operating manual tm size 40/52

MODULES ROBOTICS SYSTEMSCOMPONENTS

OPERATING MANUAL

TM Size 40/52

Project: Bill of materials:

Axxxxxxx09xxxx

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OPERATING MANUAL TM

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© by GÜDEL 2010

Translation of the original operating manual

Version a

Author sevsto

GÜDEL AG

Industrie Nord

CH-4900 Langenthal

Switzerland

phone +41 (0)62 916 91 91

fax +41 (0)62 916 91 50

e-mail [email protected]

www.gudel.com

OPERATING MANUAL TM

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Table of contents

Table of contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Purpose of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Target readership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3 Characters / Explanation of abbreviations . . . . . . . . . . . . . . . . . . . . . 8

1.4 Torque tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4.1 Tightening torques for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.4.2 Tightening torques for HV sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.4.3 Tightening torques for roller holders . . . . . . . . . . . . . . . . . . . . . . . . 111.4.4 Tightening torques for roller supports . . . . . . . . . . . . . . . . . . . . . . . 12

2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.1.2 Non-intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2 Product designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.1.2 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.1.3 Failure to comply with safety regulations . . . . . . . . . . . . . . . . . . . . . 17

3.2 Declaration of incorporation in acc. with Machinery Directive 2006/42/EC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.3 Hazard symbols and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3.1 Hazard symbols in the operating manual . . . . . . . . . . . . . . . . . . . . . 19Hazard warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Special symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.3.2 Hazard symbols on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4 Fundamentals of safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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3.4.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.4.2 Safety and monitoring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.4.3 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Danger due to electric current. . . . . . . . . . . . . . . . . . . . . . . . . . . 23Danger due to falling axes/workpieces . . . . . . . . . . . . . . . . . . . . . 24

3.4.4 Safety data sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.3 Positioning, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.3.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.3.3 Positioning, fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Base fixing with adhesive anchor . . . . . . . . . . . . . . . . . . . . . . . . . 33Base fixing with welded joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.3.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.3.5 Transport securing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.4 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45


7.2 Consumables and auxiliary agents . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.2.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477.2.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Markings at the lubricating points. . . . . . . . . . . . . . . . . . . . . . . . . 47Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7.4 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.4.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517.4.2 Maintenance tasks 100 hours after commissioning . . . . . . . . . . . . . 517.4.3 Maintenance tasks every 150 hours . . . . . . . . . . . . . . . . . . . . . . . . . 52

Lubricating the guideways, racks and pinions . . . . . . . . . . . . . . . 527.4.4 Maintenance tasks every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . 53

General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537.4.5 Maintenance tasks every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . 55

Replacing the lubricating pinions . . . . . . . . . . . . . . . . . . . . . . . . . 55Greasing the rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.4.6 Maintenance tasks every 10000 hours . . . . . . . . . . . . . . . . . . . . . . . 58Oil change in type NA / NH / FA / FH / AE gearboxes . . . . . . . 58

8 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62


8.2 Special tools, testing and measuring instruments . . . . . . . . . . . . . . . 63

8.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

8.3.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648.3.2 Replacing the bumper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648.3.3 Replacing the wiper and felt insert . . . . . . . . . . . . . . . . . . . . . . . . . . 658.3.4 Replacing the rollers and guideways . . . . . . . . . . . . . . . . . . . . . . . . . 68

Replacing the rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Replacing the guideways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

8.3.5 Setting the roller and tooth flank backlash . . . . . . . . . . . . . . . . . . . 748.3.6 Replacing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778.3.7 Setting the gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808.3.8 Replacing the motor and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 81

8.4 Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

8.5 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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9 Decommissioning, storage . . . . . . . . . . . . . . . . . . . . . . . . . . 84

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84


9.2 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

9.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

9.3.1 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 859.3.2 Cleaning / rust-proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 869.3.3 Transport securing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 869.3.4 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

9.4 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87


10.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

10.3 Waste management compliant assemblies . . . . . . . . . . . . . . . . . . . . 88

10.3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8810.3.2 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

10.4 Disposal facilities, authorities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

11 Spare part supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

11.1 Explanations regarding the spare parts list . . . . . . . . . . . . . . . . . . . . 90

11.1.1 Positioning drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9011.1.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

11.2 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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General

1 General

1.1 Purpose of the document

This operating manual describes all product life phases of the TM product:

• Transport• Repairs• Commissioning• Operation• Maintenance• Disposal

The operating manual contains the required information on how to operate the product in the intended manner. It is an important component of the TM prod-uct. The operating manual must be available at the product site throughout its entire service life. If the product is sold, it has to be transferred to the new owner with the machine.

Assembly manual forpartly completed

machinery

This operating manual serves as "Assembly manual for partly completed machin-ery" in acc. with the Machinery Directive 2006/42/EC.

NOTERead the entire operating manual before working with the prod-uct! It contains important information for your personal safety. The operating manual must be read and understood by all per-sons who work on the product in any of the product life phases.

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General

1.2 Target readership

This operating manual is aimed at the following target readership:

• Specialists• Technicians• Forwarding agents

• Operating companies

• Operating personnel

• Service personnel

1.3 Characters / Explanation of abbreviations

The following symbols and abbreviations are used in this operating manual:

Tab. 1-1 Explanation of symbols/abbreviations

1.4 Torque tables

1.4.1 Tightening torques for screws

If no other specifications have been made, the following tightening torques apply for oiled and unlubricated screws:

Symbol/Abbreviation Use Explanation

For cross-reference Page

Fig. Designates drawings Figure

Tab. Designates tables Table

Thread size

Tightening torque [Nm]

8.8 10.9 12.9

M4 3 4.6 5.1

M5 5.9 8.6 10.0

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General

Tab. 1-2 Torque table: oiled and unlubricated screws

If no other specifications have been made, the following tightening torques apply for screws lubricated with moly grease:

M6 10.1 14.9 17.4

M8 24.6 36.1 42.2

M10 48.0 71.0 83.0

M12 84.0 123.0 144.0

M14 133.0 195.0 229.0

M16 206.0 302.0 354.0

M20 415.0 592.0 692.0

M22 567.0 804.0 945.0

M24 714.0 1017.0 1190.0

M27 1050.0 1496.0 1750.0

M30 1420.0 2033.0 2380.0

M36 2482.0 3535.0 4136.0

Thread size


8.8 10.9 12.9

Thread size


8.8 10.9 12.9

M4 2.6 3.9 4.5

M5 5.2 7.6 8.9

M6 9.0 13.2 15.4

M8 21.6 31.8 37.2

M10 43.0 63.0 73.0

M12 73.0 108.0 126.0

M14 117.0 172.0 201.0

M16 180.0 264.0 309.0

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General

Tab. 1-3 Torque table: screws lubricated with moly grease

1.4.2 Tightening torques for HV sets

The following tightening torques apply to DIN6914/15/16-10.9 HV sets:

Tab. 1-4 Tightening torques: HV sets

M20 363.0 517.0 605.0

M22 495.0 704.0 824.0

M24 625.0 890.0 1041.0

M27 915.0 1304.0 1526.0

M30 1246.0 1775.0 2077.0

M36 2164.0 3082.0 3607.0

Thread size


8.8 10.9 12.9

Thread size


Lubricated with moly grease

Slightly oiled

M12 100 120

M16 250 350

M20 450 600

M22 650 900

M24 800 1100

M27 1250 1650

M30 1650 2200

M36 2800 3800

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General

1.4.3 Tightening torques for roller holders

Fig. 1-1 Tightening torques for roller holders

A Move roller with hexagonal socket wrench (tightening torque A1)B Roller holderC Tighten screw with hexagonal socket wrench (tightening torque A2)

The following tightening torques apply to roller holders:

Tab. 1-5 Tightening torques: Roller holders

D00

0772

A2

A1

A B C

SizeTightening torque [Nm]

A1 A2

40 1.5 4

52 2 4

62 3 15

72 4.5 15

90 7 15

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General

1.4.4 Tightening torques for roller supports

Fig. 1-2 Tightening torques for roller supports

A Roller supports size 72 and 90B Move roller with hexagonal socket wrench (tightening torque A1)C Roller supports size 40 and 52D Tighten nut and locknut with hexagonal key (tightening torque A2)

The following tightening torques apply to roller supports:

Tab. 1-6 Tightening torques: Roller supports

D00

0941

A1

A2A2

A1

A B C B

D D

SizeTightening torque [Nm]

A1 A2

40 1 87

52 2 120

72 3 220

90 5.5 450

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Product description

2 Product description

2.1 Purpose

2.1.1 Intended use

The TM product is intended exclusively for moving and positioning of robots.

Any other or additional use is not considered to be use in the intended manner. The manufacturer assumes no liability for any resulting damages. All risks are carried solely by the user!

2.1.2 Non-intended use

The TM product is not intended for:

• Movement of poisonous goods• Movement of explosive goods• Operation in explosive areas

Any other use shall be considered improper use and is forbidden!

Do not modify the product in any way.

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Product description

2.2 Product designation

Each product has a type plate. It contains the following information:

Fig. 2-1 Type plate

A Product, typeB Project, sales orderC Serial number (parts list)D Year of manufacture

In the declaration of conformity and declaration of incorporation, the terms are used in acc. with the legend above.

Position of the typeplate

The type plate is attached in acc. with the following illustration:

Fig. 2-2 Position of the type plate

A Type plate

D00

0102

A C DB

D00

1453

A

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Product description

2.3 Technical data

The technical data is valid for temperatures between +25 and +30 °C.

The emitted sound pressure level depends on how the product is used.

For the following data, refer to the layout(s) in chapter 13 ’Appendix’, 96:

• Dimensions• Weight• Strokes of the individual axes• Gearbox type• Gearbox ratios• Motors

Temperature ranges The following temperature ranges apply:

2.4 Options

The following options are supplied with separate documentation:

• Automatic lubrication system, battery or external 24 V DC, oil or grease• Manual lifting and safety unit: vertical axis• Holding brake• Rotary axis• Telescope axis• Pneumatic load balance

This documentation can be found in chapter 13 ’Appendix’, 96.

Transport -10 to +60°C

Operation +12 to +40°C

Storage -10 to +40°C

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Safety

3 Safety

3.1 General

3.1.1 Product safety

Residual danger The TM product corresponds to the state of the art. It was designed and con-structed according to the recognized safety regulations. However, some resid-ual danger remains during its operation.

There is danger to the personal safety of the operator, as well as to the TM product and other property.

Operation Always adhere to the instructions in this manual when operating the TM prod-uct, and ensure that it is always in perfect working order.

The product must never be modified or used in a manner contrary to its intended use. Intended use and non-intended use is described in chapter 2 ’Product description’, 13.

3.1.2 Operating personnel

Persons who work with the TM product must be technically qualified and trained. They must be familiar with all hazards associated with using the TM product.

NOTERead this chapter prior to working with the product! It contains important information for your personal safety. This chapter must be read and understood by all persons who work on the product in any of the product life phases.

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Safety

3.1.3 Failure to comply with safety regulations

Protective measures The operator is responsible for ensuring safe conditions in the vicinity of the TM product. In particular, it is mandatory to comply with all general safety reg-ulations. This includes implementing all of the safety measures before commis-sioning the system. These must cover all hazards. This is the only way to ensure that operation of the product conforms with CE regulations.

As stipulated by the machinery directive, the safety measures must:

• Correspond to the state of the art• Comply with the required safety category

Liability Güdel shall not be held liable under any of the following circumstances:

• Failure to implement safety measures• Included protective equipment was not installed• Included protective equipment was modified

DANGERDisregarding safety regulations

Disregarding the safety regulations can be very hazardous for personnel and the surroundings!

Always comply with the safety regulations!

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Safety

3.2 Declaration of incorporation in acc. with Machinery Directive 2006/42/EC

The manufacturer: GÜDEL AG, Industrie Nord, CH-4900 Langenthal

herewith declares that the partly completed machinery:

Product, type / serial number (parts list) / year of manufacture

TM Size 40/52 / 09xxxx / 2010

corresponds to the fundamental requirements of the Machinery Directive (2006/42/EC), Annex 1.

The special technical documents as per Annex VII Part B have been drawn up.

The partly completed machinery complies with the following other EC direc-tives:

• Low Voltage Directive 2006/95/EC• EMC Directive 2004/108/EC

The following harmonized standards have been applied:EN ISO12100-1; EN-ISO 1200-2; EN ISO 1421-1; EN ISO 13850; EN 60204-1; EN 1088; EN 982; EN 983; EN ISO 13849-1

Authorized representative responsible for compiling the technical documents: Martin Knuchel Tel. +41 (0)62 916 92 40

The special technical documents are submitted in electronic form, depending on the respective regulations of the national bodies.

The partly completed machinery may only be commissioned after it has been determined that the machinery into which the partly completed machinery is to be incorporated complies with the stipulations of the Machinery Directive (2006/42/EC).

Langenthal, 01/01/2010 Walter Zulauf Martin Knuchel

Director of Development Director of Systems / Robotics

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Safety

3.3 Hazard symbols and instructions

3.3.1 Hazard symbols in the operating manual

Hazard warnings

The hazard warnings are defined for the four following hazard levels:

DANGERDANGER

DANGER refers to hazards with a high risk of severe physical injury or im-mediate fatality.

WARNINGWARNING

WARNING refers to hazards with a moderate risk of severe physical injury or potential fatality.

CAUTIONCAUTION

CAUTION refers to hazards with a slight risk of moderate physical injury.

NOTENOTE

NOTE refers to a hazard that can lead to property damage.

NOTENote refers to helpful information and tips for users.

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Warning symbols

Symbol Use

Danger, warning, caution, note

Refers to hazards resulting from automatic operation of the plant

Danger, note

Refers to electrical hazards

Danger, warning

Refers to hazards from falling beams

Warning, caution

Refers to crushing hazards from gears


Refers to hazards from industrial trucks

Warning, caution

Refers to hand injury hazards

Warning, caution

Refers to hazards from heavy components


Refers to environmental pollution hazards

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Tab. 3-1 Warning symbols

Special symbols

Tab. 3-2 Special symbols


Refers to hazards from suspended loads

Danger, note

Refers to hazards from electromagnetic fields


Refers to hazards from crushing

Danger

Refers to hazards from explosion


Refers to hazardous locations

Symbol Use

Symbol Use

Note

Helpful information and other tips

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3.3.2 Hazard symbols on the product

The following labels are attached to the product:

The "Danger sign" label warns against:

• Axles falling after the transport securing device is removed• Moving the axles before the transport securing device is removed

Fig. 3-1 Danger sign label

The „Transport information“ label provides information on correctly attaching transport equipment.

Fig. 3-2 Transport information label

DANGER! GEFAHR!The vertical axis mustbe secured from motionbefore removing therack lock or otherlocking device used fortransportation!

Vor dem Entfernen derTransportsicherungZ-Achse(n) gegenherunterfallen Sichern!

WARNING! ACHTUNG!Remove all rack locks orother locking devicesused for transportationon all axes beforeattempting to move anyaxis!

Vor dem Bewegen derAchsen sämtlicheTransportsicherungenentfernen!

0156

538

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539

2X

X

X

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Safety

3.4 Fundamentals of safety

3.4.1 Intended use

The intended use is described in chapter 2.1.1 ’Intended use’, 13.

3.4.2 Safety and monitoring equipment

For information on the safety and monitoring equipment, refer to the docu-mentation on the complete system. More details can be found in the supplied risk analysis.

3.4.3 Product-specific hazards

Danger due to electric current

NOTENever remove or modify any of the safety and monitoring equip-ment! Be sure to close all of the protective equipment during op-eration!

DANGERHazardous voltage

The product contains components that are energized with hazardous volt-ages. Touching these components will cause an electric shock. Electric shocks can be fatal.

Before working in the danger area:• Switch off the main power supply and secure it against being switched on

again (main switch of complete plant)• Ground the equipment• Before switching on the product again, make sure that no one is located

in the danger area

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Danger due to falling axes/workpieces

3.4.4 Safety data sheets (MSDS)

Safety data sheets contain safety information about the materials. The operator is responsible for obtaining safety data sheets for all materials used, such as oils, greases, cleaning agents etc.

Safety data sheets can be obtained as follows:

• Chemical vendors usually deliver their substances with safety data sheets.

• Safety data sheets are available on the InternetExample: Enter "msds" plus the name of the material to find safety informa-tion for the material.

Read the safety data sheets closely and follow all instructions. We recommend that you store the safety data sheets for future reference.

WARNINGFalling axles/workpieces

Falling axles or workpieces can cause severe or fatal injuries!

Observe the following:• Secure suspended axles using the stipulated equipment and deposit any

workpieces before working in the danger area• Never enter the area below suspended axles and workpieces• Check the belts of the telescope axes for signs of breakage and tears

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Design and function

4 Design and function

4.1 Design

In the standard configuration, the TM product consists of the following assem-blies:

.

Fig. 4-1 Design

A Y-axisB Y-carriageC Y-drive

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Design and function

4.2 Functional description

The TM product can move along the following axes:

Fig. 4-2 Axis names

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5 Commissioning

5.1 Introduction

Various options are available for your product. This chapter provides informa-tion on several available options. It therefore describes components with which your product is not equipped.

5.1.1 Safety

Only perform the tasks described in this chapter after you have read and under-stood chapter 3 ’Safety’, 16. It concerns your personal safety!

5.1.2 Personnel qualifications

Only appropriately trained and authorized personnel are allowed to commis-sion the TM product.

WARNINGSuspended loads

Improper handling of suspended loads can lead to severe injuries or death!

Observe the following:• Use appropriate lifting units• Wear appropriate protective clothing• Always keep sufficient distance to suspended loads• Never enter the area below a suspended load

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5.2 Transport

The product is transported by air, land or water. The packaging depends on the means of transport.

Packaging symbols Depending on the contents, the packaging units are marked with the symbols shown below. Observe these at all times.

Fig. 5-1 Packaging symbols

A FragileB This side upC Keep dryD Handle with care

Remove the packaging only to the degree necessary for company-internal trans-port.

Transport the pallet, crate or case to the planned installation location. Use appropriate transport devices.

Truck = Shipped on a transport pallet

Aircraft = Shipped in a crate

Ship = Shipped in a case or container

NOTEImproper transport

Improper handling of the package can lead to transport damage!

Do not tip over the package. Avoid heavy vibrations and shocks. Observe the symbols on the packaging.

FRAGILE

D00

0098

D00

0099

CRAINT L'HUMIDITE

D00

0100

HANDLEWITH CARE

D00

0101

A B C D

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5.3 Positioning, assembly

5.3.1 Prerequisites

Base The base has to fulfill the requirements of the application. For information on the load per surface and the surface properties, please refer to the layout or the documentation of the complete system.

Lines The supply lines have to meet the requirements of the application. For informa-tion on the required capacities, please consult the documentation of the com-plete system.

Lifting unit Lifting units are required for positioning and assembling the product or plant. Make sure that appropriately dimensioned devices (crane etc.) are available.

5.3.2 Unpacking

Accessories and small parts are packaged in a separate case or directly with the product itself.

The components have been treated with anti-rust oil (spray) and wrapped in oil paper. Remove packaging carefully.

Dispose of the packaging in accordance with the local disposal regulations.For more information on disposal, refer to chapter 10 ’Disposal’, 87.

DeliveryChecking Check the content of the delivery by comparing it with the accompanying papers.Check the product for damage. Report transport damage immediately.

NOTEThe anti-rust oil protects the components. We recommend not remov-ing the oil.

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5.3.3 Positioning, fastening

This chapter describes the steps for positioning and fastening the TM product.If no other specifications have been made, the tightening torques as per chapter 1.4.1 ’Tightening torques for screws’, 8 apply.Before you position the product at the installation site, the requirements as per chapter 5.3.1 ’Prerequisites’, 29 have to be fulfilled.

Attaching the slings This section describes the steps for attaching the slings.

Fig. 5-2 Attaching the slings

A Transportation cradleB HookC Lifting belts

WARNINGHeavy components

Components can be very heavy. Improper handling can cause severe or fatal injuries!

Use suitable means to secure the components against tipping over. Only re-move the tip-over protection after the product has been completely assem-bled.

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X

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B

C

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Attach the slings as follows:

1 Position the lifting belts as shown in the drawing(Symmetric arrangement according to the figure)

2 Hang the ends of the lifting belts into the hooks of the transportation cra-dle

The slings are in place.

Positioning theproduct

This section describes the steps for positioning and aligning the product.

Fig. 5-3 Positioning the product

A Floor leveling screwsB Locknuts

Position the product as follows:

3 Set floor leveling screws to the specified mass

4 Position the product as shown in the layout

5 Align the product horizontally and vertically by means of floor leveling screws(Levelness: 0.5 mm, use guideways as reference)

6 Lock the floor leveling screws

The product has been completely positioned and aligned.

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Connecting theprofiles

This section describes the steps for connecting and aligning the profiles.

Fig. 5-4 Connect the profiles

A Cover plateB RacksC GuidewaysD GuidewaysE Profile EF Profile F

Connect the profiles as follows:

1 Align profile F with profile E(The profiles have to be flush)

2 Connect the profiles

2.1 Mount the guideway and rack as per Section ’Installing the guide-way’, 36

2.2 Mount the cover plates

3 Realign the product horizontally and vertically, by means of the floor lev-eling screws(Levelness: 0.5 mm)

The profiles are connected and aligned.

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Base fixing The base can be fastened either with adhesive anchors or with a welded joint.

You can find the corresponding anchor type in the layout in chapter 13 ’Appen-dix’, 96.

Base fixing with adhesive anchor

This section describes the base fixing with adhesive anchor.

This fastening requires uncracked concrete with a quality of at least C20/25 (ENV 206). The minimum concrete thickness and edge distance can be found in the table below.

Fig. 5-5 Anchored base fixing

A Floor levelling screwB Column/frameC AnchorD Adhesive capsule

NOTEOnly anchor the product after it has been correctly positioned and aligned!

Only use anchors approved by Güdel!

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h

m

b

r

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B

C

D

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Tab. 5-1 Anchored base fixing

Anchor the column as follows:

1 Make a bore hole as per the table above

2 Clean the bore hole

3 Insert the adhesive capsule

4 Screw in the anchor rod with the hammer drill

5 Wait until the hardening period specified by the manufacturer has passed

6 Screw the column tight(For the tightening torque, refer to the table above.)

7 Remove the safety devices

The column is anchored.

Base fixing with welded joint

This section describes the base fixing with welded joint.

Prior to welding the joint, you have to fasten the base plate to the floor.This fastening requires cracked or uncracked concrete with a quality of at least C20/25 (ENV 206). The minimum concrete thickness and edge distance can be found in the table below.

m (anchor size) M12 M20 M27 M30

b (concrete thickness) [mm] 140 220 300 340

r (edge distance) [mm] 110 180 240 270

d (drill diameter) [mm] ø14 ø24 ø30 ø35

h (drilling depth) [mm] 110 170 240 270

Tightening torque [Nm] 50 160 270 300

NOTEThe welding work described below may only be performed by certified personnel!

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Fig. 5-6 Welded base fixing

A ScrewB Floor levelling screwC Column/frameD Bottom plateE Base plate

Tab. 5-2 Welded base fixing

Perform the weld joint as follows:

1 Connect the floor levelling screw and bottom plate by means of the screw

2 Weld the bottom plate to the base plate(weld joint in acc. with the table above)

3 Tighten the screw

4 Remove the safety devices

The weld joint has been applied.

The product is anchored to the floor.

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m

br

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B

C

D

E

m (floor levelling screw) M24x2 M36x2 M48x3 M56x3

b (concrete thickness) [mm] 120 160 250 340

r (edge distance) [mm] 90 130 185 255

k (throat dimension) [mm] a 4 a 4 a 5 a 5

n (joint length) [mm] 140 190 190 330

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5.3.4 Installation

Installing theguideway

Proper installation of the guideways in accordance with the regulations is pre-requisite for low-wear use of the product.

Mounting aid The start and end of the rack form a half tooth gap. For precise and low-noise transition, we recommend using a mounting aid geared in the opposite direction (see chapter 8.2 ’Special tools, testing and measuring instruments’, 63).

Fig. 5-7 Mounting aid for rack assembly

A RackB Mounting aid

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This section describes the steps for installing the guideway.

Fig. 5-8 Installing the guideway

A Mounting aidB Screw clampsC RacksD Torque wrenchE GuidewaysF Reference surfaces

Install the guideway as follows:

1 Clean the reference surfaces, guideways and racks thoroughly and rub an oil stone across them

2 Clamp rack to guideway with screw clamp and mounting aid

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B

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F

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3 Use clamp screws to clamp the guideways against the reference surfaces

4 Tighten all screws

5 Inspect transition:

5.1 Guideway transition(gap dimension < 0.02 mm)

5.2 Rack transition, as per Section ’Inspecting the rack transition’, 38

6 Use a suitable measuring instrument to check that the guideways are par-allel(tolerance: ±0.04 mm)

7 If deviations occur (transition/parallelism):

7.1 Remove screws and guideway

7.2 Repeat the procedure

The guideway has been installed.

Inspecting the racktransition

This section describes the inspection of the rack transition.

The racks correspond to the qualities in the following table:

Tab. 5-3 Rack quality

Hardened racks can be recognized by the engraved Güdel logo.

Rack quality

Axle Hardened rack Soft rack

Y 9 -

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Fig. 5-9 Inspect rack transition with micrometer

A Rack transitionB Measurement boltC Micrometer position CD Micrometer position DE Micrometer position E

Tab. 5-4 Deviation method 1

Inspect the rack transition as follows:

1 Position the measurement bolt as shown in the illustration

2 Inspect the deviations in the height of positions C and E to position D with a micrometer(Permissible deviation of position C and E to D, refer to table above)

The rack transition has been set.

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Rack quality Permissibledeviation [mm]

4 0.01

6 0.03

7 0.08

8 0.20

9 0.20

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Installing the motorand coupling

This section describes the steps for installing the coupling and the motor.

Depending on the type of transport securing device used, you have to remove the device before installing the motor for the first time (see section ’Transport securing device at the gearbox’, 43).

Fig. 5-10 Installing the motor and coupling

A GearboxB Motor flangeC Measuring instrumentD CouplingE Coupling screwsF Motor screwsG Motor

Install the motor and the coupling as follows:

1 Clean the coupling and motor shaft to ensure that they are free of grease

2 Measure distance X

3 Push the coupling onto the motor shaft(Dimension Y has to match dimension X, tolerance -0.2 to -0.4 mm)

4 Tighten the coupling screws

5 Grease the gear rim of the coupling(For grease types, see 7.2.2 ’Lubricants’, 47)

6 Push the motor, with the mounted coupling, onto the gearbox

7 Tighten the motor screws

The motor and the coupling have been installed.

X

Y

D00

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A B C D GFE

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Attaching options If equipped, attach the following optional components as per the separate doc-umentation:

• Automatic lubrication system, battery or external 24 V DC, oil or grease• Manual lifting and safety unit: vertical axis• Holding brake• Rotary axis• Telescope axis• Pneumatic load balance

Attaching the load Attach the load (gripper, robot, etc.) to the TM product. Set the roller and tooth flank backlash again. This procedure is described in chapter 8.3.5 ’Setting the roller and tooth flank backlash’, 74.

Mounting the robot This section describes the steps for mounting the robot.

Fig. 5-11 Mounting the robot

A RobotB ScrewC Welded-on plateD Carriage

NOTEWear on the guideways!

Incorrectly adjusted roller and tooth flank backlash increase the wear on the guideways.

After attaching the load, set the roller backlash and tooth flank backlash again!

NOTEWhen installing the robot, use sufficiently long screws. The screws have to go at least 1xd into the carriage.

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Mount the robot as follows:

8 With a lifting unit, place the robot on the carriage and align it

9 Screw robot tight(The screws have to go at least 1xd into the carriage)

10 Remove the lifting unit

The robot has been mounted.

Integrating theproduct

Integrate the TM product into the complete plant. Connect the product with the supply lines for energy and consumables. For this procedure, refer to the documentation of the complete system.

5.3.5 Transport securing device

At delivery, a transport securing device is in effect at the gearbox. This has to be removed prior to assembling the motor.

WARNINGDanger of being crushed

After removing the transport securing devices, the carriage will move off to the side. This can cause severe or fatal injuries!

Secure the carriage before removing the transport securing device!

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Transport securingdevice at the

gearbox

This section describes the removal of the transport securing device at the gear-box.

Fig. 5-12 Transport securing device at the gearbox

A ScrewsB Transport securing device

Remove the transport securing device at the gearbox as follows:

1 Fixate the carriage

2 Loosen the screw

3 Remove the transport securing device

Transport securing device has been removed.

5.4 Function check

Prior to the functional check, ensure that:

• The product is anchored to the floor

• The safety equipment has been attached and closed

• No persons are present in the danger area

The procedure for the functional check is described in the documentation of the complete system.

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Operation

6 Operation

For information on operating the TM, refer to the appropriate chapter of the documentation of the complete product.

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Maintenance

7 Maintenance

7.1 Introduction

This chapter describes all maintenance tasks.

Work sequences Perform the work sequences in the order described. Perform the described tasks at the specified times. This ensures a long service life for your product.

Original spare parts Use only original spare parts. For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 90.

Options andthird-party products

For information on maintenance of options and third-party products, read the appropriate documents in the appendix.

Lubrication This chapter describes the steps for manually lubricating the machine. If your product is equipped with an automatic lubrication system, these tasks do not have to be performed.

Tightening torques If no other specifications have been made, the tightening torques as per chapter 1.4.1 ’Tightening torques for screws’, 8 apply.

7.1.1 Safety




Use appropriate lifting units!

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Only appropriately trained and authorized personnel are allowed to work on the TM product.

WARNINGAutomatic startup

When work is being performed on the product, there is danger of the ma-chine starting up automatically. This can cause severe or fatal injuries!

Before working in the danger area:• Secure vertical axles (if equipped) against falling• Switch off the main power supply and secure it against being switched on

again (main switch of complete plant)• Before switching on the plant again, make sure that no one is in the dan-

ger area.





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7.2 Consumables and auxiliary agents

7.2.1 Cleaning agents

For cleaning tasks, have a grease-dissolving cleaning agent (e.g. acetone) at hand.

7.2.2 Lubricants

Markings at the lubricating points

The marking disc below the grease nipple shows the type of lubricant.

Fig. 7-1 Markings at the lubricating points

A Marking discB Grease nipple

NOTEUnsuitable lubricants

Using unsuitable lubricants can lead to machine damage!

Only use the lubricants listed below. If uncertain, please contact our service departments!

D00

0314

A

B

Yellow marking disc Grease

Red marking disc Oil

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Oils

Oil types The following oil is used ex works by default:

Information on deviating cases is contained in the spare parts list in the appen-dix.

The following types of oil can be used alternatively:

Oil quantities Refer to the table below for the required oil quantities for the gearbox.

Tab. 7-1 Oil quantity for gearbox

Mobil Glygoyle 460

Aral Degol GS 460

BP Energol SG-XP-460

Texaco Pinnacle 460

Shell Tivela S 460

Klüber Klübersynth GH6-220

Type Quantity [cm3]

AE030 40

AE045 100

AE060 250

AE090 700

AE120 1400

AE180 as per type plate

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Greases

Grease types forgearbox coupling

and teeth

The following grease is used ex works for the gearbox coupling and the teeth (for manual lubrication):

Information on deviating cases is contained in the spare parts list in the appen-dix.

The following grease types can be used alternatively:

For automatic grease lubrication, the following grease is used ex works for the teeth:

Grease type forbearings of the

rollers

Always use the following grease for the rollers:

Mobil Mobilux EP 2

Aral Aralup HLP 2

BP Energol LS-EP 2

Texaco Multifak EP 2

Shell Alvania EP-2

Klüber Centoplex EP-2

Castrol Longtime PD2

INA Lithium soap greaseArcanol

LOAD150DIN 51825-KP2N-20

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7.3 Maintenance schedule

Fig. 7-2 Maintenance schedule

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2000 h

500 h

150 h

150 h

500 h

2000 h

10000 h

10000 h

Grease Replace Oil change

Oil Clean Visual inspection

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7.4 Maintenance tasks

7.4.1 General prerequisites

Prior to performing repair and maintenance tasks, do the following:

• If vertical axles are present, secure them against falling

• Switch off the plant and padlock it to secure it against being switched on again

• Make sure that all spare parts and wear items are at hand.(For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 90.)

7.4.2 Maintenance tasks 100 hours after commissioning

To ensure smooth operation, certain maintenance tasks have to be performed after commissioning.

Perform the following tasks 100h after commissioning the product:

• General inspection as per chapter ’General inspection’, 53

• Check the base fixing:• Check the tightening torques of the screws and nuts, retighten if re-

quired• Check the anchor connection, place new anchor if required

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7.4.3 Maintenance tasks every 150 hours

For more information on the lubricants, refer to chapter 7.2 ’Consumables and auxiliary agents’, 47.

Lubricating the guideways, racks and pinions

Lubricate all guideways, racks and pinions every 150 hours.

Tab. 7-2 Number of shots with the grease gun

Lubricate the guideways, racks and pinions as follows:

1 Switch off the plant and padlock it to secure it against being switched on again

2 Use a grease gun to manually inject full shots of lubricant at the lubricating point of all wiper and lubrication units and all lubricating pinions(Number of shots according to table above)

The guideways, racks and pinions are lubricated.

NOTEIncompatible lubricant!

Mixing different lubricants affects their properties.

Never mix different types of lubricant!Before using another type of lubricant, exchange the wiper and lubrication units and the lubricating pinions! Rinse the lines with fresh lubricant!

Product size Roller size Number of shots with the grease gun (1 shot = 1.5 cm3)

TM-40 40 5-6

TM-52 52 5-6

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General inspection

During the general inspection, the entire product is subjected to an overall check.

Performing a generalinspection

Perform the general inspection as follows:


2 Check the inspection points as described in the inspection table

3 Take measures as described in the inspection table

The general inspection has been performed.

Inspection tableInspection cri-terion Description Measures

Dirt Check the components for dirt:• Wiper• Rollers• Guideways

Immediately clean away any dirt

Damage Check the plant for dam-age:• Paint damage• Bent attachments (e.g.

cover plates)• Cracks in the cast

parts• Cracks at welding

seams

Immediately remedy all dis-covered damage

Loose compo-nents

Check the seating of the components:• Screws• Nuts • Attachments

• Immediately tighten loose screws to the re-quired torque

• Align and fasten loose attachments

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Tab. 7-3 Inspection table

Loss of oil Check the plant and its surroundings for signs of the following:• Puddles of oil and oil

spills on the floor or in the drip sheets

• Leaks, torn or pinched lines

• Leakage at the gearbox

• Replace defective and pinched lines

• Repair or replace the gearbox

• Remove puddles of oil and oil spills on the floor or in the drip sheets

Components Check the condition of the components:• Carriage• Rollers• Guideways• Racks• Cog belt

Replace worn components

Backlash Check for correct amount of backlash in the components:• Pinions• Rollers

Correct the backlash

Tension Correct cog belts for cor-rect tension

Correct the tension

Energy chain and cable

Check the energy chain:• Mobility• Wear• Damage• Position of the cables

and lines• Condition of the cables

and lines

• Look for cause• Replace defective or

worn energy chains• Correct the position of

cables and lines• Replace worn or defec-

tive cables

Inspection cri-terion Description Measures

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Maintenance


Replacing the lubricating pinions

A pinion soaked in lubrication runs along next to the drive pinion. It ensures continuous lubrication of the rack and the drive pinions.

Replace the lubricating pinion to ensure uniform lubrication.

This section describes the steps for replacing the lubricating pinion.

Fig. 7-3 Replacing the lubricating pinion

A ScrewsB Intermediate pieceC Lubricating pinionD O-ringE HousingF Fastening screwsG WashersH Grease nippleI Carriage

Replace the lubricating pinion as follows:


2 If there is an automatic lubrication, disconnect the supply

3 Remove the fastening screws and washers

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4 Remove the lubricating pinion unit

5 Remove the screws

6 Remove housing, O-ring and lubricating pinion

7 For oil lubrication, submerge the new lubricating pinion in oil for several minutes(Oil quality, see chapter 7.2 ’Consumables and auxiliary agents’, 47)

8 Replace O-ring

9 To assemble the lubricating pinion unit, reverse the disassembly steps

10 Only for manual lubrication: Lubricate lubricating pinion (See chapter ’Lubricating the guideways, racks and pinions’, 52)

11 Only for automatic lubrication: Connect lubrication line, start lubrication procedure(See separate operating manual on automatic lubrication)

The lubricating pinion has been replaced.

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Maintenance

Greasing the rollers

The roller supports are equipped with lubrication channels for relubrication of the bearings.For more information on the grease qualities, refer to chapter 7.2 ’Consuma-bles and auxiliary agents’, 47.

This section describes the steps for greasing the rollers.

Fig. 7-4 Greasing the rollers

A Roller supportB Lubrication channelsC Grease nipple

Tab. 7-4 Roller relubrication quantity

Grease the rollers as follows:


2 Use a grease gun to press in the grease(Relubrication quantity according to table above)

The rollers have been greased.

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B

C

Product size Roller size Relubrication quantity [g]

TM-40 40 3.3

TM-52 52 7.2

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Oil change in type NA / NH / FA / FH / AE gearboxes

Always replace the gearbox oil within the specified intervals.

For more information on the oil qualities, refer to chapter 7.2 ’Consumables and auxiliary agents’, 47.

Perform the oil change as follows:

Disassembling adrive with pinion

This section describes the steps for disassembling the drive.

WARNINGFalling axles

After transport securing device or the motor has been removed, the verti-cal axle falls down and the carriage moves off to the side. This can cause severe or fatal injuries!

Secure the vertical axle and the carriage before removing the transport se-curing device or the motor!

NOTEDo not change the position of the coupling on the motor shaft!

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Fig. 7-5 Disassembling the drive

A MotorB Motor screwsC GearboxD Gearbox screws

Disassemble the drive as follows:


2 Secure carriage or axle with transport securing device or lifting device

3 Remove the motor screws

4 Pull the motor, together with the coupling, off the gearbox

5 Remove the gearbox screws

6 Remove the gearbox

The drive has been disassembled.

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D

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Changing thegearbox oil

This section describes the steps for changing the gearbox oil.

Fig. 7-6 Oil change

A Bleed screwB Filler screwC Drain screw

Change the gearbox oil as follows:

1 Position the gearbox: Drain screw at the bottomFiller and bleed screw at the top

2 Position a suitable container below the drain screw

CAUTIONOils/greases

Oils and greases are harmful to the environment!

The oils and greases may not get into the drinking water supply:• Take appropriate measures.• Observe the country-specific safety data sheets.• Oils and greases must be disposed of as hazardous waste, even if the to-

tal quantity is small.

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3 Remove the bleed, filler and drain screw

4 Drain the oil

5 Rinse the gearbox with fresh oil(for oil types, see the Oils chapter)

6 Allow the gearbox to drain

7 Screw in the drain screw

8 Fill up the gearbox through the filler screw(for oil types and quantity, see the Oils chapter)

9 Screw in the bleed and filler screws

The gearbox oil has been changed.

Assembling the drive This section describes the steps for assembling the drive.

Assemble the drive as follows:

1 To assemble the drive, reverse the disassembly steps in section ’Disas-sembling a drive with pinion’, 58

2 Set the tooth flank backlash according to Kapitel 8.3.5, 74

3 Calibrate the measurement reference plane of the motor (This procedure is described in the documentation of the complete plant or of the motor)

The drive has been assembled.

The oil change has been completed

NOTECalibrate the measurement reference plane after each drive as-sembly.This procedure is described in the documentation of the com-plete plant or of the motor!

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8 Repairs

8.1 Introduction

This chapter describes all repair tasks.

Work sequences Perform the work sequences in the order described.

Original spare parts Use only original spare parts. For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 90.

Tightening torques If no other specifications have been made, the tightening torques as per chapter 1.4.1 ’Tightening torques for screws’, 8 apply.

8.1.1 Safety


WARNINGAutomatic startup

When work is being performed on the product, there is danger of the ma-chine starting up automatically. This can cause severe or fatal injuries!

Before working in the danger area:• Secure vertical axles (if equipped) against falling• Switch off the main power supply and secure it against being switched on

again (main switch of complete plant)• Before switching on the plant again, make sure that no one is in the dan-

ger area.



Use appropriate lifting units!

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8.2 Special tools, testing and measuring instruments

For repairs, ensure that you have the following special tools, testing and meas-uring instruments at hand:

Tab. 8-1 Special tools, testing and measuring instruments





Tool Use Item number

Micrometer Checking parallelism at the guideways

Checking the rack tran-sition

Screw clamps Installing the guideways

Mounting aid Installing the guidewaysSize 40

902 403

Installing the guidewaysSize 52, 72

902 404

Installing the guidewaysSize 90

902 405

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8.3 Repairs

8.3.1 General prerequisites

Prior to performing repair and maintenance tasks, do the following:

• If vertical axles are present, secure them against falling

• Switch off the plant and padlock it to secure it against being switched on again

• Make sure that all spare parts and wear items are at hand.(For information on spare parts and wear items, refer to chapter 11 ’Spare part supply’, 90.)

8.3.2 Replacing the bumper unit

The bumper unit is a safety component.Replace the entire bumper unit after a crash has occurred.

The bumper unit consists of the following components:

• Bumper

• Bumper block or bumper bracket

• Screws

• Sleeves and/or heavy-duty spring tension pins

WARNINGWeak safety component

After a crash, it is not immediately apparent whether bumper unit elements have been weakened or are defective. Another crash can cause severe or fatal injuries.

Always replace the entire bumper unit!

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8.3.3 Replacing the wiper and felt insert

Continuous lubrication of the guideways at operating temperatures under 0 °C or with grease requires a modification to the wiper and felt insert. This proce-dure is described in the sections:

• ’Preparing the wiper’, 66• ’Preparing the felt insert’, 67.

This section describes the steps for replacing the wiper and the felt insert.

Fig. 8-1 Wiper and felt insert

A ScrewsB WiperC Felt insert

Replace the wiper and felt insert as follows:


2 If there is an automatic lubrication, disconnect the supply

3 Remove the screws

4 Replace the wiper

5 Replace the felt insert

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6 Only for oil lubrication:Submerge new felt insert in oil for several minutes(Oil quality, see chapter 7.2 ’Consumables and auxiliary agents’, 47)

7 To install the wiper and felt insert, reverse the removal steps

8 Only for manual lubrication: Lubricate guideways (See chapter ’Lubricating the guideways, racks and pinions’, 52)

9 Only for automatic lubrication:(See separate operating manual on automatic lubrication)

9.1 Connect lubrication line

9.2 Start lubrication procedure(See separate operating manual on automatic lubrication)

The wiper and felt insert have been replaced.

Preparing the wiper This section describes the steps for preparing the wiper. This applies for oil lubrication, operating temperature under 0 °C or grease lubrication.

Fig. 8-2 Preparing the wiper

A WiperB Recess

Prepare the wiper as follows:

1 Attach recess(Mass according to figure)

The wiper has been prepared.

10...12

2.5.

..3

8...10D00

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A

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Preparing the feltinsert

This section describes the steps for preparing the felt insert. This applies for oil lubrication, operating temperature under 0 °C or grease lubrication.

Fig. 8-3 Preparing the felt insert

A ReductionB Slot

Prepare the felt insert as follows:

1 Shorten the felt insert to the 5 mm dimension

2 Increase dimension S by 1 mm(Only for oil lubrication, operating temperature below 0 °C)

The felt insert has been prepared.

5D

0010

35

S +

1

A

B

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8.3.4 Replacing the rollers and guideways

The rollers, guideways and racks are designed for continuous use. Certain ambi-ent conditions can increase the wear on these components.

Replacing the rollers, guideways and racks involves a considerable amount of work. Always replace these components simultaneously.

Replacing the rollers

Centering andeccentric roller

The roller support contains centering and eccentric rollers. The supporting roll-ers are equipped with concentric sleeves. The rollers with eccentric sleeves are used to set the roller and tooth flank backlash.

Fig. 8-4 Centering and eccentric roller

A Lubrication boreB SleeveC Centering rollerD GuidewayE Eccentric roller (zero position)

NOTEThe lubrication bore should not be in the loaded zone. This is valid only for the centering roller.The lubrication bore lies across from the engraved letter Z.

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This chapter describes the steps for replacing rollers.

Fig. 8-5 Replacing the rollers

A Roller supports, size 72 and 90B Centering roller (R1)C Eccentric roller (R2)D Roller supports, size 40 and 52E Eccentric roller (R3)F NutG Locknut

Replace the rollers as follows:


2 Attach the carriage to a lifting device

3 Move the carriage off the axle

4 Remove the nuts and locknuts

5 Replace the rollers

6 Install R1 roller:

6.1 Mount the centering roller(Observe the position of the lubricating bore as per chapter ’Centering and eccentric roller’, 68)

6.2 Tighten nut and locknut(Secure the roller against twisting by means of a hexagonal socket wrench, torque as per Tab. 1-6 ’Tightening torques: Roller sup-ports’, 12)

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R2

R3

R1

R2

R3

A B EC BD

G F E FG C

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7 Install R2 and R3 rollers:

7.1 Mount the eccentric rollers in zero position(refer to Fig. 8-4 ’Centering and eccentric roller’, 68)

7.2 Apply nuts and locknuts

8 Move carriage onto axle

9 Remove the lifting device

10 Set roller and tooth flank backlash as per Kapitel 8.3.5, 74

The rollers have been replaced.

Replacing the guideways

Replace the guideways as soon as the surfaces show signs of wear.

The term "guideway" includes:

• Guideway• Rack

Replace the guideways as follows:

Removing theguideway

The designations refer to Fig. 8-7, 72.

Remove the guideway as follows:


2 Attach the carriage to a lifting device

3 Move the carriage off the guideway or axle to be replaced

4 Remove all screws(See Fig. 8-7, 72)

5 Remove the guideway

The guideway has been removed.

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Installing theguideway

Proper installation of the guideways in accordance with the regulations is pre-requisite for low-wear use of the product.

Mounting aid The start and end of the rack form a half tooth gap. For precise and low-noise transition, we recommend using a mounting aid geared in the opposite direction (see chapter 8.2 ’Special tools, testing and measuring instruments’, 63).

Fig. 8-6 Mounting aid for rack assembly

A RackB Mounting aid

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This section describes the steps for installing the guideway.

Fig. 8-7 Installing the guideway

A Mounting aidB Screw clampsC RacksD Torque wrenchE GuidewaysF Reference surfaces

Install the guideway as follows:

1 Clean the reference surfaces, guideways and racks thoroughly and rub an oil stone across them

2 Clamp rack to guideway with screw clamp and mounting aid

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B

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F

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3 Use clamp screws to clamp the guideways against the reference surfaces

4 Tighten all screws

5 Inspect transition:

5.1 Guideway transition(gap dimension < 0.02 mm)

5.2 Rack transition, as per Section ’Inspecting the rack transition’, 38

6 Use a suitable measuring instrument to check that the guideways are par-allel(tolerance: ±0.04 mm)

7 If deviations occur (transition/parallelism):

7.1 Remove screws and guideway

7.2 Repeat the procedure

The guideway has been installed.

Final tasks The following tasks must be performed after assembly of the guideway.

Perform these final tasks as follows:

1 Move the carriage onto the axle if necessary

2 Insert the Z-axis, if required

3 Remove the lifting device

4 If necessary, adjust the rollers

The final tasks have been performed.

The guideway has been replaced.

The guideways have been replaced.

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8.3.5 Setting the roller and tooth flank backlash

Reset the roller and tooth flank backlash after each roller, guideway or gearbox change.

This section describes the steps for setting the roller and tooth flank backlash.

When tightening the rollers, nuts and locknuts, the maximum tightening tor-ques apply, refer to Tab. 1-6, 12.

In products with more than four roller supports per carriage, set the roller backlash and tooth flank backlash by means of the rollers of the four corner roller supports (as per the handling instructions on the following pages). Tighten the residual rollers with the tightening torques specified in Tab. 1-6, 12.

NOTEAlways set the roller backlash and tooth flank backlash with load attached and at operating temperature!

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Fig. 8-8 Setting the roller and tooth flank backlash

A GearboxB Dial gaugeC AxleD Depth gauge (distance of roller support on guideway)E CarriageF Drive pinions

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X

R1R2

R3

R1R2

R3

Y

A

B

C

E

F

D

Size of roller support

Distance X/Y[mm]

Tooth flank backlash [mm]

40 50 0.06

52 56 0.07

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Tab. 8-2 Roller and tooth flank backlash

Set the roller and tooth flank backlash as follows:(For descriptions, see also Fig. 8-5, 69)

1 You may need to make the following preparations:

1.1 Loosen the nuts and locknuts of the R2 and R3 rollers

1.2 Move away the R2 and R3 rollers

2 Block the drive pinions

3 Remove the wiper and lubrication unit

4 Move the R2 rollers on the gearbox side closer by rotating them clock-wise

5 Measure distance of the roller supports on the guideway(Target value: X = Y ±0.1 mm)

6 Move the R2 rollers opposite of the gearbox closer by rotating them clockwise

7 Tighten the nuts and locknuts of all R2 rollers(Secure the rollers against twisting by means of a hexagonal socket wrench)

8 Check the tooth flank backlash:

8.1 Mount the dial gauge

8.2 Move the carriage in the direction of travel

8.3 Read the tooth flank backlash on the dial gauge(Tooth flank backlash acc. to table above)

9 If deviations occur:

9.1 Loosen the locknuts, nuts and R2 rollers opposite of the gearbox

9.2 Backlash too large: Move the R2 rollers on the gearbox side closer by rotating them clockwise

72 90 0.08

90 107 0.1

Size of roller support

Distance X/Y[mm]

Tooth flank backlash [mm]

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9.3 Backlash too small: Move the R2 rollers on the gearbox side away by rotating them counterclockwise

9.4 Check the parallelism between the carriage and axle

9.5 Repeat process from step 5

10 Move the R3 rollers closer by rotating them clockwise uniformly

11 Tighten the nuts and locknuts

12 Install the wiper and lubrication unit

13 Unblock the drive pinions

The roller and tooth flank backlash have been set.

8.3.6 Replacing the gearbox

This section describes the steps for replacing the gearbox.

Disassemble the drive to replace the gearbox.

Disassembling adrive with pinion

This section describes the steps for disassembling the drive.

WARNINGFalling axles

After transport securing device or the motor has been removed, the verti-cal axle falls down and the carriage moves off to the side. This can cause severe or fatal injuries!

Secure the vertical axle and the carriage before removing the transport se-curing device or the motor!

NOTEDo not change the position of the coupling on the motor shaft!

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Fig. 8-9 Disassembling the drive

A MotorB Motor screwsC GearboxD Gearbox screws

Disassemble the drive as follows:


2 Secure carriage or axle with transport securing device or lifting device

3 Remove the motor screws


5 Remove the gearbox screws

6 Remove the gearbox

The drive has been disassembled.

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D

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Replace the gearbox This section describes the steps for replacing and installing the new gearbox.

Replace and install the gearbox as follows:

1 Replace the gearbox

2 To assemble the drive, reverse the disassembly steps

3 Set the tooth flank backlash according to Kapitel 8.3.5, 74

4 Calibrate the measurement reference plane of the motor(This procedure is described in the documentation of the complete plant or of the motor)

The gearbox has been replaced and installed.


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8.3.7 Setting the gear backlash

Ex works, the gear backlash is set to a value lower than 6‘. If the backlash increases, it has to be readjusted.

Fig. 8-10 Setting the gear backlash

A Worm shaftB ScrewsC Casing cover

Set the gear backlash as follows:


2 Disassemble the drive according to section 8.3.6 ’Replacing the gearbox’, 77

3 Remove all screws on both sides

4 Rotate both covers to the next higher, cast-in number

NOTE• Do not remove the casing cover, else the gearbox oil will leak

out!• Always align both casing covers in the identical position!

2

3

4

1

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C

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5 Tighten two screws on each of the two sides

6 Check the gear backlash:Rotate the worm shaft 360° by hand

6.1 The shaft does not resist rotation:Repeat from step 3

6.2 The shaft resists rotation:Remove the screws, set both gearbox covers one level lower

7 Insert all screws on both sides and tighten crosswise

8 Check the backlash again, as described in step 6.

The gear backlash has been set

8.3.8 Replacing the motor and coupling

This chapter describes the steps for replacing the motor and the coupling

Replace the motor and coupling as follows (for descriptions, see Fig. 8-11, 82):

Removing the motorand coupling

This section describes the steps for removing the coupling and the motor.

Remove the motor and the coupling as follows:


2 Loosen the motor screws


4 Loosen the coupling screws

5 Pull the coupling off the motor shaft

The motor and the coupling have been removed.


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Installing the motorand coupling

This section describes the steps for installing the coupling and the motor.Depending on the type of transport securing device used, you have to remove the device before installing the motor for the first time (see section ’Transport securing device at the gearbox’, 43).

Fig. 8-11 Installing the motor and coupling

A GearboxB Motor flangeC Measuring instrumentD CouplingE Coupling screwsF Motor screwsG Motor

Install the motor and the coupling as follows:

1 Clean the coupling and motor shaft to ensure that they are free of grease

2 Measure distance X

3 Push the coupling onto the motor shaft(Dimension Y has to match dimension X, tolerance -0.2 to -0.4 mm)

4 Tighten the coupling screws

5 Grease the gear rim of the coupling(For grease types, see 7.2.2 ’Lubricants’, 47)

6 Push the motor, with the mounted coupling, onto the gearbox

7 Tighten the motor screws

The motor and the coupling have been installed.The motor and the coupling have been replaced.

X

Y

D00

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A B C D GFE

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8.4 Other documents

For information on the available options, read the appropriate documents in the appendix.

8.5 Service departments

If you have questions, please contact the service departments. For a list with their contact information, see chapter 11.2 ’Service departments’, 91.

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Decommissioning, storage

9 Decommissioning, storage

9.1 Introduction

9.1.1 Safety




9.2 Storage conditions

Room Store the product in a dry location. For information on the required space and the floor capacity, refer to the machine layout or general layout.Use a covering to protect the product against dust and dirt.

Temperature The ambient storage temperature must remain between -10 and +40°C. Make sure that the product is not subjected to large temperature fluctuations.

Air humidity The air humidity must be below 75%.

CAUTIONLeaking fluids

During storage, substances that are hazardous to the environment could leak!

Hazardous substances may not get into the drinking water supply:• Take appropriate measures.• Observe the country-specific safety data sheets.• Fluids must be disposed of as hazardous waste, even if the total quantity

is small.

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9.3 Decommissioning

9.3.1 Shutdown

This chapter provides information on shutting down the product.

To shut down the product, proceed as follows:

1 Fixate the axles

2 Shut down the plant(main switch of complete system)

3 Disconnect the supply lines for energy and consumables

4 Automatic lubrication system (optional): Unscrew the lubricator and remove the batteries

The product has been decommissioned.





NOTEDo not empty the lubrication lines and the gearbox when shut-ting down the product!

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9.3.2 Cleaning / rust-proofing

Prior to performing rust-proofing, clean away any dirt and dust from the prod-uct. Clean the product thoroughly.

Apply corrosion protection to all parts.

9.3.3 Transport securing device

On unbraked motors, mount the transport securing devices.

9.3.4 Labeling

Label the product with the following data:

• Date of decommissioning• Internal machine number/name• Further data as per internal guidelines

9.4 Recommissioning

For recommissioning, follow the steps described for commissioning.

Prior to recommissioning, perform the general inspection as set out in chapter 7.4 ’Maintenance tasks’, 51. Perform the required maintenance tasks and repairs.

If the machine has been standing still for more than one year, perform the fol-lowing tasks:

• Change the gearbox oil• Rinse the lubrication lines with fresh lubricant• Replace the felt inserts and lubricating pinions• Check the gaskets and replace if necessary

NOTEDispose of any cloths soaked in oils and/or greases in an environ-mentally friendly manner! For more information on disposal, re-fer to chapter 10 ’Disposal’, 87.

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10 Disposal

10.1 Introduction

Observe the following during disposal:

• Adhere to the country-specific regulations• Separate the material groups• Dispose of the materials in an environmentally friendly way• Recycle waste if possible

10.1.1 Safety




10.2 Disposal

Your product consists of the following units:

• Packaging • Contaminated materials /auxiliary agents (oil paper)• Wood• Plastic (film)

• Consumables• Lubricants (oils/greases)• Batteries

• Base unit• Metals (steel/aluminum)• Plastics (thermoplasts/duroplasts)• Contaminated materials/auxiliary agents (felt/cleaning cloths)• Electrical material (cables)

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10.3 Waste management compliant assemblies

10.3.1 Disassembly

This chapter describes how to disassemble the product.

Prior to disassembly, shut down product as described in chapter 9.3.1 ’Shut-down’, 85.

Disassemble the product as follows:

1 Remove connecting elements(cables / energy chains)

2 Dismount mobile axes

3 Remove the gearbox and drain the oil

4 Dismount the carriage

WARNINGSuspended loads

Improper handling of suspended loads can lead to severe injuries or death!

Observe the following:• Use appropriate lifting units• Wear appropriate protective clothing• Always keep sufficient distance to suspended loads• Never enter the area below a suspended load

CAUTIONOils/greases

Oils and greases are harmful to the environment!

The oils and greases may not get into the drinking water supply:• Take appropriate measures.• Observe the country-specific safety data sheets.• Oils and greases must be disposed of as hazardous waste, even if the to-

tal quantity is small.

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5 Dismount fixed assemblies(axes/columns)

6 Take the assemblies apart and separate the different materials.

The product has been disassembled.

10.3.2 Material groups

Dispose of the material groups in accordance with the following table.

Tab. 10-1 Disposal: material groups

10.4 Disposal facilities, authorities

The disposal facilities and authorities differ from country to country. Observe the local laws and regulations on disposal.

Material Disposal route

Contaminated mate-rials/auxiliary agents

Hazardous waste

Wood Municipal waste

Plastic Collecting point or municipal waste

Lubricants Collecting pointDisposal in accordance with the safety data sheets 3.4.4 ’Safety data sheets (MSDS)’, 24

Batteries Battery collection

Metals Scrap metal collection

Electrical material Electrical rubbish

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Spare part supply

11 Spare part supply

11.1 Explanations regarding the spare parts list

The spare parts list can be found in chapter 13 ’Appendix’, 96. It contains position drawings and the complete parts list of your product.

11.1.1 Positioning drawings

The positions of the spare parts can be seen on the drawings. These are stand-ard drawings. Individual positions or images might differ from your product.

11.1.2 Parts list

The parts list contains all parts of your product. The spare parts and wear items are indicated as described in the explanation of symbols.

Explanation ofsymbols

Fig. 11-1 Explanation of symbols

A Spare part statusB Availability

14.07.2008 / Page 1 of 1

BCH034580 VS0035 2-Amod ZP-4 M MO mec 3.10 10947-001A

WEtinUytitnauQgniwarDtxeTrebmun metInoitisoP

300 V000134 Y ktS1230-32580029=L V 52-022/022PL sixA-

EktS770.002.71.093SUGI 0.002.71.093 niahc ygrenE4001410203 A

400 0916667 Y ktS2030-32584-PZ egairraC-900 406015-10.00 Worm gear unit AE060/L left

Ratio i=10.00

AE060 2 Stk E B

910 406089 Motor flange 060 18x116x116 ø130/110 8030-018a 2 Stk E C

1000 0910499 Mechanical multi limit switch accessories 750 Y 8523-024 2 Stk

1100 230803 Felt pinion for lubrication

ø40.6x20, Modul m=2.387 pitch P=7.5, Z=15

8102-039d 1 Stk V A

Güdel AGInsustrie Nord

CH-4900 Langnethalphone +41 62 916 91 91fax +41 62 916 91 [email protected]

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Spare part supply

The information on availability is given without warranty. The delivery times might in some cases differ.

11.2 Service departments

If you have questions on service, please use the service form at www.gudel.com or contact the offices in the appropriate country:

For urgent service requests, our Helpdesk provides after-hour assistance (24-hour support):

Please have the following information, as labeled on the type plate, at hand:

• Serial no.• Part list no. • Drawing number (if applicable)

Spare part status (column E): EV

==

Spare partWear item

Availability (column W): ABC

===

Available from stockDelivery time approx. 2 - 3 weeksDelivery time upon request

Germany: +49 6291 6446 41

Great Britain: +44 24 7669 5444

India: +91 20 5622 7165

Italy: +39 0292 170920

South Korea: +82 2168 98 00

Taiwan: +88 635 97 8808

USA: +1 734 214 0000

All other countries and Switzerland:+41 62 916 91 91

Europe/Asia: +41 62 916 9170

USA: +1 248 456 0440

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Index

12 Index

AAppendix . . . . . . . . . . . . . . . . . . . . . . . . 96Assembly . . . . . . . . . . . . . . . . . . . . .29, 36

Drive . . . . . . . . . . . . . . . . . . . . . . . . . 61Guideway . . . . . . . . . . . . . . . . . .36, 71Motor . . . . . . . . . . . . . . . . . . . . .40, 82

Assembly manual for partly completed machinery . . . . . . . . . . . . . . . . . . . . . 7

AttachingLoad . . . . . . . . . . . . . . . . . . . . . . . . . 41Options . . . . . . . . . . . . . . . . . . . . . . 41Slings . . . . . . . . . . . . . . . . . . . . . . . . . 30

Authorities . . . . . . . . . . . . . . . . . . . . . . 89Auxiliary agents . . . . . . . . . . . . . . . . . . 47Axis names . . . . . . . . . . . . . . . . . . . . . . 26

BBase fixing . . . . . . . . . . . . . . . . . . . . . . . 33

Adhesive anchor . . . . . . . . . . . . . . . 33Welded joining . . . . . . . . . . . . . . . . 34

Bumper unitReplacing . . . . . . . . . . . . . . . . . . . . . 64

CCentering roller . . . . . . . . . . . . . . . . . . 68Change

Gearbox oil . . . . . . . . . . . . . . . . . . . 60Checking

Delivery . . . . . . . . . . . . . . . . . . . . . . 29Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 86Cleaning agents . . . . . . . . . . . . . . . . . . . 47Commissioning . . . . . . . . . . . . . . . . . . . 27Connecting

Profiles . . . . . . . . . . . . . . . . . . . . . . . 32Consumables . . . . . . . . . . . . . . . . . . . . . 47Coupling

Installing . . . . . . . . . . . . . . . . . . .40, 82Removing . . . . . . . . . . . . . . . . . . . . . 81Replacing . . . . . . . . . . . . . . . . . . . . . 81

DDeclaration of incorporation . . . . . . 18Decommissioning . . . . . . . . . . . . . 84, 85Delivery

Checking . . . . . . . . . . . . . . . . . . . . . 29Design . . . . . . . . . . . . . . . . . . . . . . . . . . 25Disassembly . . . . . . . . . . . . . . . . . . . . . 88

Coupling . . . . . . . . . . . . . . . . . . . . . 81Drive with pinion . . . . . . . . . . . 58, 77Guideways . . . . . . . . . . . . . . . . . . . . 70Motor . . . . . . . . . . . . . . . . . . . . . . . 81

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . 87Disposal facilities . . . . . . . . . . . . . . . . . 89Drive

Assembly . . . . . . . . . . . . . . . . . . . . . 61Disassembling with pinion . . . 58, 77

EEccentric roller . . . . . . . . . . . . . . . . . . 68Explanation

Abbreviation . . . . . . . . . . . . . . . . . . . 8Symbols . . . . . . . . . . . . . . . . . . . . . . . 8

Explanation of abbreviations . . . . . . . . 8Explanation of symbols . . . . . . . . . . . . . 8

FFastening . . . . . . . . . . . . . . . . . . . . . . . . 30Felt insert

preparing . . . . . . . . . . . . . . . . . . . . . 67Final tasks . . . . . . . . . . . . . . . . . . . . . . . 73Function . . . . . . . . . . . . . . . . . . . . . . . . 25Functional check . . . . . . . . . . . . . . . . . 43Functional description . . . . . . . . . . . . 26Fundamentals of safety . . . . . . . . . . . . 23

GGear

Setting the backlash . . . . . . . . . . . . 80

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Index

GearboxOil change . . . . . . . . . . . . . . . . . . . . 60Replacing . . . . . . . . . . . . . . . . . .77, 79

General inspection . . . . . . . . . . . . . . . . 53Greases . . . . . . . . . . . . . . . . . . . . . . . . . 49Greasing

Roller . . . . . . . . . . . . . . . . . . . . . . . . 57Guideway

Installing . . . . . . . . . . . . . . . . . . .36, 71Lubricating . . . . . . . . . . . . . . . . . . . . 52Removing . . . . . . . . . . . . . . . . . . . . . 70Replacing . . . . . . . . . . . . . . . . . . . . . 70

HHazard symbols

Operating manual . . . . . . . . . . . . . . 19Product . . . . . . . . . . . . . . . . . . . . . . 22

Hazard warningCaution . . . . . . . . . . . . . . . . . . . . . . 19Danger . . . . . . . . . . . . . . . . . . . . . . . 19Note . . . . . . . . . . . . . . . . . . . . . . . . . 19Warning . . . . . . . . . . . . . . . . . . . . . . 19

IInspecting

Rack transition . . . . . . . . . . . . . . . . 38Installing

Coupling . . . . . . . . . . . . . . . . . . .40, 82Integrating

Product . . . . . . . . . . . . . . . . . . . . . . 42

LLabeling . . . . . . . . . . . . . . . . . . . . . . . . . 86Liability . . . . . . . . . . . . . . . . . . . . . . . . . . 17Load

Attaching . . . . . . . . . . . . . . . . . . . . . 41Lubricants . . . . . . . . . . . . . . . . . . . . . . . 47Lubricating

Guideways . . . . . . . . . . . . . . . . . . . . 52Pinions . . . . . . . . . . . . . . . . . . . . . . . 52Racks . . . . . . . . . . . . . . . . . . . . . . . . 52

Lubricating pinionReplacing . . . . . . . . . . . . . . . . . . . . . 55

MMaintenance . . . . . . . . . . . . . . . . . . . . . 45

10000 hours . . . . . . . . . . . . . . . . . . 58150 hours . . . . . . . . . . . . . . . . . . . . 522000 hours . . . . . . . . . . . . . . . . . . . 55500 hours . . . . . . . . . . . . . . . . . . . . 53Schedule . . . . . . . . . . . . . . . . . . . . . 50Tasks . . . . . . . . . . . . . . . . . . . . . . . . 51

Maintenance schedule . . . . . . . . . . . . 50Maintenance tasks 100 hours after

commissioning . . . . . . . . . . . . . . . . 51Markings

Lubricating points . . . . . . . . . . . . . 47Material groups . . . . . . . . . . . . . . . . . . 89Measuring instruments . . . . . . . . . . . . 63Monitoring equipment . . . . . . . . . . . . 23Motor

Installing . . . . . . . . . . . . . . . . . . . 40, 82Removing . . . . . . . . . . . . . . . . . . . . 81Replacing . . . . . . . . . . . . . . . . . . . . . 81

MountingRobot . . . . . . . . . . . . . . . . . . . . . . . . 41

Mounting aid . . . . . . . . . . . . . . . . . . 36, 71

OOil change

Gearbox . . . . . . . . . . . . . . . . . . . . . 58Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Operating personnel . . . . . . . . . . . . . . 16Operation . . . . . . . . . . . . . . . . . . . . . . . 44Options . . . . . . . . . . . . . . . . . . . . . . . . . 15

Attaching . . . . . . . . . . . . . . . . . . . . . 41Other documents . . . . . . . . . . . . . . . . 83

PPackaging symbols . . . . . . . . . . . . . . . . 28Parts list . . . . . . . . . . . . . . . . . . . . . . . . 90Personnel qualification 27, 46, 63, 84, 87Pinion

Lubricating . . . . . . . . . . . . . . . . . . . 52Position drawings . . . . . . . . . . . . . . . . 90Preparing

Felt insert . . . . . . . . . . . . . . . . . . . . 67Wiper . . . . . . . . . . . . . . . . . . . . . . . 66

Prerequisites . . . . . . . . . . . . . . . . . . . . 29Base . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Lifting unit . . . . . . . . . . . . . . . . . . . . 29Lines . . . . . . . . . . . . . . . . . . . . . . . . . 29Maintenance, repair . . . . . . . . .51, 64Positioning . . . . . . . . . . . . . . . . . . . . 29

ProductDescription . . . . . . . . . . . . . . . . . . . 13Designation . . . . . . . . . . . . . . . . . . . 14Integrating . . . . . . . . . . . . . . . . . . . . 42Positioning . . . . . . . . . . . . . . . . . . . . 31Safety . . . . . . . . . . . . . . . . . . . . . . . . 16

Product-specific hazards . . . . . . . . . . . 23Profiles

Connecting . . . . . . . . . . . . . . . . . . . 32Protective measures . . . . . . . . . . . . . . 17Purpose of the document . . . . . . . . . . . 7

RRack

Inspecting transition . . . . . . . . . . . . 38Lubricating . . . . . . . . . . . . . . . . . . . . 52

Recommissioning . . . . . . . . . . . . . . . . . 86Repairs . . . . . . . . . . . . . . . . . . . . . . .62, 64Replacing

Bumper unit . . . . . . . . . . . . . . . . . . . 64Coupling . . . . . . . . . . . . . . . . . . . . . . 81Gearbox . . . . . . . . . . . . . . . . . . .77, 79Guideways . . . . . . . . . . . . . . . . . . . . 70Lubricating pinions . . . . . . . . . . . . . 55Motor . . . . . . . . . . . . . . . . . . . . . . . . 81Roller . . . . . . . . . . . . . . . . . . . . . . . . 68Roller and guideways . . . . . . . . . . . 68

Residual danger . . . . . . . . . . . . . . . . . . 16Robot

Mounting . . . . . . . . . . . . . . . . . . . . . 41Roller

Greasing . . . . . . . . . . . . . . . . . . . . . . 57Rollers

Replacing . . . . . . . . . . . . . . . . . . . . . 68Rust-proofing . . . . . . . . . . . . . . . . . . . . 86

SSafety . . . . . . . . . . . 16, 27, 45, 62, 84, 87Safety data sheets . . . . . . . . . . . . . . . . 24Safety equipment . . . . . . . . . . . . . . . . . 23Safety regulations

Failure to comply . . . . . . . . . . . . . . 17

Service departments . . . . . . . . . . . . . . 91Set up . . . . . . . . . . . . . . . . . . . . . . . 29, 30Setting

Gear backlash . . . . . . . . . . . . . . . . . 80Roller backlash . . . . . . . . . . . . . . . . 74Tooth flank backlash . . . . . . . . . . . 74

Setting the roller backlash . . . . . . . . . 74Setting the tooth flank backlash . . . . 74Setup

Product . . . . . . . . . . . . . . . . . . . . . . 31Shutdown . . . . . . . . . . . . . . . . . . . . . . . 85Slings

Attaching . . . . . . . . . . . . . . . . . . . . . 30Spare part supply . . . . . . . . . . . . . . . . . 90Spare parts list . . . . . . . . . . . . . . . . . . . 90

Explanation of symbols . . . . . . . . . 90Explanations . . . . . . . . . . . . . . . . . . 90

Special symbols . . . . . . . . . . . . . . . . . . 21Special tools . . . . . . . . . . . . . . . . . . . . . 63Storage . . . . . . . . . . . . . . . . . . . . . . . . . 84Storage conditions . . . . . . . . . . . . . . . 84Symbols

Special symbols . . . . . . . . . . . . . . . 21Warning symbols . . . . . . . . . . . . . . 20

TTarget readership . . . . . . . . . . . . . . . . . 8Technical data . . . . . . . . . . . . . . . . . . . 15Temperature ranges . . . . . . . . . . . . . . 15Testing instruments . . . . . . . . . . . . . . 63Tightening torques

HV sets . . . . . . . . . . . . . . . . . . . . . . 10Roller holders . . . . . . . . . . . . . . . . . 11Roller supports . . . . . . . . . . . . . . . 12Screws . . . . . . . . . . . . . . . . . . . . . . . . 8

Torque tables . . . . . . . . . . . . . . . . . . . . . 8Transport . . . . . . . . . . . . . . . . . . . . . . . 28Transport securing devices . . . . . 42, 86Type plate . . . . . . . . . . . . . . . . . . . . . . . 14

UUnpacking . . . . . . . . . . . . . . . . . . . . . . . 29Use

Improper . . . . . . . . . . . . . . . . . . . . . 13Intended . . . . . . . . . . . . . . . . . . . . . 13Purpose . . . . . . . . . . . . . . . . . . . . . . 13

94

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Index

WWarning symbols . . . . . . . . . . . . . . . . . 20Waste management compliant assemblies 88Wiper

preparing . . . . . . . . . . . . . . . . . . . . . 66

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Appendix

13 Appendix

The appendix of this operating manual contains the following documents:

• Hazard analysis / Risk analysis

• Layout

• Options

• Third-party products

• Spare parts list

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Hazard analysis / Risk analysis

Hazard analysis / Risk analysis

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A B C D E F G H I J K L M 1 4 10 1 2 3 The following should be prevented:

1.1 x x x x x x x x x x x x x x

Processing of hazardous materials.Fire and danger of explosionThermal factors

All Noncompliance with the intended use Persons are injured or killed x x 10 3/d Intended use of the product.

A Güdel device is only used to bring objects to a specific position, hold them there or to move simultaneously with other machine movements.No hazardous (e.g. poisonous or explosive) objects may be moved. A Güdel device may not be operated in a potentially explosive area. The ambient temperature during operation must be between 12° and 40 °C.

If the intended use is modified, hazards can results that are not covered by the safety concept.

x J

1.2 x x x x x x x x Suspended loads

TechniciansCommissio

ning technicians

Improper use of lifting equipmentPerson is surprised by unexpected movement and injured or killed as a result.

x x 10 3/d No persons may be injured by falling parts.Use appropriate lifting equipment. Wear protective

clothing. Keep a safe distance.Do not walk under suspended loads. x J

1.3 x

Movement of the axes.Suspended loads(Z-axis and workpieces)

OperatorMaintenance

personnel

Gripper problemsDefective motor brakeGeneral problems in the drive train

Person is surprised by vertical movement and injured as a result. x x 20 3/d

The areas of movement must be secured so that neither operating personnel nor third parties can reach or walk into the hazardous locations where automatic movements are performed.

The areas of movement must be enclosed by light grids,

light curtains as well as mechanical safety fences so that

it is impossible to enter this area from any direction.

There must be door elements or light curtains that allow

entry into the danger area or to a portion of the danger

area.

The height of the safety fences is described in EN ISO

13857.

Safety shutdown situation:

The vacuum system remains active in a de-energized

state.

Door elements: when opening the danger area, a safety

shutdown is performed for at least the drives that pose a

hazard in this area.

The door elements are also locked electromechanically.

Light barriers: these are to be monitored so that when

contact is broken, at least the drives that pose a hazard

in this area are shutdown. The distance between the

source of the danger and the light barriers is described

in EN 999 Art. 6.

In normal operation, all protective hoods must be closed, removable protective hoods must be screwed securely.Required behavior:Inspect the protective hoods before starting normal operation. Safety shutdown situation: do not walk under suspended workpieces and Z-axes.

x J

1.4 xManual workstations

Operator Automatic movements at the manual workstationPerson is surprised by the automation, body parts are crushed and injuries result.

x x 20 3/d

It must be ensured that neither operating personnel nor third parties are injured during manual insertion and ejection of the workpieces.

Insertion or ejection axes may only be moved in jog

mode or with two-hand operation. The drive

configuration is such that at the maximum speed of the

drive motor only a slow axis speed is achieved. The

operating elements for insertion and ejection must be

configured so that the operator has a clear view onto

the movement and cannot be endangered. Areas where

body parts could be crushed are to be prevented with

design measures to the greatest possible extent.

Extra attention is required of the operator at manual workstations.Only perform movements if no other person is in the danger area and none of your own body parts are in the line of danger of the corresponding axis

x J

1.5 x Parts that are flung outOperator

Third parties

Parts clamped improperlyBreakage of rotating tools

Person is surprised by parts flying away and injured as a result x x 10 3/dIt must be ensured that neither operating personnel nor third parties are injured by parts that become loose and fly off.

Mechanical guards must be placed in the possible flight

path of parts that could fly off.

Safety devices are inspected using calculations and

trials.

In normal operation, all protective hoods must be closed, removable protective hoods must be screwed securely.Required behavior: Inspect the protective hoods before starting normal operation.

x J

1.6 x x x x x x x Electrical hazard

OperatorMaintenance

personnel

Technicians

Touching the machineDefective insulationImproper el. installationUnsuitable components

Person suffers an electric shock and is injured or killed as a result. x x 10 3/dIt must be ensured that neither operating personnel nor third parties are injured by direct or indirect electrical contact.

Only contact-protected components are to be used.Before working on electrical installations, always disconnect the system (plug/main switch) and double check.Work on electrical installations, switch cabinets and devices may only be performed by authorized specialists.Control cabinet fuses

Work on electrical installations requires expertise and extra care.

x J

1.7 x Disruption of the energy supply

OperatorMaintenance

personnel Power failure, lightning Person is surprised by unexpected movement and injured as a result. x x 10 3/dThe effects of a power failure must not be dangerous for the operator or for third parties.

The movement of the drives is mechanically limited in case the supply voltage fails (mechanical stops and holding brakes).The movement of the drives is braked if the supply

voltage fails

The operator and third parties are outside the danger

area.

After a crash, defective elements of the mechanical stops cannot necessarily be recognized immediately. The entire bumper unit must always be replaced.

x J

1.8 x Malfunction of the control system

OperatorMaintenance

personnel Failure of control unit components Person is surprised by unexpected movement and injured as a result. x x 10 3/dThe effects of a control system malfunction must not be dangerous for the operator or for third parties.

The areas of movement are to be encompassed by

mechanical safety fences and light curtains and light

grids so that it is not possible to enter this area from any

side.

Movements must transition to static states as quickly as

possible.

In normal operation, all protective hoods must be closed, removable protective hoods must be screwed securely.Required behavior: Inspect the protective hoods before starting normal operation.

x J

Hazard analysis / risk assessment

Safety goal

(negation of the event)

Pro

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Inte

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Nor

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Source of danger

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Risk assessment/safety goals/protective measures/residual risks1)

Solution suggested to the customer (cursive, Times New Roman)

Güdel solution (Arial)

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[Y/N

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Residual risks

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Protective measures

(existing protective measures)

Affe

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Triggering factor

Event

(Worst case)(Without protective measures)

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Customer:

Machine type: all modules without control system

Project no.:

Document no.:

Copyright © 2009 by GÜDEL AG Process owner: M. Knuchel Version 30 / Risikobeurteilung_en.xls Page1 / 3

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Safety goal


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Residual risks

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Protective measures


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Triggering factor

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Customer:


Project no.:

Document no.:

1.9 x x x x x Malfunction of protection measures

OperatorMaintenance

personnelAging, fatigue fracture, failure due to vibration or overloading

Person is surprised by unexpected situation and injured as a result. x x 10 3/d Averting an emerging hazard

The plant is equipped with emergency stop devices,

which trigger an emergency stop of the plant. A lock-out

(overview of the switch off locations) draws attention to

the switch-off devices.

Do not walk under suspended workpieces or Z-axes. Only possible in setup mode.Permanent workstations are not permitted in the direction of movement of the axes.

x J

1.1 x

Movement of the axes.Suspended loads(Z-axis and workpieces)

TechniciansRemoval of transport securing device without supporting suspended loads and axes.

Person is surprised by unexpected movement and injured as a result. x x 10 3/dIt must be ensured that suspended loads do not fall down.

Before removing the transport securing device, support

the suspended loads or axis.Do not walk under suspended loads. x J

1.11 x x x xMovement of the axes.Parts that are flung out

OperatorMaintenance

personnelCleaning

personnel

Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/dIt must be ensured that an expected start of moving parts is prevented.

A start-up of the plant without the permissive button

being pressed must be prevented.

With the permission device pressed, moving plant parts

can be moved in a controlled manner, even if the plant

is unsecured.

When the permissive button is pressed, it must not be

possible for the operator to be endangered by an

automatic movement triggered by a third party.

Do not walk under suspended workpieces and Z-axes.

In confirmation mode, the operator must pay great attention and have a high level of individual responsibility.

x J

1.12 x Movement of the axes. Setters Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/d

When the permissive button is pressed, it must not be possible for the operator to be endangered by an automatic movement triggered by a third party.

Axes can only be moved individually by one two-hand

operating device in jog mode. For multiple carriages on

one gantry, the individual carriages must be selected

using a key switch. The permissive button is a "shock

button".

For the permissive button to be activated, only one

safety door may be open and the others must be closed

and reset. Safety-relevant parts of the control are

inspected in appropriate time intervals by the machine

control system.

In confirmation mode, the operator must pay great attention and have a high level of individual responsibility. Only perform movements if no other person is in the danger area and none of your own body parts are in the line of danger of the corresponding axis.

x J

1.13 xSuspended loads.(Z-axes, telescopic axes, counter balance cylinders and workpieces)

Setters

Gripper problemsDefective motor brakeTorn belt (telescopic axis)Pressure drop (load balancing)General problems in the drive train

Person is surprised by unexpected situation and injured as a result. x x 10 3/d

It must be ensured that no persons can be endangered by Z-axes, telescopic axes and workpieces that fall down when the permissive button is not pressed.

Grippers must remain in the de-energized state in the

clamp position.

For very frequent set-up under Z-axes, Z-axes can be

secured redundantly with an additional brake on the

pinion and the motor brake.

Telescopic axes: and load balancing cylinders: Special

attention is required here. The axis (for a telescopic

axis, the 2nd stage) is to be secured with a mechanism.

Operation in setup mode only when the safety area is

closed off.

Do not walk under suspended workpieces or Z-axes. Take especial care with telescopic axes. Inspect belts before every setup procedure for cracks and tears.

x J

1.14 xSuspended loads.(Z-axes, telescopic axes, counter balance cylinders and workpieces)

Setters Inattention and/or careless operation by operator Person is surprised by unexpected situation and injured as a result. x x 10 3/dWorkpieces must not be dropped accidentally.

Grippers can only be operated in the storage position.

Do not walk under suspended workpieces or Z-axes. Take especial care with telescopic axes. Inspect belts before every setup procedure for cracks and tears.

x J

1.15 x Parts that are flung outSetters

Third parties

Gripper problemsDefective motor brakeTorn belt (telescopic axis)Pressure drop (load balancing)General problems in the drive train

Person is surprised by parts flying away and injured as a result x x 10 3/d No parts may be flung out.The axes can only be moved with reduced speed.

Rotating parts must be shut down securely.

Work in this mode requires a high level of individual responsibility from the operator. Only perform movements if no other person is in the danger area and none of your own body parts are in the line of danger of the corresponding axis.

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1.16 x x Disruption of the energy supply Setters Power failure, lightning Person is surprised by unexpected situation and injured as a result.The effects of a power failure must not be dangerous for the operator or for third parties.

The movement of the drives is limited by mechanical stops in case the supply voltage fails. The drives have already been switched off in case of a

power failure (safety shutdown situation). The

movement of the drives is braked in case of supply

voltage failure by the motor brake or holding brake in

the drive train.

After a crash, defective elements of the mechanical stops cannot necessarily be recognized immediately. The entire bumper unit must always be replaced.

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1.17 x Malfunction of the control system Setters Failure of control unit components Person is surprised by unexpected movement and injured as a result. x x 10 3/dThe risk of possible hazard must be kept as low as possible.

Only drive systems are used. They comply with the state

of the art and the standards referenced in the machine

directives.

Work in this mode requires a high level of individual responsibility from the operator. There is no way to completely ensure that a malfunction of the control system does not create a dangerous situation by moving the axes.The operator must therefore try to never be in the possible direction of travel of the axes and ensure that no third parties are in the possible danger zones.

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Project no.:

Document no.:

1.18 x x xMovement of the axes.Parts that are flung out

Service personnelCleaning personnel

Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/d Starting up the plant must be prevented.The lockable main plant switch breaks all main and

control circuits.

If motors or gearboxes are removed, vertical axes must always be secured or supported.

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1.19 x x x

Suspended loads(Z-axes, telescopic axes, counter balance cylinders and workpieces)

Service personnelCleaning personnel

Unexpected startDefective motor brakeTorn belt (telescopic axis)Pressure drop (load balancing)General problems in the drive trainDisassembly of the Z-axis motor

Person is surprised by unexpected situation and injured as a result. x x 10 3/d Z-axes falling down must be prevented.

Workpieces must be deposited beforehand in automatic

or setup mode.

Z-axes must be secured with the Z-axes device or with

the transport securing device.

Telescopic axes must be secured against falling down

with appropriate auxiliary means (cables, auxiliary

supports, etc.).

Avoid walking under suspended workpieces or Z-axes. Take especial care with telescopic axes. Inspect belts before every maintenance procedure for cracks and tears.Workpieces must be deposited beforehand in automatic or setup mode.Z-axes must be secured with the Z-axes device or with the transport securing device.Telescopic axes must be secured against falling down with appropriate auxiliary means (cables, auxiliary supports, etc.).

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1.20 x x Incorrect assembly All Incorrectly assembled plant Person is surprised by unexpected situation and injured as a result. x x 10 3/d Incorrect assembly must be prevented. The content of the operating manual is known.

Before a Güdel device is transported to the location of use, unpacked, assembled and commissioned, the operating manual must first be read and understood.

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1.21 x x Loss of stability All Inattention and/or careless operation Machine/plant tips over x x 10 3/dTipping over or falling down of equipment must be prevented.

Equipment without base supports:To connect to customer supports, the specified screw configuration according to the Güdel layout must be used with the corresponding screws.Equipment with base supports:The supplied screws for assembly must be used.For the connection of the supports to the floor, the anchoring suggestion according to the Güdel layout must be taken into consideration.Fall protection must be mounted for surface gantries.

Check the connections that are responsible for the stability of the device before starting the plant. The operating manual must be read and understood.

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1.22 xImproper disposal can cause environmental damage.

All Disposal regulations are not observed Environmental hazard x x 10 3/dThe device and its consumables must be disposed of accordingly after the end of its service life.

Statewide regulations regarding disposal of the plant must be observed.

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1) Protective measures (comments):

The suggested solutions printed in italics are binding suggestions for achieving CE conformity.We point out, however, that before commissioning of the plant, suitable protective measures must be implemented for all hazards to ensure CE-compliant use of the Güdel devices. According to the CE Machinery Directive 2006/42/EC, these suitable protective measures, including all modifications, must comply with the "state of the art" and ensure the necessary safety category. If not all protective measures are implemented for any reason, or if any protective measures supplied and/or installed by Güdel have been been modified or not installed, Güdel will not commission the plant and will not assume liability or provide a warranty relating to any resulting events.


OPERATING MANUAL TM

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Layout

Layout

OPERATING MANUAL TM

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Options

Options

OPERATING MANUAL TM

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Third-party products

Third-party products

OPERATING MANUAL TM

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Spare parts list

Spare parts list

operating manual tm size 40/52

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