GUDEL TMO Series User manual

OPERATING MANUAL
TMO 1-4 V2
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG TMO 1-4 V218014398814262539_V2.0_EN-US
B1M.1xxxxxxx-xxxx
10xxxxxxxx
991xxxxxxx
2018

© GÜDEL
Translation of the original instructions
This manual contains standard illustrations that may deviate from the original.
In the case of special models, options, or technical changes, the scope of deliv-
ery may differ from the descriptions here. Reprinting the instructions, in whole
or in part, requires our permission. Subject to change due to technical im-
provements.
18014398814262539_v2.0_EN-US

Revision history
Version Date Description
2.0 23.04.2018 Valid from product version TMO-1 V2.20;
TMO-2 V2.20; TMO-3 V2.20; TMO-4 V2.20
New:
• Downtimes ÜChapter7.3,251
• Initial lubrication Ü2123
• Feedback on the instructions
ÜChapter9.7,2233
• Maintenance tasks after downtimes <4
weeks ÜChapter9.3.4,2144
• Maintenance tasks after downtimes >4
weeks ÜChapter9.3.5,2145
• Intervention report
• Malfunctions / Troubleshooting
ÜChapter10.4,2259
Modified:
• New gearbox unit with elastomer cou-
pling
• Maintenance concept according to
MTBF_public_180103 Ü2140
Updated:
• General inspection Ü2149
• Setting the gear backlash Ü2251
• Service departments Ü2275
Removed:
• Planetary gear option
1.0 09.05.2017 Basic version
Table-1 Revision history
Revision historyOPERATING MANUAL TMO 1-4 V2
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Revision history OPERATING MANUAL TMO 1-4 V2
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Table of contents
1 Declaration of incorporation 17
2 General 19
2.1 Further applicable documentation................ .................19
2.2 Purpose of the document..................... ......................19
2.3 Explanation of symbols/abbreviations.............................. 20
3 Safety 21
3.1 General ...............................................................21
3.1.1 Product safety .........................................................21
3.1.2 Personnel qualifications..................................................21
3.1.2.1 Operating companies....................................................22
3.1.2.2 Transport specialists....................................................22
3.1.2.3 Fitters ................................ .................................23
3.1.2.4 Commissioning technicians ...................... .......................23
3.1.2.5 Operators .............................. ...............................23
3.1.2.6 Manufacturer's technicians.............................................. 24
3.1.2.7 Maintenance technicians.................................................24
3.1.2.8 Service technicians .......................... ...........................25
3.1.2.9 Disposal specialists.......................... ...........................25
3.1.3 Disregarding safety regulations.......................................... 25
3.1.4 Installation instructions..................................................26
3.2 Hazard symbols in the manual .....................................27
3.2.1 Hazard warnings .......................................................27
3.2.2 Explanation of warning symbol.......................................... 28
3.3 Hazard symbols on the product.................................... 29
3.3.1 Danger label "danger sign"...............................................29
3.3.2 Danger label "Tearing due to rack"...................................... 30
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3.4 Fundamentals of safety..............................................31
3.4.1 Separating protective equipment, monitoring equipment........ .........31
3.4.2 Product-specific hazards.................................................31
3.4.3 Material safety data sheets (MSDS)...................................... 33
4 Product description 35
4.1 Use ................................. ..................................35
4.1.1 Intended use............................. ..............................35
4.1.2 Non-intended use.......................................................35
4.2 Product designation........................ .........................36
4.2.1 Type plate .............................. ...............................36
4.2.2 Position of the type plate................................................36
4.3 Technical data........................... ............................37
4.4 Options .............................. ................................37
5 Design, function 39
5.1 Design................................................................ 39
5.1.1 TMO 1-4 ...............................................................39
5.1.2 Double roller support option..................... ......................40
5.1.3 Fastening types..........................................................41
5.2 Function .............................................................42
6 Transport 43
6.1 Packaging symbols....................................................44
6.2 Industrial trucks .......................... ...........................45
6.3 Slings................................ .................................45
6.3.1 Attaching the slings: Beam...............................................45
6.3.2 Attaching the slings: Güdel uprights.................. ...................47
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7 Commissioning 49
7.1 Introduction .........................................................49
7.1.1 Safety.................................................................. 49
7.1.2 Personnel qualifications..................................................50
7.2 Intermediate storage................................................50
7.3 Downtimes ............................ ..............................51
7.4 Setup, fastening .....................................................53
7.4.1 General................................................................ 53
7.4.2 Prerequisites............................................................53
7.4.3 Unpacking .............................................................54
7.4.4 Attaching the slings: Beam...............................................55
7.4.5 Attaching the slings: Güdel uprights.................. ...................57
7.4.6 Setup process.......................................................... 58
7.4.6.1 Special tools, testing and measuring instruments..........................59
7.4.6.2 Positioning the base plates.............................................. 60
7.4.6.3 Anchoring the base plates ...............................................61
7.4.6.4 Set up an upright........................... ............................63
7.4.6.5 Leveling uprights ........................... ............................65
Measuring height of upright.......................................... 65
Determining average upright height ..................................66
Correcting the upright height........................................ 66
7.4.6.6 Securing uprights against falling over .....................................67
7.4.6.7 Installing a beam: Standard.............................................. 67
7.4.6.8 Connecting the beams.................................................. 69
7.4.6.9 Straightening beams.....................................................70
Aligning upright and beam............................................ 72
7.4.6.10 Assembling the bumper unit.............................................73
Bumper unit with shearing sleeves.................................... 75
Bumper unit with pins............................................... 76
Bumper unit with limit stops.........................................77
7.4.7 Anchoring the product ........................ .........................78
7.4.7.1 Base mounting with adhesive anchor.....................................78
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7.4.7.2 Fixing base with welded joint ..................... ......................81
HST3............................................................... 82
HAS-TZ / HVU-TZ.................................................. 83
HIT-Z / HIT-HY-200-A.............................................. 85
7.5 Installing .............................................................87
7.5.1 Using the mounting aid: Installing the rack................................87
7.5.2 Installing the rack .......................................................88
7.5.3 Check rack transition....................................................90
7.5.4 Installing the guideway.................................................. 92
7.5.5 Installing the motor .....................................................93
7.5.5.1 Prerequisites............................................................93
7.5.5.2 Aligning the gearbox flange .............................................94
7.5.5.3 Aligning the input shaft to the gearbox flange............................ 96
7.5.5.4 Positioning the coupling on the motor shaft.............. ...............97
7.5.5.5 Installing the motor and coupling........................................101
7.5.6 Changing the lubricating position........................................104
7.5.7 Check leveling of the guide chute.......................................105
7.5.8 Connecting the side panels .............................................106
7.6 Assembling the energy chain ...................................... 107
7.6.1 Laying the cables and lines...................... .......................107
7.6.2 Installing the energy chain..............................................110
7.6.3 Installing the slide bars..................................................112
7.6.4 Relieving the cables and lines of strain.................................. 113
7.7 Connection .........................................................115
7.7.1 Attaching optional components........................................ 115
7.7.2 Installing the robot.................................................... 116
7.7.3 Attaching the load .....................................................116
7.7.4 Integrating the product................................................ 117
7.8 Transport securing devices ........................................ 117
7.8.1 Removing the transport securing device................................ 117
7.8.2 Installing transport securing device.................. ...................119
7.9 Initial lubrication ...................................................123
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7.9.1 Clean guideways and racks..............................................123
7.9.2 Pre-lubricate guideways and racks...................................... 125
7.9.3 Carrying out a lubrication check.......................................126
7.10 Functional check....................................................127
8 Operation 129
8.1 General .............................................................129
8.2 Personnel ...........................................................129
9 Maintenance 131
9.1 Introduction ........................... ............................ 131
9.1.1 Safety................................ .................................131
9.1.2 Personnel qualifications................................................ 133
9.2 Consumables and auxiliary agents................ ................ 133
9.2.1 Cleaning agents .......................................................133
9.2.1.1 Table of cleaning agents ...............................................133
9.2.2 Lubricants .............................................................134
9.2.2.1 Lubrication ...........................................................134
Manual lubrication..................................................135
Automatic lubrication system.......................................137
9.2.2.2 Lubricant table........................................................ 139
9.3 Maintenance tasks..................................................140
9.3.1 General prerequisites..................................................140
9.3.2 Maintenance intervals..................................................141
9.3.3 Special tools, testing and measuring instruments........................ 143
9.3.4 Maintenance tasks after downtimes <4 weeks.......................... 144
9.3.5 Maintenance tasks after downtimes >4 weeks.......................... 145
9.3.6 Maintenance tasks 100 hours after commissioning.......................146
9.3.6.1 Carrying out a lubrication check.......................................147
9.3.7 Maintenance tasks after 150 hours.................. ...................148
9.3.7.1 Lubricating guideways, racks and pinions ...............................148
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9.3.8 Maintenance tasks after 2,250 hours ...................................149
9.3.8.1 General inspection.....................................................149
9.3.8.2 Greasing the roller.....................................................153
9.3.8.3 Replacing the battery.................................................. 154
9.3.8.4 Replacing the cartridge.................................................154
9.3.8.5 Carrying out a lubrication check.......................................155
9.3.9 Maintenance tasks after 6,750 hours ...................................156
9.3.9.1 Replacing the lubricating pinion.........................................156
9.3.9.2 Replacing the wiper and lubricating element............................ 158
9.3.10 Maintenance tasks after 11,250 hours...................................160
9.3.10.1 Checking automatic lubrication system................ .................160
9.3.11 Maintenance tasks after 22,500 hours...................................161
9.3.11.1 Replacing the automatic lubrication pump...............................161
9.3.11.2 Replacing the energy chain..............................................161
Removing the energy chain .........................................161
Laying the cables and lines..........................................161
Installing the energy chain...........................................164
Final tasks..........................................................166
9.3.11.3 Replacing the slide bars................................................ 166
Replacing and pre-assembling the slide bars..........................166
Installing the slide bars..............................................166
9.3.11.4 Replacing the gearbox unit..............................................167
Attaching the slings: Motor .........................................168
Attaching the slings: Güdel gearbox unit.............................169
Removing the motor and coupling...................................170
Removing the gearbox unit .........................................172
Replacing the gearbox unit..........................................173
Installing the gearbox unit...........................................173
Installing the motor ................................................175
Final tasks..........................................................185
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9.3.11.5 Replacing the roller....................................................186
Roller holder installation types......................................186
Roller holder arrangement..........................................186
Replacing the roller ................................................188
TMO-C and TMO-E................................................189
TMO-W...........................................................195
9.3.11.6 Replacing the guideway................................................ 196
Disassembling the guideway.........................................196
Installing the guideway..............................................197
Final tasks..........................................................198
9.3.11.7 Replacing the rack.......................... ...........................198
Disassembling the rack .............................................198
Using the mounting aid: Installing the rack...........................199
Installing the rack ..................................................199
Check rack transition ..............................................202
Final tasks..........................................................203
9.3.11.8 Replacing switches, sensors............................................ 204
9.3.12 Setting the tooth flank backlash........................................ 204
9.3.12.1 Eccentric marking.......................... ...........................205
9.3.12.2 Blocking, unblocking the eccentric ring................ .................206
9.3.12.3 Eccentric .............................................................207
9.3.12.4 Check the tooth flank backlash .........................................208
Blocking the drive pinions...........................................208
Rack quality and module............................................209
Exact measuring method............................................209
Inexact measuring method..........................................211
9.4 Maintenance schedules...................... ...................... 213
9.4.1 Maintenance schedule .................................................215
9.4.2 Güdel gearbox unit maintenance schedule.............................. 217
9.4.3 Maintenance schedule for automatic lubrication system........ .........219
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9.5 Maintenance table..................................................221
9.6 Intervention protocol: Maintenance............... ............... 223
9.7 Feedback on the instructions...................................... 233
10 Repairs 234
10.1 Introduction ........................... ............................ 234
10.1.1 Safety................................ .................................234
10.1.2 Personnel qualifications................................................ 235
10.2 Repairs .............................................................. 235
10.2.1 General prerequisites..................................................235
10.2.2 Replacing lubricant .....................................................236
10.2.2.1 Attaching the slings: Motor.............................................236
10.2.2.2 Attaching the slings: Güdel gearbox unit................................237
10.2.2.3 Remove the motor.................................................... 238
10.2.2.4 Removing the gearbox unit.............................................240
10.2.2.5 Replacing lubricant .....................................................241
10.2.2.6 Installing the gearbox unit .............................................243
10.2.2.7 Installing the motor ...................................................244
10.2.2.8 Final tasks .............................................................245
10.2.3 Replacing the motor....................................................245
10.2.4 Replacing the motor flange and gearbox flange..........................247
10.2.5 Replacing pinion, bearing, and clamping set .............................249
10.2.6 Setting the gear backlash................................................251
10.2.7 Replacing the elastomer gear rim .......................................253
10.3 Tasks to perform after a crash ................. .................. 255
10.3.1 Replacing the bumper unit...................... .......................255
10.3.1.1 Bumper unit with shearing sleeves .....................................256
10.3.1.2 Bumper unit with pins........................ .........................257
10.3.1.3 Bumper unit with limit stops............................................258
10.3.2 Referencing the axes ...................................................258
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10.4 Malfunctions / Troubleshooting....................................259
10.5 Intervention report: Repairs................... ....................261
10.6 Other documentation..............................................263
10.7 Service departments....................... ........................263
11 Decommissioning, storage 264
11.1 Introduction ........................... ............................ 264
11.1.1 Personnel qualifications................................................ 264
11.2 Storage conditions .................................................264
11.3 Decommissioning......................... ......................... 265
11.3.1 Shutdown.............................. ...............................265
11.3.2 Cleaning, rust-proofing.................................................265
11.3.3 Transport securing devices .............................................265
11.3.4 Identification.......................................................... 266
11.4 Recommissioning......................... ..........................266
12 Disposal 269
12.1 Introduction ........................... ............................ 269
12.1.1 Safety................................ .................................269
12.1.2 Personnel qualifications................................................ 270
12.2 Disposal .............................................................270
12.3 Waste management compliant assemblies........... ............271
12.3.1 Disassembly ...........................................................271
12.3.2 Material groups .......................................................272
12.4 Disposal facilities, authorities......................................272
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13 Spare parts supply 273
13.1 Service departments....................... ........................275
13.2 Explanations regarding the spare parts list.......................281
13.2.1 Parts list...............................................................281
13.2.2 Position drawings .....................................................281
14 Torque tables 282
14.1 Tightening torques for screws................... ................... 282
14.1.1 Zinc plated screws ......................................................283
14.1.2 Black screws ............................................................284
14.1.3 Stainless steel screws ...................................................285
14.2 Tightening torques for roller holders .............................. 286
14.3 Tightening torques for HV sets .....................................287
14.4 Tightening torques for clamping sets .............................. 288
14.5 Thread rolling screws ....................... ........................289
Illustrations 291
List of tables 295
Index 299
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Appendix
Hazard analysis, Risk analysis
Addition to declaration of incorporation
Technical data
Layout
Spare parts lists
Options
Third-party documentation
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Table of contents OPERATING MANUAL TMO 1-4 V2
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1 Declaration of incorporation
The manufacturer: GÜDEL AG
Industrie Nord
CH-4900 Langenthal
hereby declares that the partly completed machine:
Product, type
Serial number
Parts list
Year of manufacture
corresponds to the fundamental requirements of the Machinery Directive
(2006/42/EC), Appendix 1.
The partly completed machine may only be commissioned after it has been
determined that the machine into which the partly completed machine is to
be incorporated complies with the stipulations of Machinery Directive
(2006/42/EC).
The special technical documentation as per Appendix VII Part B has been
compiled. This is submitted in electronic form, depending on the respective
regulations of the national bodies.
Authorized representative responsible for compiling the technical documenta-
tion:
Alain Knuchel Tel. [phone]
The partly completed machine complies with the following additional EC di-
rectives:
• Low Voltage Directive2014/35/EU
• EMC Directive2014/30/EU
The following harmonized standards have basically been applied:
EN ISO 12100:2010; EN ISO 13850:2015; EN 60204-1:2006; EN ISO
14119:2013; EN ISO 4413:2010; EN ISO 4414:2010; EN ISO 13849-1:2015
Langenthal,
Markus Ruprecht
CEO
Alain Knuchel
General Manager
Robotics
Declaration of conformity, declaration of incorporationOPERATING MANUAL TMO 1-4 V2
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TMO 1-4 V2
991xxxxxxx
10xxxxxxxx
2018
xx.xx.20xx

Declaration of conformity, declaration of incorporation OPERATING MANUAL TMO 1-4 V2
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2 General
Read the entire manual before working with the product. The manual con-
tains important information for your personal safety. The manual must be
read and understood by all persons who work on the product in any of the
product life phases.
2.1 Further applicable documentation
All documents delivered with this manual are further applicable documenta-
tion. They must be observed in addition to this operating manual for the safe
handling of the product.
2.2 Purpose of the document
This manual describes all the product life phases of the product:
• Transport
• Commissioning
• Operation
• Maintenance
• Repairs
• Disposal
The manual contains the information required for using the product as in-
tended. It is an essential component of the product.
The manual must be available at the product site throughout the entire ser-
vice life of the product. If the product is sold, the manual must be transferred
to the new owner.
Assembly instruc-
tions for partly
completed ma-
chinery
This document serves as the "Assembly instructions for partly completed ma-
chines" in accordance with the Machinery Directive 2006/42/EC, and is in this
respect an "Operating Manual".
GeneralOPERATING MANUAL TMO 1-4 V2
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2.3 Explanation of symbols/abbreviations
The following symbols and abbreviations are used in this manual:
Symbol / Abbrevia-
tion
Use Explanation
Ü
For cross-reference See
2
Possibly for cross-ref-
erence
Page
Fig. Designation of graphics Figure
Tab. Designation of tables Table
In the tip Information or tip
TMO In these instructions Overhead Trackmotion
product name
TMO-C In these instructions Overhead Trackmotion
ceiling mounting
TMO-W In these instructions Overhead Trackmotion
wall mounting
TMO-E In these instructions Overhead Trackmotion
elevated mounting
Table2-1 Explanation of symbols/abbreviations
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