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
	Use only the appropriate tools and fitting aids. Always carry out the operations in the specified sequence.
	Do not carry out “prestrung mounting” – do not slide carriages already mounted on the machine table onto guideways that are also already mounted.
	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
	Monorail guidance systems should only be transported and stored in their original packaging. Guideways longer than 1,5 m must be supported at a minimum of 3 points.
	Monorail guidance systems should only be removed from their original packaging once they are at the assembly area and immediately before mounting.
	Monorail guidance systems should not be mounted in the vicinity of machines or equipment that generate swarf or dust.
	Do not transmit electrical currents, for example during welding, through the monorail guidance systems.

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.

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.

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 basic greasing	pre­assembled as unit	guideway and carriage separate
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.

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.

Dismounting and mounting of carriages

Observe and if necessary note the mounting position of the carriages (locating face).

Dismounting of carriages

Locate the dummy guideway

on one end face of the guideway

and slide the carriage

carefully onto the dummy guideway 

, ➤ Figure.

Mounting of carriages

Locate the dummy guideway

with the carriage

on one end face of the guideway

, ➤ Figure.

Slide the carriage

carefully onto the guideway, taking care not to damage the seal lips.

Location of carriages

Series RUE and KUSE

Location of guideways

Tightening scheme

Tighten the fixing screws in accordance with the scheme, ➤ Figure:

• Tighten all the screws to 0,4×M_A.
• Tighten the screws marked in red to 0,7×M_A.
• Tighten the screws marked in black to 0,7×M_A.
• Tighten the screws marked in red to M_A.
• Tighten the screws marked in black to M_A.

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.

Screw mount the guideways in accordance with the tightening scheme, ➤ Figure. Leave the carriages located at the joint. Then check the joints again.

Fitting of closing plugs

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

  

  in the correct position in the counterbore.
• Place the press-in block

  

  vertically on the closing plugs.
• Knock in the closing plugs by means of concentric impacts.
• Remove the ring-shaped burr from the closing plugs

  

  .

Carry out final fitting of the closing plugs, ➤ Figure :

• Knock the closing plugs in flush with the surface of the guideway 

  

  by means of a second impact.
• 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”.

Fitting of brass closing plugs using fitting device

Insert the closing plugs in the counterbore, ➤ Figure :

• Insert the closing plug

  

  in the correct position in the counterbore.

Fit the fitting device, ➤ Figure :

• Place the fitting device MVH 

  

  on the guideway.
• Connect the fitting device to the hydraulic source

  

  and ensure that the bleed

  

  is activated.

Press in the closing plugs, ➤ Figure :

• Position the fitting device

  

  over the closing plug

  

  until the pawl

  

  contacts the next closing plug that has not yet been pressed in; for the last closing plug, carry out this alignment visually

  

  .
• Press in the closing plug using a maximum of 300 bar.

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.

Fitting of two-piece plastic closing plugs

Press in the closing plugs, ➤ Figure :

• Insert the plastic clinch rings

  

  in the holes.
• Press the closing plugs

  

  in flush using a press-in block

  

  .

Fitting of adhesive bonded covering strip

Place the covering strip in the slot, ➤ Figure:

• Unroll a portion of the covering strip

  

  and place with the adhesive film side face down in the slot

  

  – the covering strip should finish approx. 2 mm from the end of the guideway.

Stick down the covering strip, ➤ Figure:

• Peel off the protective film

  

  over a length of approx. 30 mm and fold it out at an angle to one side.
• Align the covering strip in the slot and stick it down by applying pressure – for example by means of a pressure roller

  

  . The strength of the bond will depend on the pressure used.
• Remove the protective film

  

  and finish fitting the covering strip.

The final adhesive force is achieved at room temperature after approx. 72 hours.

Fitting of clip fit covering strip

Cleaning and inspection, ➤ Figure :

• Check the covering strip 

  

  for damage.
• Clean the covering strip

  

  and guideway slot 

  

  using a lint-free cloth

  

  .

Insert and roll out the covering strip, ➤ Figure :

• Insert the covering strip 

  

  with the convex side upwards in the slot

  

  .
• Unroll the covering strip 

  

  by at least 200 mm. Leave the strip protruding by 10 mm to 20 mm. Bend the protruding length downwards by approx. 45° for fixing.
• Unroll the covering strip 

  

  completely and position it in the slot 

  

  .
• Secure the covering strip

  

  by means of retaining plates 

  

  .

Roll in the covering strip 

, ➤ Figure :

• Position the rolling-in device 

  

  tangentially with the chamfered side marked with an arrow first, avoiding tilting.
• Move the rolling-in device 

  

  with a uniform movement and without stopping along the covering strip 

  

  .
• Slide the retaining plates

  

  away.
• Slide the rolling-in device 

  

  a further two to four times along the covering strip 

  

  .

Secure the ends of the covering strip 

, ➤ Figure :

• Cut off the protruding ends of the covering strip

  

  using snips.
• Fit 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

Align the clamping element, ➤ Figure :

• Tighten the fixing screws

  

  in the clamping element finger tight. Use all the threaded holes.
• Place one dial gauge

  

  at each corner of one longitudinal side

  

  of the clamping element.
• Press the clamping element against one longitudinal side of the guideway (in the direction of the arrows) and set the dial gauges to “0”

  

  .

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 

  

  , observing the tightening torque.
• Connect the hydraulic connector

  

  to the clamping element.
• Increase the oil pressure slowly to the maximum operating pressure.
• Check the clamping element for seal integrity, reduce the oil pressure.

Fitting of damping carriage

Align the damping carriage, ➤ Figure :

• Insert the fixing screws

  

  in the damping carriage

  

  and tighten finger tight.
• Place one dial gauge

  

  at each corner of one longitudinal side of the damping carriage.
• Press one longitudinal side of the damping carriage against the guideway (in the direction of the arrow)

  

  and set the dial gauges to “0”

  

  .

Carry out final fitting of the damping carriage, ➤ Figure:

• Press the damping carriage

  

  against the opposing side of the guideway (in the direction of the arrow).
• Read off and record the measured values on both dial gauges

  

  .
• Calculate the mean value

  

  from the measured values.
• Set the damping carriage to half the mean value.
• Tighten the fixing screws 

  

  ; observe the tightening torque M_A.
• Make the lubrication connection and charge the system with oil.

Mounting example for a linear guidance system

Screw mount the datum side, ➤ Figure :

• Press the guideway on the datum side

  

  against the locating face (in the direction of the arrows) and screw mount; observe the tightening torque M_A.

Screw mount the adjustment side, ➤ Figure:

• Screw mount the guideway on the adjustment side

  

  finger tight.

Screw mount the table, ➤ Figure :

• Place the table

  

  gently on the carriages.
• Screw mount the carriages on the datum and adjustment sides to the table; observe the tightening torque M_A.

Screw mount the adjustment side, ➤ Figure:

• Align the guideway on the adjustment side

  

  with the table

  

  and screw mount; observe the tightening torque M_A.

Fit the closing plugs, ➤ Figure :

• Fit the closing plugs flush with the guideway surface 

  

  , 

  

  , see link.
• Clean the surface 

  

  (not in the case of plastic closing plugs).

Commissioning the guidance system

Oil lubrication

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 Q_min, 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

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.