, VDA 6.3), electronics manufacturing material flow (IEC 62443), lean manufacturing cells and Kanban replenishment stations, and light industrial intralogistics (EU Machinery Directive 2006/42/EC).

✓

Authorized Bosch Rexroth Distributor Genuine Kistenhubgeräte - TS 2plus and TS 5 system compatible

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9 Variants Available from Stock Ready for immediate dispatch into manual production lines

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CE-Compliant and Norm-Verified EU Machinery Directive 2006/42/EC, DIN EN ISO 11228-2