Mounting guidelines
Guidelines for mounting of monorail guidance systems
The guidance systems can only achieve their function and maximum operating life if they are correctly mounted and maintained, see link.
Guidelines
General |
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Use only the appropriate tools and fitting aids. Always carry out the operations in the specified sequence. |
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Do not carry out “prestrung mounting” – do not |
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Hands should be kept clean and dry, wear cotton gloves if necessary. Perspiration can lead to corrosion on monorail guidance systems with a dry preservative. |
Transport, storage and fitting area |
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Monorail guidance systems should only be transported and stored in their original packaging. Guideways longer than 1,5 m must be supported |
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Monorail guidance systems should only be |
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Monorail guidance systems should not be |
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Do not transmit electrical currents, for example during welding, through the monorail guidance systems. |
ACHTUNG
Observe the specifications and regulations in accordance with the table.
The mounting guidelines are structured such that they can be used as a basis for creating individual mounting manuals as easily as possible.
Mounting manuals can be called up on the Internet http://www.schaeffler.de/std/1D51.
Mounting manuals available from Schaeffler in the field of monorail guidance systems:
- RUE: MON 30, MON 40, MON 41, MON 42
- KUSE: MON 22
- KUVE: MON 38, MON 45, MON 46
- accessories: MON 01, MON 07, MON 21, MON 65
- HLE: MON 50.
ACHTUNG
Risk of injury. In your handling or mounting manuals, please draw attention to the sharp edges caused by the design on guideways, holes and covering strips.
Risk of injury. Draw attention in your handling or mounting manuals to the normal hazards that are generally present in the mounting of machines and when working with lifting gear and tools.
Fixing screws for carriages and guideways
Monorail guidance systems must only be located using the specified screws.
It is vital to follow the information:
- in this catalogue
- in the technical proposal letter
- in the assembly drawing – if contained therein.
ACHTUNG
The screw specifications and tightening torques must be observed.
Any deviations will influence the performance of the screw connections as well as the function and operating life of the guidance systems.
Only fixing screws of the specified grades must be used.
If there is a possibility of settling, the fixing screws should be secured against rotation.
Ensure that the adjacent construction is of adequate strength.
The technical performance capability can only be achieved through the use of:
- all threaded fixing holes
- the specified screw grade
- the specified tightening torques for screws.
Delivered condition
Monorail guidance systems are supplied with a preservative, basic greasing or initial greasing, see table.
The preservative is compatible with oils and greases having a mineral oil base.
Delivered condition
Designation |
Delivered condition |
||||
---|---|---|---|---|---|
Lubrication |
Mounting |
||||
coated with preservative |
with initial greasing |
with |
preassembled as unit |
guideway |
|
RUE..-E |
● |
❍ |
‒ |
● |
❍ |
KUSE |
● |
❍ |
‒ |
● |
❍ |
KUVE..-B |
❍ |
❍ |
● |
● |
❍ |
KUVE25-B..-HS |
❍ |
● |
‒ |
● |
❍ |
KUVE..-W |
❍ |
❍ |
● |
● |
❍ |
KUVS |
❍ |
● |
‒ |
‒ |
● |
●
Standard.
❍
Optional.
Protection of wipers
The sharp-edged counterbores of the holes in the guideways are covered by an adhesive strip, ➤ Figure.
ACHTUNG
The adhesive strip protects the seal lips on the wipers of the carriages. The adhesive strip should not be removed until immediately before the guidance system is mounted.
The counterbores may cause injury.
Holes covered by adhesive strip


Marking of locating face and marked face
The locating face is always on the opposing side to the marked face. The locating face of the guideway and the locating face of the carriage are on the same side when supplied, ➤ Figure. If the locating faces shall not be on the same side, the position of the locating faces must be indicated when ordering. If the carriage is separated from the guideway for mounting, it must be ensured that the position of the locating faces corresponds to the initial situation, when joining the carriage and the guideway.
The locating heights and corner radii in the table must be observed, see the section for the specific series.
Position of locating face and marked face




Dismounting and mounting of carriages
Observe and if necessary note the mounting position of the carriages (locating face).
ACHTUNG
Only remove carriages from the guideway if necessary.
Dismounting of carriages
Locate the dummy guideway




ACHTUNG
Do not move carriages over the counterbores of fixing holes that have not been closed off. Ensure that the seal lips of the wipers are protected if carriages are moved.
Do not remove the dummy guideway from the carriage. Protect the rolling element set against contamination and damage.
Mounting of carriages
Locate the dummy guideway



Slide the carriage

Dismounting and mounting of carriages




Location of carriages
ACHTUNG
The tightening torques MA in the dimension tables are valid for screws coated with preservative. If there is a possibility of settling, the fixing screws should be secured against rotation.
Observe the tightening torques MA for the fixing screws.
If the carriages are not connected to a central lubrication system, grease the carriages using the initial grease quantity.
The guideways and carriages must be protected before and during mounting against solid and fluid contaminants.
Series RUE and KUSE
ACHTUNG
Before the carriages are screw mounted to the adjacent construction, check the seat of the O rings.
Location of guideways
ACHTUNG
The sharp-edged counterbores for the fixing screws may cause injury.
The tightening torques MA in the dimension tables are valid for screws coated with preservative.
Tightening scheme
Tighten the fixing screws in accordance with the scheme, ➤ Figure:
- Tighten all the screws to 0,4×MA .
- Tighten the screws marked in red to 0,7×MA .
- Tighten the screws marked in black to 0,7×MA .
- Tighten the screws marked in red to MA.
- Tighten the screws marked in black to MA.
Tightening scheme for guideways

Multi-piece guideways
The end faces of the guideways are abutted against each other and the carriages are moved over the joint – this gives almost ideal alignment of the guideways.
ACHTUNG
In the case of multi-piece guideways, the gap at the end faces between two segments must be < 0,05 mm.
Screw mount the guideways in accordance with the tightening scheme, ➤ Figure. Leave the carriages located at the joint. Then check the joints again.
ACHTUNG
The guideway segments are marked with numbers and letters, ➤ Figure.
During mounting, the numbers and letters of the ends at each joint must match.
Butt joints on multi-piece guideways




Fitting of closing plugs
ACHTUNG
The sharp-edged counterbores for the fixing screws may cause injury.
Before mounting, guideways must be located using the tightening torque MA.
Do not move carriages over the counterbores of fixing holes that have not been closed off. Ensure that the seal lips of the wipers are protected if carriages are moved.
Depending on the environment and operating conditions, the counterbores are closed off using plastic or brass closing plugs. A fitting device for brass closing plugs is available, see link.
Knock in the closing plugs, ➤ Figure:
- Insert the closing plugs
- Place the press-in block
- Knock in the closing plugs by means of concentric impacts.
- Remove the ring-shaped burr from the closing plugs
Knocking in of closing plugs




Carry out final fitting of the closing plugs, ➤ Figure :
- Knock the closing plugs in flush with the surface of the guideway
- Smooth off the top surface of brass closing plugs flat using an oilstone
- Clean the guideway using a lint-free clean cloth and check that the closing plugs are fitted flush by means of a “fingertip test”.
Final fitting of closing plugs



Fitting of brass closing plugs using fitting device
ACHTUNG
The sharp-edged counterbores for the fixing screws may cause injury.
Insert the closing plugs in the counterbore, ➤ Figure :
- Insert the closing plug
Inserting the closing plugs in the counterbore


Fit the fitting device, ➤ Figure :
- Place the fitting device MVH
- Connect the fitting device to the hydraulic source
Fitting the fitting device




Press in the closing plugs, ➤ Figure :
- Position the fitting device
- Press in the closing plug using a maximum of 300 bar.
Pressing in the closing plugs





Smooth off the closing plugs flat, ➤ Figure:
- Smooth off the top surface of brass closing plugs flat using an oilstone
- Then clean the guideway using a lint-free clean cloth.
Smoothing off the closing plugs flat


Fitting of two-piece plastic closing plugs
ACHTUNG
The sharp-edged counterbores for the fixing screws may cause injury.
Press in the closing plugs, ➤ Figure :
- Insert the plastic clinch rings
- Press the closing plugs
Pressing in the closing plugs




Do not work using an oilstone


Fitting of adhesive bonded covering strip
ACHTUNG
Risk of injury due to the sharp edges of the slot and on the covering strip.
Do not use the covering strip ADB if using the damping carriage RUDS.
Only fit the covering strip to guideways that have been located.
The surface for adhesive bonding – the slot in the guideway – must be clean, free of grease and dry.
Avoid damaging the seal lip on the carriage.
Place the covering strip in the slot, ➤ Figure:
- Unroll a portion of the covering strip
Placing the covering strip in the slot



Stick down the covering strip, ➤ Figure:
- Peel off the protective film
- Align the covering strip in the slot and stick it down by applying pressure – for example by means of a pressure roller
- Remove the protective film
The final adhesive force is achieved at room temperature after approx. 72 hours.
ACHTUNG
Check the storage life of the adhesive tape, see printed information on packaging.
Sticking down the covering strip



Fitting of clip fit covering strip
ACHTUNG
Risk of injury. The slot in the guideway and the ends of the covering strip have sharp edges.
Do not use the covering strip ADK if using the damping carriage RUDS.
Fit the covering strip only if it is free from creases and damage. Protect the covering strip and slot against contamination during fitting. Handle the covering strip with great care, avoiding alignment. Do not reuse the covering strip.
Cleaning and inspection, ➤ Figure :
- Check the covering strip
- Clean the covering strip
Inspecting and cleaning the covering strip and guideway slot




ACHTUNG
The covering strip may spring out of the slot if retaining plates are not used, so it must always be secured.
Insert and roll out the covering strip, ➤ Figure :
- Insert the covering strip
- Unroll the covering strip
- Unroll the covering strip
- Secure the covering strip
Placing the covering strip in the slot

ACHTUNG
The covering strip must be completely inserted in the slot before it is rolled in.
Always observe the travel direction of the rolling-in device. Do not tilt or reverse the rolling-in device.
Fit the covering strip without interruption.
Roll in the covering strip

- Position the rolling-in device
- Move the rolling-in device
- Slide the retaining plates
- Slide the rolling-in device
Rolling in the covering strip





Secure the ends of the covering strip

- Cut off the protruding ends of the covering strip
- Fit the retaining plate
Cutting off the protruding ends and mounting the retaining plate




Mounting and maintenance manual
Comprehensive information, see MON 65, Covering Strip ADK for Guideway TSX, TKSD, TKVD..
Mounting with a positioned carriage
If the covering strip is to be fitted when the carriage is already on the guideway, please contact us.
Fitting of clamping element
ACHTUNG
Fix the clamping element RUKS in place only after the guideways and carriages have been mounted.
Before fitting, close off the counterbores of the fixing holes in the guideways or fit the covering strips ADB or ADK.
Align the clamping element, ➤ Figure :
- Tighten the fixing screws
- Place one dial gauge
- Press the clamping element against one longitudinal side of the guideway (in the direction of the arrows) and set the dial gauges to “0”
Aligning the clamping element




ACHTUNG
Do not exceed the maximum oil pressure of 350 bar. Pay attention to pressure spikes.
Carry out final fitting of the clamping element, ➤ Figure:
- Press the clamping element onto the opposing longitudinal side of the guideway (in the direction of the arrow).
- Read off and record the measurement values on both dial gauges
- Calculate the mean value of the measurement values
- Set the RUKS to half the mean value.
- Tighten the fixing screws
- Connect the hydraulic connector
- Increase the oil pressure slowly to the maximum operating pressure.
- Check the clamping element for seal integrity, reduce the oil pressure.
Final fitting of the clamping element







Fitting of damping carriage
ACHTUNG
The damping carriage RUDS should only be fixed in place once the guideways and carriages have been mounted.
The counterbores of the fixing holes in the guideways must first be closed off. Only use brass closing plugs.
Keep the guideways free from oil.
Align the damping carriage, ➤ Figure :
- Insert the fixing screws
- Place one dial gauge
- Press one longitudinal side of the damping carriage against the guideway (in the direction of the arrow)
Aligning the damping carriage





Carry out final fitting of the damping carriage, ➤ Figure:
- Press the damping carriage
- Read off and record the measured values on both dial gauges
- Calculate the mean value
- Set the damping carriage to half the mean value.
- Tighten the fixing screws
- Make the lubrication connection and charge the system with oil.
Final fitting of the damping carriage







Mounting example for a linear guidance system
Screw mount the datum side, ➤ Figure :
- Press the guideway on the datum side
Screw mounting of the datum side



Screw mount the adjustment side, ➤ Figure:
- Screw mount the guideway on the adjustment side
Screw mounting of the adjustment side


Screw mount the table, ➤ Figure :
- Place the table
- Screw mount the carriages on the datum and adjustment sides to the table; observe the tightening torque MA.
Screw mounting of the table to the carriages


Screw mount the adjustment side, ➤ Figure:
- Align the guideway on the adjustment side
Screw mounting of the adjustment side



Fit the closing plugs, ➤ Figure :
- Fit the closing plugs flush with the guideway surface
- Clean the surface
Fitting of the closing plugs




Commissioning the guidance system
Oil lubrication
ACHTUNG
Ensure that the guideways show a visible oil film.
Supply the guidance system with oil:
- In order to ensure cleanliness and prevent corrosion, flush and fill all lubrication point supply pipes and lubrication holes immediately after connection.
- At the time of commissioning, monorail guidance systems should be oiled with the minimum oil quantity Qmin, moving the carriage four times the carriage length during this process.
Damping carriage
Connect the damping carriage RUDS to the unpressurised lubricant supply system.
Grease lubrication
ACHTUNG
Ensure that the guideways show a visible grease film.
Linear recirculating ball bearing and guideway assemblies KUVE..-B have a basic greasing.
Supply the guidance system with grease:
- Fill a clean grease gun or other lubrication device with fresh grease.
- Clean the lubrication connector and its immediate environment.
- Lightly grease the cleaned guideways.
- Fill the carriages with the initial grease quantity, moving the carriages four times their length during this process.
Influence of grease
During commissioning and relubrication, the coefficient of friction increases temporarily due to the fresh grease. After a short running-in period, however, the coefficient of friction returns to its original lower value.
The friction behaviour is determined significantly by the characteristics of the grease used. The consistency and base oil viscosity serve as approximate guide values.