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
18014398814262539_v2.0_EN-US
3

Revision history OPERATING MANUAL TMO 1-4 V2
18014398814262539_v2.0_EN-US
4

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
Table of contentsOPERATING MANUAL TMO 1-4 V2
18014398814262539_v2.0_EN-US
5

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
Table of contents OPERATING MANUAL TMO 1-4 V2
18014398814262539_v2.0_EN-US
6

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
Table of contentsOPERATING MANUAL TMO 1-4 V2
18014398814262539_v2.0_EN-US
7

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
Table of contents OPERATING MANUAL TMO 1-4 V2
18014398814262539_v2.0_EN-US
8

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
Table of contentsOPERATING MANUAL TMO 1-4 V2
18014398814262539_v2.0_EN-US
9

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
Table of contents OPERATING MANUAL TMO 1-4 V2
18014398814262539_v2.0_EN-US
10