Gudel Rail System

COMPONENTS MODULES ROBOTICS SYSTEMS
OPERATING MANUAL
TMF Size 1-4
Project/Order: 14-1898
Bill of materials: BUS033209
Year of manufacture: 2015
OPERATING MANUAL TMF
© by GÜDEL 2012
Translation of the original operating manual
This operating manual contains standard illustrations that may deviate from
the original. In the case of special models, options, or technical changes, the
scope of delivery may differ from the descriptions here. Any reproduction
of this operating manual, in whole or in part, requires our express permis-
sion. Subject to change in the course of technical improvements.
Version aUS
Author chrgal
GÜDEL AG
Industrie Nord
CH-4900 Langenthal
Switzerland
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phone +41 (0)62 916 91 91

fax +41 (0)62 916 91 50
e-mail info@ch.gudel.com
www.gudel.com
2
OPERATING MANUAL TMF
Version Date Specification / Description
a 21.05.2012 Basic version
Tab. 0-1 Revision history

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OPERATING MANUAL TMF Table of contents
Table of contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Further applicable documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Purpose of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Target readership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Explanation of symbols/abbreviations . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Torque tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5.1 Tightening torques for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5.2 Tightening torques for HV sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5.3 Tightening torques for roller holder . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5.4 Tightening torques for roller support . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Thread rolling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.2 Non-intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Product designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.2 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.3 Failure to comply with safety regulations . . . . . . . . . . . . . . . . . . . . . 21
3.1.4 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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3.2 Hazard symbols and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.2.1 Hazard symbols in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hazard warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Special symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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3.2.2 Hazard symbols on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3 Fundamentals of safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.2 Safety and monitoring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.3 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Danger from electric current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Danger from falling axles/workpieces . . . . . . . . . . . . . . . . . . . . . . 28
3.3.4 Safety data sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1.1 Standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1.2 Option FullCover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1.3 Planetary gear option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1.4 Double roller support option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3 Intermediate storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4 Positioning, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4.3 Positioning, fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Base fixing with adhesive anchor . . . . . . . . . . . . . . . . . . . . . . . . . 42
Base fixing with welded joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.4.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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5.4.5 Transport securing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.5 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5
6.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.2 Consumables and auxiliary agents for . . . . . . . . . . . . . . . . . . . . . . . . 61
7.2.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.2.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Markings at the lubrication points. . . . . . . . . . . . . . . . . . . . . . . . . 64
7.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.4 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.4.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.4.2 Maintenance tasks 100 hours after commissioning . . . . . . . . . . . . . 66
7.4.3 Maintenance tasks every 150 hours . . . . . . . . . . . . . . . . . . . . . . . . . 67
Lubricating guideways, racks and pinions . . . . . . . . . . . . . . . . . . . 67
7.4.4 Maintenance tasks every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . 68
General inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.4.5 Maintenance tasks every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . 70
Replacing the lubricating pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.4.6 Maintenance tasks every 10000 hours . . . . . . . . . . . . . . . . . . . . . . . 72
Oil change in type NA / NH / FA / FH / AE gearboxes . . . . . . . . 72
8 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.2 Special tools, testing and measuring instruments . . . . . . . . . . . . . . . 79
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8.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3.1 General prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3.2 Replacing the bumper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3.3 Replacing the wiper and felt insert . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.3.4 Replacing the rollers and guideways . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacing guideways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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8.3.5 Setting rollers and tooth flank backlash . . . . . . . . . . . . . . . . . . . . . . 90

8.3.6 Replacing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.3.7 Setting the gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8.3.8 Replacing motor and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.4 Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
8.5 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9 Decommissioning, storage . . . . . . . . . . . . . . . . . . . . . . . . . 107

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.1.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.2 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.3.1 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.3.2 Cleaning / rust-proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.3.3 Transport securing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.3.4 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.4 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.1.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10.3 Waste management compliant assemblies. . . . . . . . . . . . . . . . . . . . 113
10.3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10.3.2 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.4 Disposal facilities, authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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11 Spare part supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

11.1 Explanations regarding the spare parts list . . . . . . . . . . . . . . . . . . . 116
11.1.1 Positioning drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
11.1.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7
11.2 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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OPERATING MANUAL TMF General
1 General
1.1 Further applicable documentation

All documents in the appendix of this operating manual are further applicable
documentation. They must be observed in addition to this operating manual for
the safe handling of the product.
1.2 Purpose of the document

This operating manual describes all product life phases of the product TMF:
• 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 product
TMF.
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 instruc- This document serves as the "Assembly instructions for partly completed
tions for partly machinery" in acc. with the Machinery Directive 2006/42/EC, and is in this
completed respect an "Operating Manual".
machinery
NOTE
Read the entire operating manual before working with the prod-
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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.
9
1.3 Target readership

This operating manual is aimed at the following target readership:
• Construction
• Specialists
• Technicians
• Forwarding agents
• Operating companies
• Operating personnel
• Service personnel
1.4 Explanation of symbols/abbreviations

The following symbols and abbreviations are used in this operating manual:
Symbol /
Abbrevia- Use Explanation
tion
 For cross-reference Page

Fig. Description of drawings Figure
Tab. Description of tables Table
HPG In the instructions High Performance Gearbox
Tab. 1-1 Explanation of symbols/abbreviations

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10
1.5 Torque tables
1.5.1 Tightening torques for screws
NOTE
Screw connections on moving parts have to
be secured with Loctite medium strength 242. The adhesive has
to be applied onto the nut thread, not onto the screw!
If no other specifications have been made, the following tightening torques apply
for zinced plated screws lubricated with Molykote(MoS2) grease or secured
with Loctite 242:
Tightening torque [Nm]

Thread
size 8.8 10.9 12.9
M3 1.1 1.7 2.0

M4 2.6 3.9 4.5
M5 5.2 7.6 8.9
M6 9 13 15
M8 22 32 37
M10 42 62 72
M12 74 108 126
M14 117 172 201
M16 180 264 309
M20 363 517 605
M22 495 704 824
M24 625 890 1041
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M27 915 1304 1526

M30 1246 1775 2077
M36 2164 3082 3607
Tab. 1-2 Torque table for zinced plated screws lubricated with Molykote(MoS2) grease
11
If no other specifications have been made, the following tightening torques apply
for black oiled and unlubricated screws, or screws secured with Loctite 242:

Thread
size
8.8 10.9 12.9
M4 3 4.6 5.1
M5 5.9 8.6 10
M6 10.1 14.9 17.4
M8 24.6 36.1 42.2
M10 48 71 83
M12 84 123 144
M14 133 195 229
M16 206 302 354
M20 415 592 692
M22 567 804 945
M24 714 1017 1190
M27 1050 1496 1750
M30 1420 2033 2380
M36 2482 3535 4136
Tab. 1-3 Torque table for black oiled and unlubricated screws
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1.5.2 Tightening torques for HV sets
The following tightening torques apply to DIN6914/15/16-10.9 HV sets:

Thread
size Lubricated with
Slightly oiled
moly grease
M12 100 120

M16 250 350
M20 450 600
M22 650 900
M24 800 1100
M27 1250 1650
M30 1650 2200
M36 2800 3800
Tab. 1-4 Tightening torques: HV sets

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1.5.3 Tightening torques for roller holder

A B C
D000772
A1
A2
Fig. 1-1 Tightening torques for roller holders
A Move roller with hexagonal socket wrench (tightening torque A1)

B Roller holder
C Tighten screw with hexagonal socket wrench (tightening torque A2)
The following tightening torques apply to roller holders:

Size
A1 A2
40 1.5 4
52 2 4
62 3 15
72 4.5 15
90 7 15
Tab. 1-5 Tightening torques: Roller holders

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1.5.4 Tightening torques for roller support

A B C B
D000941
A1 A1
A2
A2
D D
Fig. 1-2 Tightening torques for roller supports
A Roller supports size 72 and 90

B Move roller with hexagonal socket wrench (tightening torque A1)
C Roller supports size 40 and 52
D Tighten nut and locknut with hexagonal key (tightening torque A2)
The following tightening torques apply to roller supports:

Size
A1 A2
40 1 87
52 2 120
72 3 220
90 5.5 450
Tab. 1-6 Tightening torques: Roller supports

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1.6 Thread rolling screws

Thread rolling screws are mainly used for guideways, mounting plates, as well
as for cable tray brackets.
1 2
!Nicht
.
.
Gewindeschneiden
No tapping
3 MA max 2
A
. M8 30Nm 1
.
. M10 60Nm
0181843
3
.
M12 100Nm
.
MA
Gewindefurchende
0181843
Schrauben
Thread grooving screw
E B B D
Fig. 1-3 Use of thread rolling screws
A Label
B Thread rolling screws
C Mounting plate
D Cable tray bracket
E Guideways
Thread rolling screws, recognizable with Güdel by a Torx drive, can be screwed
in directly in the core hole. It is not necessary to cut the thread in advance.
After the first use of a thread-cutting screw, a metric screw can also be
employed.
Drill holes without thread need to be furrowed. No thread may be cut in. This
can also be read on the label.
The following tightening torques apply to thread rolling screws when turned in
the first time:

Size
Steel S355J2 Aluminum
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M8x30 30 35
M10x45 63 71
M12x40 108 123
Tab. 1-7 Tightening torques for thread rolling screws
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OPERATING MANUAL TMF Product description
2 Product description
2.1 Purpose
2.1.1 Intended use
The TMF product is intended exclusively for moving and positioning of robots.
Other use or use that goes beyond the described purpose does not fall under
the intended use. The manufacturer assumes no liability for any resulting dam-
ages. All risks are carried solely by the user!
2.1.2 Non-intended use
The TMF 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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2.2 Product designation

Each product has a type plate. It contains the following information:
D001120
A B C D
Fig. 2-1 Type plate
A Product, type
B Project, sales order
C 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 type The type plate is attached in accordance with the following illustration:
plate
D001453
A
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Fig. 2-2 Position of the type plate
A Type plate
18
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’,  122:
• Dimensions
• Weight
• Strokes of the individual axes
• Gearbox type
• Gearbox ratios
• Motors
Temperature ranges The following temperature and air humidity ranges apply:
Transport -10 to +60°C

Operation +5 to +40°C Up to and with 85%, condensation formation not
permissible
Storage -10 to +40°C up to 75%
2.4 Options
The following options are available for the product TMF:
• Automatic lubrication system
• Planetary gear
• Double roller support
• FullCover
In general, in these operating instructions the complete covering option is called

FullCover.
Information on any available options can be found in the spare parts lists and
the layout in chapter 13 ’Appendix’,  122. You may also find relevant docu-
D003125
mentation in the same chapter under "Options".
19
OPERATING MANUAL TMF Safety
3 Safety
3.1 General
NOTE
Read 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.
3.1.1 Product safety
Residual danger The TMF 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 TMF
product and other property.
Operation Always adhere to the instructions in this manual when operating the TMF prod-
uct, and ensure that it is always in perfect working order.
3.1.2 Operating personnel
Persons who work with the TMF product must be technically qualified and
trained. They must be familiar with all hazards associated with using the TMF
product.
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20
3.1.3 Failure to comply with safety regulations
DANGER
Disregarding safety regulations
Disregarding the safety regulations can be very hazardous for personnel and
the surroundings!
Always comply with the safety regulations!
Liability Güdel shall not be held liable under any of the following circumstances:
• The installation regulations were disregarded
• Included protective equipment was not installed
• Included protective equipment was modified
3.1.4 Installation instructions
Protective measures The operator is responsible for ensuring safe conditions in the vicinity of the
product TMF, in particular, for complying with all general safety regulations,
guidelines and standards . This includes implementing all of the safety measures
before commissioning 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 protective measures must:

• Correspond to best practices
• Comply with the required safety category
Changes 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’,  17.
General rules for The generally accepted occupational safety rules have to be observed and fol-
occupational safety lowed.
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21
3.2 Hazard symbols and instructions
3.2.1 Hazard symbols in the manual
Hazard warnings
The hazard warnings are defined for the following four types of danger levels:
DANGER
DANGER
DANGER refers to hazards with a high risk of severe physical injury or im-
mediate fatality.
WARNING
WARNING
WARNING refers to hazards with a moderate risk of severe physical injury
or potential fatality.
CAUTION
CAUTION
CAUTION refers to hazards with a slight risk of moderate physical injury.
NOTE
NOTE
NOTE refers to a hazard that can lead to property damage.
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NOTE
NOTE refers to helpful information and tips for users.
22
Warning symbols
The hazard warnings for the levels DANGER, WARNING, and CAUTION
include the corresponding symbol for the hazard. Warnings of hazards that lead
to property damage always contain the symbol "Hazards due to common
causes".
Symbol Explanation of symbols
Hazards resulting from automatic startup of

the plant
Hazards due to dangerous electrical voltage
Hazards due to falling beams
Hazards due to toothed wheels
Hazards due to overpressure
Hand injury hazards
Hazards due to heavy components

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23
Hazards due to environmental pollution
Hazards due to suspended loads
Hazards due to electromagnetic fields
Danger of crushing
Danger of explosion
Hazards due to heat
Hazards due to sharp edges of the rack
Hazards due to tipping

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Hazards due to transmission functions
24
Hazards due to loose connecting elements
Hazards due to common causes
Tab. 3-1 Warning symbols
Special symbols
Helpful information and other tips
Tab. 3-2 Special symbols
3.2.2 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
D000095
0156538
DANGER! GEFAHR!
The vertical axis must
be secured from motion Vor dem Entfernen der
before removing the Transportsicherung
rack lock or other Z-Achse(n) gegen
locking device used for herunterfallen Sichern!
transportation!
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WARNING! ACHTUNG!
Remove all rack locks or
other locking devices Vor dem Bewegen der
used for transportation Achsen sämtliche
on all axes before Transportsicherungen
attempting to move any entfernen!
axis!
Fig. 3-1 Danger sign label
25
The "Transport information" label provides information on correctly attaching

transport equipment.
D001401
0156539
X
2X
X
Fig. 3-2 Transport information label

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26
3.3 Fundamentals of safety
3.3.1 Intended use
The intended use is described in chapter 2.1.1 ’Intended use’,  17.
3.3.2 Safety and monitoring equipment
NOTE
Never remove or modify any of the safety and monitoring equip-
ment! Be sure to close all of the protective equipment during op-
eration!
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.
3.3.3 Product-specific hazards
Danger from electric current
DANGER
Hazardous 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)
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• Ground the equipment

• Before switching on the product again, make sure that no one is located
in the danger area
27
Danger from falling axles/workpieces
WARNING
Falling 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
3.3.4 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 Internet
Example: 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.
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28
OPERATING MANUAL TMF Design and function
4 Design and function
4.1 Design
4.1.1 Standard configuration
In the standard configuration, the TMF product consists of the following assem-
blies:
A B C
D003145
G F E D
Fig. 4-1 Design

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A Energy chain
B Y-carriage
C Y-drive (gearbox)
D Lubricating pinion unit
E Roller support
F Y-axis
G Bumper unit
29
4.1.2 Option FullCover
The TMF product with the FullCover option consists of the following assem-
blies:
A B C D
D003145
Fig. 4-2 FullCover option design
A Complete covering
B Y-axis
C Y-drive (gearbox or planetary gear)
D Y-carriage
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30
4.1.3 Planetary gear option
The TMF product with the planetary gear option consists of the following
assemblies:
A B C
D003236
Fig. 4-3 Planetary gear option design
A Y-axis
B Y-carriage
C Y-drive (planetary gear)
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31
4.1.4 Double roller support option
The TMF product with the double roller support option consists of the follow-
ing assemblies:
A B C D
D003235
Fig. 4-4 Double roller support design
A Y-axis
B Y-carriage with double roller support
C Y-drive (gearbox)
D Double roller support
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32
4.2 Functional description

The TMF product can move along the following axes:
D001459
Fig. 4-5 Axis names

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33
OPERATING MANUAL TMF Commissioning
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’,  20. It concerns your personal safety!
WARNING
Suspended loads
Improper handling of suspended loads can lead to severe injuries or death!
• Use appropriate lifting units
• Wear appropriate protective clothing
• Always keep sufficient distance to suspended loads
• Never enter the area below a suspended load
5.1.2 Personnel qualification
Only appropriately trained and authorized personnel are allowed to commis-

sion the TMF product.
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34
5.2 Transport
The product is transported by air, land or water. The packaging depends on the
means of transport.
Truck = Shipped on a transport pallet

Aircraft = Shipped in a crate
Ship = Shipped in a case or container
NOTE
Improper 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.
Packaging symbols Consider the following symbols while transporting transport pallets / crates /
cases:
A B
D003601
D003600
CENTER OF SLING SLING

GRAVITY HERE HERE
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Fig. 5-1 Attaching the slings
A Center of gravity
B fixation point
35
Depending on the contents, the packaging units are marked with the symbols
shown below. Observe these at all times.
A B C D
D000099
D000100
D000101
D000098
HANDLE
FRAGILE CRAINT L'HUMIDITE WITH CARE
Fig. 5-2 Packaging symbols
A Fragile
B This side up
C Keep dry
D 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.
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36
5.3 Intermediate storage

If intermediate storage is required before installing the product, refer to the
storage conditions described in chapter Decommissioning, storage.
5.4 Positioning, assembly
5.4.1 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 installing the product or plant.
Make sure that appropriately dimensioned devices (crane etc.) are available.
5.4.2 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.
NOTE
The anti-rust oil protects the components. We recommend not
removing the oil.
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Dispose of the packaging in accordance with the local disposal regulations.

For more information on disposal, refer to chapter 10 ’Disposal’,  112.
37
DeliveryChecking Check the content of the delivery by comparing it with the accompanying
papers.
Check the product for damage. Report transport damage immediately.
5.4.3 Positioning, fastening
This chapter describes the steps for setting up and fastening the TMF product.
If no other specifications have been made, the tightening torques as per chapter
1.5.1 ’Tightening torques for screws’,  11 apply.
Before you position the product at the installation site, the requirements listed
in chapter 5.4.1 ’Prerequisites’,  37 have to be fulfilled.
WARNING
Heavy 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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38
Attaching slings This section describes the steps for attaching the slings.
D001467 B
2X
Fig. 5-3 Attaching the slings
A Transportation cradle
B Hook
C Lifting belts
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.

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39
Positioning the This section describes the steps for positioning and aligning the product.
product
D003150
25
A B
Fig. 5-4 Positioning the product
A Floor leveling screws

B Locknuts
Position the product as follows:
1 Set floor levelling screws to the specified mass

2 Position the product as shown in the layout
3 Align the product horizontally and vertically by means of floor leveling
screws (use guideways as reference)
Flatness along overall length of the axis:
up to 10 meters = 0.5 mm,
up to 30 meters = 0.7 mm, etc.
(max 0.1 mm tolerance for every 10 m extension)
4 Lock the floor leveling screws
The product has been completely positioned and aligned.

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40
Connecting the This section describes the steps for connecting and aligning the profiles.
profiles
A B C
D003152
F E D
Fig. 5-5 Connecting the profiles
A Cover plate
B Racks
C Profile C
D Screws
E Profile E
F Guideways
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41
Connect the profiles as follows:
1 Align profile E with profile C. Distance between: 5 mm

Alignment on the overall length of the axis:
2 Connect the profiles
2.1 Mount the guideway and rack as per Section ’Installing the guide-
way’,  46
2.2 Mount the cover plates
3 Realign the product horizontally and vertically, by means of the floor lev-
eling screws (use as reference guideways)
Flatness along overall length of the axis:
The profiles are connected and aligned.
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’,  122.
NOTE
Only anchor the product after it has been correctly positioned
and aligned!
Only use anchors approved by Güdel!
Base fixing with adhesive anchor

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This section describes the base fixing with adhesive anchor.
This fastening requires uncracked concrete with a quality of at least C20/25

(ENV 206) with ideal stiffness. Deviations can be found in the layout in the
appendix. The minimum concrete thickness, edge distance and maximum per-
missible tensile and compressive loads can be found in the table below.
42
D000106
A
D
h
d
r
Fig. 5-6 Anchored base fixing
A Floor levelling screw

B Upright/frame
C Anchor
D Adhesive capsule
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
Permissible tensile load [kN] 12.8 36.5 78 101.6
Permissible compressive load 34 60 80 135
[kN]
Tab. 5-1 Anchored base fixing

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Anchor the upright 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
43
5 Wait until the hardening period specified by the manufacturer has passed
6 Screw the upright tight
(For the tightening torque, refer to the table above.)
7 Remove the safety devices
The upright 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) with ideal stiffness. Deviations can be found in the layout in
the appendix. The minimum concrete thickness, edge distance and maximum
permissible tensile and compressive loads can be found in the table below.
NOTE
The welding work described below may only be performed by
certified personnel!
A
D000107
B
m
C
k n
D
E
b
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Fig. 5-7 Welded base fixing
A Screw
B Floor levelling screw
C Upright/frame
D Bottom plate
E Base plate
44
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] a4 a4 a5 a5
n (joint length) [mm] 140 190 190 330
Permissible tensile load [kN] 12.8 36.5 78 101.6
Permissible compressive load 34 60 80 135
[kN]
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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45
5.4.4 Assembly
Installing the Proper installation of the guideways in accordance with the regulations is pre-
guideway 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’,  79).
D001018
A B
Fig. 5-8 Mounting aid for rack assembly
A Rack
B Mounting aid
This section describes the steps for installing the guideway.
For axes over 20 meters, the assembly of the guideways must be performed
from the middle.
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46
A B A C D E
D003156
A H G F
Fig. 5-9 Installing the guideway
A Reference surfaces
B Screws
C Screw clamp
D Mounting aid
E Rack
F Torque wrench
G Screws
H Guideway
Install the guideway as follows:
1 Clean the reference surfaces and guideways thoroughly and rub an oil
stone across them
2 Lay first pair of guideways and racks on the reference surface. Lightly
tighten with outermost screws (all holes must be aligned)
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3 Mount next pair of guides and rack as in step 2

4 Clamp mounting aid to guides and racks with screw clamp
5 Install the rest of the screws and tighten with all the others
6 Inspect transition:
47
6.1 For guideways with gears, transition according to section ’Inspect-

ing rack transition’,  48
6.2 For guideways without gears
(gap dimension < 0.02 mm)
7 Use a suitable measuring instrument to check that the guideways are par-
allel
(tolerance: ±0.04 mm)
8 If deviations occur (transition/parallelism):
8.1 Remove screws and guideway
8.2 Repeat the procedure
The guideway has been installed.
Inspecting rack This section describes the inspection of the rack transition.
transition
The racks correspond to the qualities in the following table:
Rack quality
Standard configura-
Planetary gear option
tion
Q9 Q6
Tab. 5-3 Rack quality
Hardened racks can be recognized by the engraved Güdel logo.

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48
A B
D001060
E D C
Fig. 5-10 Inspect rack transition with micrometer
A Rack transition
B Measurement bolt
C Micrometer position C
D Micrometer position D
E Micrometer position E
Permissible deviation [mm]
Module Module Module

Rack quality
m≤3 3<m≤8 8 < m ≤ 12
Q4 h21 0.014 0.016 0.022
Q5 h22 0.022 0.027 0.034
Q6 h23 0.034 0.041 0.055
Q7 h25 0.082 0.110 0.137
Q8 h27 0.220 0.275 0.343
Q9 h27 0.220 0.275 0.343
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Tab. 5-4 Deviation method 1
49
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 via
micrometer
(Permissible deviation of position C and E to D, refer to table above)
The rack transition has been inspected.
Mounting motor and This section describes the steps for assembly of the coupling and the motor.
coupling
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’,  56).
WARNING
Danger of being crushed
Incorrect tightening torques can lead to suddenly moving axes or workpiec-
es. This can cause severe or fatal injuries!
• Calibrate and check the torque wrench periodically
• Tighten all screws with a torque wrench to the specified tightening tor-
ques
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50
D000111
X
A B C D E F G
Fig. 5-11 Installing the motor and coupling
A Gearbox
B Motor flange
C Measuring instrument
D Coupling
E Coupling screws
F Motor screws
G 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
For the tightening torque, refer to tab. 1-2,  11
5 Grease the gear rim of the coupling
(For grease types, see 7.2.2 ’Lubricants’,  61)
6 Push the motor, with the mounted coupling, onto the gearbox
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7 Tighten the motor screws
The motor and the coupling have been installed.
51
Attaching optional If equipped, attach the following optional components as per the separate doc-
components umentation:
• Automatic lubrication system

• Manual lifting and safety unit: vertical axis
• Safety brake system to vertical axle
• Rotary axis
• Telescope axis
• Pneumatic load balance
Attaching the load Attach the load (gripper, robot, etc.) to the TMF product. Set the roller and
tooth flank backlash again. This procedure is described in chapter 8.3.5 ’Setting
rollers and tooth flank backlash’,  90.
NOTE
Wear 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!
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52
Mounting the robot This section describes the steps for mounting the robot.
NOTE
When installing the robot, use sufficiently long screws. The
screws have to go at least 1xd into the plate.
D001499
C
d
D
1xd
Fig. 5-12 Mounting the robot
A Robot
B Screw
C Plate
D Carriage
Mount the robot as follows:
1 With a lifting unit, place the robot on the carriage and align it
2 Screw robot tight
(The screws have to go at least 1xd into the plate)
3 Remove the lifting unit
The robot has been mounted.
Integrating product Integrate the TMF 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.
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53
Cables and Lines This section provides information on the proper handling of cables and lines.
NOTE
Improper handling of cables
The improper handling of cables leads to cable damage, unnecessary
maintenance work and stopped operation.
Observe the instructions for use of cables and lines.
A B C D
D003044
H G F E
Fig. 5-13 Cables and lines
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A Strain relief version cable fitting

B Energy chain
C Strain relief version ChainFix
D Cable description
E Reel with dispenser
F Vertical divider
G Fixed side
H Driver
54
Observe the following when handling cables and lines:
• Use only highly flexible, energy chain capable lines! The line's minimum ben-
ding radius must be smaller than the smallest radius of the energy chain.
• Roll the cable off evenly, never take off in loops
• Layout cables without twisting for at least 24 hours before putting them into
energy chains! The cable description will aid you in doing so.
• Prepare vertical dividers:
• Cables are separated by vertical dividers, cables are not permitted to
be layed next to each other
• Piled up cables with variant sheath materials must be separated from
each other (danger of sticking)
• The vertical dividers are not allowed to be positioned in an offset man-
ner in the roll-off direction
• The cable must have play on all sides of the cable divider. At its mini-
mum, it should be 10% of the cable diameter. However, it should not
be less than one millimeter.
• Lay cables in, never pull them in!
• If the process paths of the energy chain are less than 50m:
• Relieve cable strain at the driver and the fixed side
• The distance between the end of bend movement and strain re-
lief is 10-30 times the diameter of the cable
• Strain relief version cable fitting:
Two pieces 4.5mm wide on the appropriate holders,
Do not damage the sheaths of the cables!
• Strain relief version ChainFix (IGUS energy chains):
Do not exceed a tightening torque of 1 Nm!
• Run cable straight at least 20cm after the strain relief on the fixed side
(length L)
• For process paths of the energy chain larger than 50m:
• Relieve cable strain at the drive
• The distance between the end of bend movement and strain re-
lief is 10-30 times the diameter of the cable
• Strain relief version cable fitting:
Two pieces 4.5mm wide on the appropriate holders,
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Do not damage the sheaths of the cables!

• Strain relief version ChainFix (IGUS energy chains):
Do not exceed a tightening torque of 1 Nm!
• Run cable straight at least 50cm after the strain relief on the fixed side
(length L)
55
• Pressure hoses from the hydraulic system and pneumatics have to be strain
relieved at the driver and at the fixed side. Except if they expand under pres-
sure (only fabric hoses).
• Before commissioning, label cables during strain relief so they can be read-
justed during maintenance work
5.4.5 Transport securing devices
At delivery, a transport securing device is in effect at the gearbox. This has to

be removed prior to assembling the motor.
WARNING
After removing the transport securing device or the motor, the carriage
may run off to the side. This can cause severe or fatal injuries!
Secure the carriage before removing the transport securing device or the
motor!
Transport securing This section describes the removal of the transport securing device at the gear-
device at the box.
gearbox
A
D000097
B
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Fig. 5-14 Transport securing device at the gearbox
A Screws
B Transport securing device
56
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.
5.5 Functional check
WARNING
Hazard due to tipping
Products that are incorrectly anchored can tip over. This can cause severe
or fatal injuries!
Ensure that the product is anchored tightly.
Prior to the functional check, make sure that:

• The installation regulations were observed.
• The product is anchored tightly.
• The safety equipment has been attached and is closed.
• No persons are present in the danger area.
The procedure for the functional check is described in the documentation of

the complete plant.
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57
OPERATING MANUAL TMF Operation
6 Operation
6.1 General
Operate the product only after the Installation instructions has been observed!
For information on how to operate the product TMF refer to the respective
chapters of the documentation of the complete plant.
6.2 Personnel
WARNING
Training of operating personnel
Wrong behavior of untrained or insufficiently trained operating personnel
can lead to severe personal or material damage.
Before the operating personnel begins working with the product:
• Train and instruct the operating personnel
• Point out dangers in the work area to the operating personnel
• Assess qualification of operating personnel before approving them
• Keep the operating personnel trained in best practices. Inform them also
about technical progress, changes, etc.
If these measures are not complied with, you alone as operating company
are liable for damages that may result!
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58
OPERATING MANUAL TMF 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’,  116.
Options and For information on maintenance of options and third-party products, read the
Third-party products appropriate documents in the appendix.
Lubrication This chapter describes the steps for manually lubricating the product. If your
product has an automatic lubrication system, manual lubrication of guideways,
racks and pinions is not necessary. However, perform lubrication work when
the first signs of tribocorrosion (reddish discoloration of the track) show.
Tightening torques If no other specifications have been made, the tightening torques as per chapter
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59
7.1.1 Safety
WARNING
Automatic 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!
• Secure vertical axles (if equipped) against falling
• Before switching on the plant again, make sure that no one is in the dan-
ger area.
WARNING
WARNING
Heavy components
injuries!
Use appropriate lifting units!
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Only appropriately trained and authorized personnel are allowed to work on

the TMF product.
60
7.2 Consumables and auxiliary agents for
7.2.1 Cleaning agents
For cleaning tasks, have a grease-dissolving cleaning agent (e.g. acetone) at hand.
7.2.2 Lubricants
NOTE
Unsuitable lubricants
Using unsuitable lubricants can lead to machine damage!
Only use the listed lubricants. If uncertain, please contact our service de-
partments!
For more information on the lubricants, refer to the tables below. For further
information, refer to the chapter "Maintenance tasks" and the respective third
party documentation.
Special lubricants If special lubricants have been delivered ex works at the request of the cus-
Güdel tomer, you can find the relevant specifications in the spare parts list.
Low temperatures / Observe the application range limits of lubricants according to the safety data
food grade sheet.
Alternative manufac- The following tables show the specifications of the lubricants.
turers Please inform your manufacturer accordingly. This will enable the manufacturer
to suggest an alternative from his product range to you.
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61
Oils
Manufac- Lubrication
Component Specifications
turer ex works
Automatic Güdel Güdel H1 cannot be found

lubrication system NSF No.146621
FlexxPump
Automatic Memolub Mobil CLP PD 460
lubrication system Glygoyle 460 in acc. with DIN
NSF No.136467 51502
Gear box unit Güdel
AE, HPG, NA, etc.
Manual lubrication: Güdel
• Guideway
• Rack
• Pinion
Planetary gearbox Güdel-Redex Klüber CLP HC 150
Klübersynth in acc. with DIN
EG4-150 51502
Planetary gearbox Wittenstein as per type plate -
Planetary gearbox Güdel Klüber CLP PD 220
Klübersynth in acc. with DIN
GH 6 -220 51502
Tab. 7-1 Oil types and specifications
Oil quantities For required oil quantities, please refer to the following table:
Manufac-
Component Type Quantity [cm3]
turer
Gearbox unit Güdel HPG / AE 030 40

Güdel HPG / AE 045 100
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Güdel HPG / AE 180 as per type plate
Tab. 7-2 Oil quantities
62
Greases
Manufac- Lubrication
Component Specifications
turer ex works
Automatic Memolub Castrol KP2N-30

lubrication system Longtime in acc. with DIN
PD2 51502
Automatic SKF-Vogel Shell GP00G-20
lubrication system Gadus in acc. with DIN
S2 V220 00 51502
Manual lubrication: Güdel Mobil KP2K-30
• Guideway Mobilux in acc. with DIN
• Rack EP 2 51502
• Pinion
Gear teeth Güdel Motorex KPF2K-20
gearbox coupling Grease in acc. with DIN
218 M 51502 MoS2 con-
Clamping set of Güdel
tent minimum 3%
the gearbox unit
Bearing of the INA ARAL KP2N-20
roller Arcanol in acc. with DIN
LOAD 150 51825
high quality lith-
ium soap grease
Precision drive Nabtesco / Virogrease RE 0 GHCF0K-40
Teijin in acc. with DIN
51825
semi-synthetic
Tab. 7-3 Grease types and specifications

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63
Markings at the lubrication points
The markings apply to manual lubrication of the following Güdel components:

• Roller support
• Lubricating pinion unit
• Wiper and lubrication unit
D000314
Fig. 7-1 Markings at the lubrication points
A Identification disc
B Grease nipple
Yellow identification disc Grease

Red identification disc Oil
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64
7.3 Maintenance schedule

10000 h
2000 h
500 h
150 h
D003249
150 h
500 h
2000 h
10000 h
Fig. 7-2 Maintenance schedule

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Grease Replace Oil change
Oil Cleaning Visual inspection
65
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’,  116)
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’,  68
• 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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66
7.4.3 Maintenance tasks every 150 hours
For more information on the lubricants, refer to chapter 7.2 ’Consumables and
auxiliary agents for’,  61.
Lubricating guideways, racks and pinions
Lubricate all guideways, racks and pinions every 150 hours.
NOTE
Incompatible 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!
Number of shots with the grease

Product size Roller size
gun (1 shot = 1.5 cm3)
TMF-1 40 5-6
TMF-2 52 5-6
TMF-3 72 8-10
TMF-4 90 8-10
Tab. 7-4 Number of shots with the grease gun
Lubricate the guideways, racks and pinions as follows:
1 Switch off the system 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
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(Number of shots according to table above)
The guideways, racks and pinions are lubricated.
67
General inspection
During the general inspection, the entire product is subjected to an overall

check.
Performing a general Perform the general inspection as follows:

inspection
1 Switch off the plant and padlock it to secure it against being switched on
again
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 table
Inspection cri- Specification /
Measures
terion Description
Dirt Check the components Immediately clean away any

for dirt: dirt
• Wipers
• Rollers
• Guideways
Damage Check the plant for dam- Immediately remedy all dis-
age: covered damage
• Paint damage
• Bent attachments (e.g.
cover plates)
• Cracks in the cast
parts
• Cracks at welding
seams
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Loose compo- Check the seating of the • Immediately tighten

nents components: loose screws to the re-
• Screws quired torque
• Nuts • Align and fasten loose
• Attachments attachments
68
Inspection cri- Specification /

Measures
terion Description
Loss of oil Check the plant and its • Replace defective and
surroundings for signs of pinched lines
the following: • Repair or replace the
• Puddles of oil and oil gearbox
spills on the floor or in • Remove puddles of oil
the drip sheets and oil spills on the floor
• Leaks, torn or pinched or in the drip sheets
lines
• Leakage at the gearbox
Components Check the condition of Replace worn components
the components:
• Carriage
• Rollers
• Guideways
• Racks
• Cog belt
Backlash Check for correct Correct the backlash
amount of backlash in the
components:
• Pinions
• Rollers
Tension Correct cog belts for cor- Correct the tension
rect tension
Energy chain and Check the energy chain: • Look for cause
cable • Mobility • Replace defective or
• Wear worn energy chains
• Damage • Correct the position of
• Position of the cables cables and lines
and lines • Replace worn or defec-
• Condition of the cables tive cables
and lines • Correct the tightening
• Tightening torques, torque
strain relief
(e.g. 1Nm at IGUS
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Chainfix)
Tab. 7-5 Inspection table
69
Replacing the lubricating pinion
A pinion soaked in lubrication runs along next to the drive pinion. It ensures a
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.
D003232
E D C
Fig. 7-3 Replacing the lubricating pinion
A Lubrication point
B Holder of the axle to the lubricating pinion
C Axle to the lubricating pinion
D Lubricating pinion
E Gasket
Replace the lubricating pinion as follows:
on again
2 If there is an automatic lubrication, disconnect the supply
3 Remove the entire lubricating pinion unit
4 Replace the lubricating pinion:
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For oil lubrication, submerge the new lubricating pinion in oil for several
minutes
(Oil quality, see chapter 7.2 ’Consumables and auxiliary agents for’,  61)
5 If necessary, replace the gasket
6 To install the entire lubricating pinion unit, reverse the removal steps
70
7 Lubricate the lubricating pinion at the lubrication point

7.1 For manual lubrication:
Lubricate the lubricating pinion according to the chapter "Lubricat-
ing the rack and pinion"
7.2 For automatic lubrication:
Connect supply line, start lubrication procedure
(See separate operating manual on automatic lubrication)
The lubricating pinion has been replaced.
This section describes the steps for greasing the roller.

D000722
Fig. 7-4 Greasing the roller
A Grease nipple
B Covering
Product Relubrication
Roller size
size quantity [g]
TMF-1 40 1.1
TMF-2 52 2.4
TMF-3 72 7.3
TMF-4 90 7.3
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Tab. 7-6 Roller relubrication quantity
71
Grease the roller as follows:
on again
2 Remove the covering
3 Use a grease gun to press in the grease
(Relubrication quantity according to table above)
The roller has been greased.
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 for’,  61.
Perform the oil change as follows:
Disassembling a This section describes the steps for disassembling the drive.
drive with pinion
WARNING
motor!
NOTE
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Do not change the position of the coupling on the motor shaft!
72
A B C D
D003229
F E
Fig. 7-5 Disassembling the drive
A Gearbox screws
B Gearbox
C Motor screws
D Motor
E Eccentric ring
F Headless set screw
Disassemble the drive as follows:

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on again
2 Secure carriage or axle with transport securing device or lifting device
3 Remove coverings if necessary
4 Remove lubricating pinion if necessary
73
5 Mark eccentric position

6 Remove the motor, together with the coupling
7 Remove headless set screw
8 Remove the gearbox
The drive has been disassembled.
Changing the This section describes the steps for changing the gearbox oil.
gearbox oil
WARNING
Hot gearbox oil
Working on the gearbox carries the risk of severe injury due to burns!
Let the gearbox cool before commencing any work.
CAUTION
Oils/greases
Oils and greases are harmful to the environment!
The oils and greases must 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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74
A B
D000270
Fig. 7-6 Oil change
A Bleed screw
B Filler screw
C Drain screw
Change the gearbox oil as follows:
1 Position the gearbox: Drain screw at the bottom

Filler and bleed screw at the top
2 Position a suitable container below the drain screw
3 Remove the bleed, filler and drain screws
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
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(for oil types and quantity, see the Oils chapter)

9 Screw in the bleed and filler screws
The gearbox oil has been changed.
75
Tighten the gearbox This section describes the steps for tightening the gearbox screws.
screws
NOTE
Observe the tightening torques.
You will otherwise destroy the cast casing!
NOTE
Observe, without exception, the agreed installation position for
the size 180!
D003689
Fig. 7-7 Mounting the gearbox unit
Size 030 045 060 090 120 180
Thread size M6 M8 M10 M12 M16 M20

Tightening torque [Nm] 9 22 42 50 120 240
Tab. 7-7 Tightening torques for gearbox screws

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76
Installing the drive This section describes the steps for installing the drive.
NOTE
Calibrate the measurement reference plane after each drive as-
sembly.
This procedure is described in the documentation of the com-
plete system or of the motor!
Install the drive as follows:
1 To install the drive, reverse the disassembly steps as described in section

’Disassembling a drive with pinion’,  72 and “Tighten the gearbox
screws”
2 Set the tooth flank backlash according to chapter 8.3.5,  90
3 Calibrate the reference plane of the motor (this procedure is described
in the documentation of the complete system or of the motor)
The drive has been installed.
The oil change has been completed

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77
OPERATING MANUAL TMF Repairs
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’,  116.
Tightening torques If no other specifications have been made, the tightening torques as per chapter
8.1.1 Safety
WARNING
Automatic 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!
• Secure vertical axles (if equipped) against falling
• Before switching on the plant again, make sure that no one is in the dan-
ger area.
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78
WARNING
WARNING
Heavy components
injuries!
Use appropriate lifting units!

the TMF product.
8.2 Special tools, testing and measuring instruments

For repairs, make sure that you have the following special tools, testing and
measuring instruments at hand:
Tool Use Item number
Pin-type face spanner Setting the tooth flank 999 758

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backlash (TMF 1)
Dial gauge Setting the tooth flank
backlash
79
Tool Use Item number
Micrometer Checking parallelism at

the guideways
Inspecting the rack
transition
Screw clamps Assembly of the racks
Mounting aid Assembly of rack mod- 902282
ule 2.5
helical
Assembly of rack mod- 902283
ule 3
helical
Assembly of rack mod- 902284
ule 4
helical
Fastening device Blocking the drive pin- 0917452
ion AE030
Blocking the drive pin- 0917453
ion AE045
ion AE060
ion AE090
ion AE120
ion AE180
Adjusting tool Adjusting the rollers 0919690
Size 40/52
Adjusting the rollers 0915289
Size 72/90
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Tab. 8-1 Special tools, testing and measuring instruments
80
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’,  116)
8.3.2 Replacing the bumper unit
The bumper unit is a safety component.

Replace the entire bumper unit after a crash has occurred.
WARNING
Weak 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!
The buffer unit consists of the following components:
• Bumper
• Bumper block or bumper bracket
• Screws
• Sleeves and/or heavy-duty spring tension pins
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81
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’,  83
• ’Preparing the felt insert’,  84
This section describes the steps for replacing the wiper and the lubricating ele-
ment.
D000349
A B C
Fig. 8-1 Wiper and lubricating element
A Wiper
B Screws
C Lubricating element
Replace the wiper and lubricating element as follows:
again
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2 If there is an automatic lubrication, disconnect the supply

3 Remove the screws
4 Replace the wiper
5 Replacing the lubricating element
82
6 Only for oil lubrication:

Submerge the new lubricating element in the oil for several minutes
(Oil quality, see chapter 7.2 ’Consumables and auxiliary agents for’,  61)
7 To install the wiper and lubricating element, reverse the removal steps
8 Only for manual lubrication: Lubricating guideways
(see chapter ’Lubricating guideways, racks and pinions’,  67)
9 Only for automatic lubrication:
9.1 Connect lubrication line
9.2 Start lubrication procedure
The wiper and lubricating element 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.
D001053
..12 8...
10. 10
B
2.5...3
Fig. 8-2 Preparing the wiper
A Wiper
B Recess
Prepare the wiper as follows:
1 Attach recess
(Mass according to figure)
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The wiper has been prepared.
83
Preparing the felt This section describes the steps for preparing the felt insert. This applies for oil
insert lubrication, operating temperature under 0 °C or grease lubrication.
5
D001035
S+1 B
Fig. 8-3 Preparing the felt insert
A Reduction
B 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.
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.
Roller holder instal- The roller holders have installation types for setting the roller backlash and
lation types tooth flank backlash.
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84
D000759
+ +
- -
A B C
Fig. 8-4 Roller holder installation types
A Installation type (E1): Eccentric zero position, fixed with positioning screw
B Installation type (E2): Eccentric infinitely adjustable, fixed with flange
C Installation type (E3): Eccentric adjustable in increments, fixed with positioning screw
Roller holder The roller holders are to be arranged according to the following figure:
arrangement
A B C
D003190
H G D F E D
Fig. 8-5 Roller holder arrangement
A Roller holder E2 unloaded

B Roller holder E1 loaded
C Roller support
D E1 roller holder
E Gearbox side
F Direction of load
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G E2 roller holder
H Fastening screws and flange
FullCover option:
For this option the roller supports are installed rotated by 90°.
Roller holder (A) corresponds thus to the installation type E1 loaded and Roller
holder (B) to installation type E2.
85
Double roller support option:

The double roller support has two loaded (B) and two unloaded (A) roller hold-
ers.
This chapter describes the steps for replacing the roller.
A B C D E F
D000753
Fig. 8-6 Replacing the roller
A Screw
B Peg
C Supporting roller
D Roller holder
E Covering
F Positioning screw
G Flange
H Fastening screws
Replace the roller as follows:
on again
2
D003125
Secure vertical axis, if equipped

3 Support the carriage or secure it to a lifting device
4 Remove fastening screws and flange
5 If there is a positioning screw, remove it
6 Remove the covering
86
7 Remove the entire roller holder

7.1 Remove screw and peg
7.2 Replace the roller
7.3 To assemble the roller holder, reverse the disassembly steps
(Secure screw with Loctite 242, tightening torque according to
tab. 1-5,  14)
8 Install E1 roller holder:
(Type and arrangement of installation, see chapter ’Roller holder instal-
lation types’,  84)
8.1 Fix roller holder in eccentric zero position with positioning screw
8.2 Mount flange
8.3 Tighten fastening screws
9 Install E2 roller holder:
9.1 Turn roller holder to eccentric minimum setting
9.2 Mount flange
9.3 Move fastening screws slightly
10 If it is present, turn E3 roller holder to eccentric minimum setting
11 Remove the securing element, support or lifting device
12 Set roller and tooth flank backlash as per chapter 8.3.5,  90
The roller has been replaced.
Replacing guideways
Replace the guideways as soon as the surfaces show signs of wear.
The term "guideway" includes:
• Guideway
• Rack
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Replace the guideways as follows:
Guideway The designations refer to fig. 8-8,  89.

disassembly
Remove the guideway as follows:
87
on again
2 Attach the carriage or axle to a lifting device
3 Expose guideway:
3.1 Remove coverings if necessary
3.2 Move the carriage off the guideway or axle to be replaced if neces-
sary
3.3 Extend the vertical axis, if required
4 Remove all screws
(See fig. 8-8,  89)
5 Remove the guideways
The guideway has been removed.
Installing the Proper installation of the guideways in accordance with the regulations is pre-
guideway 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’,  79).
D001018
A B
Fig. 8-7 Mounting aid for rack assembly
A Rack
D003125
B Mounting aid
This section describes the steps for installing the guideway.
For axes over 20 meters, the assembly of the guideways must be performed
from the middle.
88
A B A C D E
D003156
A H G F
Fig. 8-8 Installing the guideway
A Reference surfaces
B Screws
C Screw clamp
D Mounting aid
E Rack
F Torque wrench
G Screws
H Guideway
Install the guideway as follows:
1 Clean the reference surfaces and guideways thoroughly and rub an oil
stone across them
2 Lay first pair of guideways and racks on the reference surface. Lightly
tighten with outermost screws (all holes must be aligned)
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3 Mount next pair of guides and rack as in step 2

4 Clamp mounting aid to guides and racks with screw clamp
5 Install the rest of the screws and tighten with all the others
6 Inspect transition:
89
6.1 For guideways with gears, transition according to section ’Inspect-

ing rack transition’,  48
6.2 For guideways without gears
(gap dimension < 0.02 mm)
7 Use a suitable measuring instrument to check that the guideways are par-
allel
(tolerance: ±0.04 mm)
8 If deviations occur (transition/parallelism):
8.1 Remove screws and guideway
8.2 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 Retract the vertical 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.
8.3.5 Setting rollers and tooth flank backlash
Reset the roller and tooth flank backlash after each roller, guideway or gearbox
change.
D003125
NOTE
Always set the roller backlash and tooth flank backlash with load
attached and at operating temperature!
90
Blocking the drive This section describes the steps for blocking the drive pinion.
pinion Block the drive pinion in order to check the tooth flank backlash.
Unblock the drive pinion after repair work has been finished. For this purpose,
remove the fastening device and place the plug back onto the gearbox.
D002894
Fig. 8-9 Blocking the drive pinion
A Motor
B Carriage
C Gearbox
D Fastening device
E Plug
Block the drive pinion as follows:
again
2 Remove the plug
3 Attach fastening device to gearbox
The drive pinion is blocked.

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91
Setting rollers This section describes the steps for setting the roller
The designations refer to section "Roller holder arrangement".
Adjust the rollers as follows:
1 You may need to make the following preparations:

1.1 Slightly loosen the fastening screws of all E2 roller holders
1.2 Loosen flanges of the E2 roller holders
1.3 Remove coverings if necessary
2 Move the E2 roller holders closer by rotating them clockwise uniformly
(For the tightening torque, refer to tab. 1-5,  14)
3 Fixate the position with the flange and the securing screws
4 If there are deviations:
4.1 Check zero position of E1 roller holder
4.2 Repeat process from step 2
5 Move the unloaded E2 roller holders closer by rotating them clockwise
uniformly
(For the tightening torque, refer to tab. 1-5,  14)
6 Fixate the position with the flange and the securing screws
7 Install coverings if necessary
The rollers have been set.

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92
Setting the tooth This section describes the steps for setting the tooth flank backlash.
flank backlash
Inspect the tooth flank backlash according to the section "Checking the tooth
flank backlash". Only adjust if a deviation is detected.
A B C D
D003209
G F E
Fig. 8-10 Setting the tooth flank backlash
A Gearbox
B Screw
C Marking bore
D Headless set screw
E Rack
F Eccentric ring
G Drive pinions
Set the tooth flank backlash as follows:

3 Loosen headless set screw
D003125
4 Slightly loosen the gearbox screws

5 Turn eccentric ring with bolt remover or pin-type face wrench
(Marking bore near the rack = minimum play; marking bore far away =
maximum play)
6 Tighten the gearbox screws
93
7 Inspect tooth flank backlash according to section "Checking the tooth

flank backlash"
8 If there are deviations:
8.1 Slightly loosen the gearbox screws
8.2 Backlash too large: Turn marking bore closer to the rack
8.3 Backlash too small: Turn marking bore away from the rack
8.4 Repeat process from step 6
The tooth flank backlash has been set.

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94
Checking the tooth This section describes the inspection of the tooth flank backlash.
flank backlash
If the axis is not driven with Güdel gearbox type NA / NH / FA / FH / AE / HPG,
then use the procedure described in the operating manual of the gearbox!
NOTE
The inexact measurement method described here can lead to in-
correct interpretation and subsequent damage of any kind!
Only use it when the exact method is not possible!
A B C D
D003176
G F E
Fig. 8-11 Checking the tooth flank backlash
D003125
A Carriage
B Axis
C Guideway
D Rack
E Gearbox
F Drive pinions
G Dial gauge
95
Rack quality and module can be found in tab. 5-3,  48.
Tooth flank backlash [mm]
Module Module Module

Rack quality
m≤3 3<m≤8 8 < m ≤ 12
Q4 h21 0.010 0.012 0.016

Q5 h22 0.016 0.019 0.025
Q6 h23 0.025 0.03 0.04
Q7 h25 0.059 0.079 0.099
Q8 h27 0.158 0.198 0.247
Q9 h27 0.158 0.198 0.247
Tab. 8-2 Tooth flank backlash
Check the tooth flank backlash as follows:
1 Measurement method 1 (exact measurement method):

1.1 Block the drive pinion according to the section "Blocking the drive
pinion"
1.2 Mount the dial gauge to the guideway
1.3 Mount dial gauge in the direction of travel aligned with the center
of the drive pinion
1.4 Zero the dial gauge
1.5 Move the carriage or axis in the direction of travel
1.6 Read the tooth flank backlash on the dial gauge
2 Measurement method 2 (inexact measurement method only when neces-
sary due to weight reasons):
2.1 Insert paper strip from DIN A4 80 g/m2 with width b between drive
pinion and rack
2.2 Move carriage or axis with auxiliary agents
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(Paper strip is “turned through”)

2.3 Paper strip worn:
Tooth flank backlash <0.05 mm
2.4 Paper strip cut, partially disconnected pieces: Tooth flank backlash
~ 0.05 mm
96
2.5 Paper strips mildly cut, no disconnected pieces: Tooth flank back-
lash ~ 0.07 mm
2.6 Paper strip wavy:
Tooth flank backlash ~ 0.1 mm
2.7 Paper strip undamaged:
Tooth flank backlash >0.1 mm
3 Interpret tooth flank backlash according to the previous table
The tooth flank backlash has been checked.

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97
8.3.6 Replacing the gearbox
This section describes the steps for replacing the gearbox.
Disassemble the drive to replace the gearbox.
Disassembling a This section describes the steps for disassembling the drive.
drive with pinion
WARNING
motor!
NOTE
Do not change the position of the coupling on the motor shaft!
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98
A B C D
D003229
F E
Fig. 8-12 Disassembling the drive
A Gearbox screws
B Gearbox
C Motor screws
D Motor
E Eccentric ring
F Headless set screw
Disassemble the drive as follows:

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on again
2 Secure carriage or axle with transport securing device or lifting device
99
5 Mark eccentric position

6 Remove the motor, together with the coupling
7 Remove headless set screw
8 Remove the gearbox
The drive has been disassembled.
Tighten the gearbox This section describes the steps for tightening the gearbox screws.
screws
NOTE
Observe the tightening torques.
You will otherwise destroy the cast casing!
NOTE
Observe, without exception, the agreed installation position for
the size 180!
D003689
Fig. 8-13 Mounting the gearbox unit
Size 030 045 060 090 120 180
Thread size M6 M8 M10 M12 M16 M20

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Tab. 8-3 Tightening torques for gearbox screws
100
Replacing the This section describes the steps for replacing and installing the new gearbox.
gearbox
NOTE
sembly.
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 chapter 8.3.5,  90
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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101
8.3.7 Setting the gear backlash
Ex works, the gear backlash is set to a value of less than 6‘. If the backlash
increases, it has to be readjusted.
NOTE
• Do not remove the casing cover, else the gearbox oil will leak
out!
• Always align both casing covers in the identical position!
D000317
C
4
1 2
Fig. 8-14 Setting the gear backlash
A Worm shaft
B Casing cover
C Screws
Size 030 045 060 090 120 180
Tab. 8-4 Tightening torques

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Set the gear backlash as follows:
again
2 Disassemble the drive according to section ’Disassembling a drive with
pinion’,  98
102
3 Remove all screws on both sides

4 Rotate both covers toward the next higher, cast-in number
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 gear backlash:
Rotate the worm shaft 360° by hand
8.1 The shaft resists rotation:
Repeat from step 3
The gear backlash has been set.
8.3.8 Replacing motor and coupling
This chapter describes the steps for replacing the motor and the coupling.
NOTE
sembly.
WARNING
Falling axles
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After the removal of transport securing devices, brake or motors, the ver-
tical axles fall down, carriages can run away to the side. This can cause se-
vere or fatal injuries!
Secure if necessary the vertical axle and the carriage before removing the
transport securing devices, brake or motors!
103
Replace the motor and coupling as follows (for descriptions, see fig. 8-15,
 105):
Disassembling This section describes the steps for removing the coupling and the motor.
motor and coupling
Remove the motor and the coupling as follows:
on again
2 Loosen the motor screws
3 Pull the motor, together with the coupling, off the gearbox
4 Loosen the coupling screws
5 Pull the coupling off the motor shaft
The motor and the coupling have been removed
Assembling the This section describes the steps for assembly of the coupling and the motor.
Motor and coupling
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’,  56).
WARNING
Falling axes / workpieces
Incorrect tightening torques can lead to falling axes or
workpieces. This can cause severe or fatal injuries!
• Calibrate and check the torque wrench periodically
• Tighten all screws with a torque wrench to the specified tightening tor-
ques
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104
D000111
X
A B C D E F G
Fig. 8-15 Installing the motor and coupling
A Gearbox
B Motor flange
C Measuring instrument
D Coupling
E Coupling screws
F Motor screws
G 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
For the tightening torque, refer to tab. 1-2,  11
5 Grease the gear rim of the coupling
(For grease types, see 7.2.2 ’Lubricants’,  61)
6 Push the motor, with the mounted coupling, onto the gearbox
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7 Tighten the motor screws
The motor and the coupling have been installed.
The motor and the coupling have been replaced.
105
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’,  117.
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106
OPERATING MANUAL TMF Decommissioning, storage
9 Decommissioning, storage
9.1 Introduction
9.1.1 Safety

the TMF product.
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107
9.2 Storage conditions
CAUTION
Leaking fluids
During storage, substances that are hazardous to the environment could
leak!
Hazardous substances must not get into the drinking water supply:
• Fluids must be disposed of as hazardous waste, even if the total quantity
is small.
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%.

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108
9.3 Decommissioning
9.3.1 Shutdown
This chapter provides information on shutting down the product.
WARNING
NOTE
Do not empty the lubrication lines and the gearbox when shut-
ting 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.

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109
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.
NOTE
Dispose 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’,  112.
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
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110
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’,  66. 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
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111
OPERATING MANUAL TMF Disposal
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

the TMF product.
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112
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)
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’,  109.
WARNING
Suspended loads
Improper handling of suspended loads can lead to severe injuries or death!
• Use appropriate lifting units
• Wear appropriate protective clothing
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• Always keep sufficient distance to suspended loads

• Never enter the area below a suspended load
113
CAUTION
Oils/greases
Oils and greases are harmful to the environment!
The oils and greases must not get into the drinking water supply:
• Oils and greases must be disposed of as hazardous waste, even if the to-
tal quantity is small.
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
5 Dismount fixed assemblies
(axes/columns)
6 Take the assemblies apart and separate the different materials.
The product has been disassembled.

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114
10.3.2 Material groups
Dispose of the material groups in accordance with the following table.
Material Disposal route
Contaminated mate- Hazardous waste

rials/auxiliary agents
Wood Municipal waste
Plastic Collecting point or municipal waste
Lubricants Collecting point
Disposal in accordance with the safety data
sheets 3.3.4 ’Safety data sheets (MSDS)’,  28
Batteries Battery collection
Metals Scrap metal collection
Electrical material Electrical rubbish
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.
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115
OPERATING MANUAL TMF 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’,  122. 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 of
D000094
symbols Güdel AG
Insustrie Nord
CH-4900 Langnethal
phone +41 62 916 91 91
fax +41 62 916 95 29
info@ch.gudel.com 14.07.2008 / Page 1 of 1
A
VS0035 2-Amod ZP-4 M MO mec 3.10 10947-001A
Position Item number Text Drawing Quantity Unit E

300 V000134 Y-Axis LP220/220-25 V L=9200 8523-032 1 Stk
302 0141004 Energy chain 390.17.200.0 IGUS 390.17.200.0 77 Stk E
400 0916667 Y-Carriage ZP-4 8523-030 2 Stk
900 406015-10.00 Worm gear unit AE060/L left AE060 2 Stk E
Ratio i=10.00
910 406089 Motor flange 060 18x116x116 ø130/110 8030-018a 2 Stk E
1000 0910499 Mechanical multi limit switch accessories 750 Y 8523-024 2 Stk
1100 230803 Felt pinion for lubrication 8102-039d 1 Stk V
ø40.6x20, Modul m=2.387 pitch P=7.5, Z=15
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Fig. 11-1 Explanation of symbols
A Spare part status
Spare part status (column E): E = Spare part

V = Wear item
116
OPERATING MANUAL TMF Spare part supply
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:
Germany: +49 6291 6446 41

Great Britain: +44 24 7669 5444
India: +91 20 5622 7165
Italy: +39 02 9217021
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
For urgent service requests, our Helpdesk provides after-hour assistance

(24-hour support):
Europe/Asia: +41 62 916 9170 service@ch.gudel.com

USA: +1 248 456 0440
Please have the following information, as labeled on the type plate, at hand:
• Serial no.
• Part list no.
• Drawing number (if applicable)
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117
OPERATING MANUAL TMF Index
12 Index
A Coupling
Appendix . . . . . . . . . . . . . . . . . . . . . . . 122 Assembling . . . . . . . . . . . . . . . . . . 104
Arrangement Assembly . . . . . . . . . . . . . . . . . . . . . 50
Roller holder . . . . . . . . . . . . . . . . . . 85 Disassembly . . . . . . . . . . . . . . . . . 104
Assembly . . . . . . . . . . . . . . . . . . . . .37, 46 Replacing . . . . . . . . . . . . . . . . . . . . 103
Coupling . . . . . . . . . . . . . . . . . .50, 104
Guideway . . . . . . . . . . . . . . . . . .46, 88
Motor . . . . . . . . . . . . . . . . . . . . . . . . 50
Robot . . . . . . . . . . . . . . . . . . . . . . . . 53
D
Assembly instructions for partly Decommissioning . . . . . . . . . . . 107, 109
completed machinery . . . . . . . . . . . 9 Delivery
Attaching Checking . . . . . . . . . . . . . . . . . . . . . 38
Optional components . . . . . . . . . . 52 Design . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Slings . . . . . . . . . . . . . . . . . . . . . . . . . 39 Disassembly . . . . . . . . . . . . . . . . . . . . 113
Authorities . . . . . . . . . . . . . . . . . . . . . 115 Coupling . . . . . . . . . . . . . . . . . . . . 104
Auxiliary agents . . . . . . . . . . . . . . . . . . 61 Drive with pinion . . . . . . . . . . . 72, 98
Axis names . . . . . . . . . . . . . . . . . . . . . . 33 Guideway . . . . . . . . . . . . . . . . . . . . 87
Motor . . . . . . . . . . . . . . . . . . . . . . . 104
Disposal . . . . . . . . . . . . . . . . . . . . 112, 113
Disposal facilities . . . . . . . . . . . . . . . . 115
B Drive
Base fixing . . . . . . . . . . . . . . . . . . . . . . . 42 Disassembly with pinion . . . . . 72, 98
Adhesive anchor . . . . . . . . . . . . . . . 42 Installation . . . . . . . . . . . . . . . . . . . . 77
Welded joint . . . . . . . . . . . . . . . . . . 44 Drive pinion
Blocking Blocking . . . . . . . . . . . . . . . . . . . . . . 91
Drive pinion . . . . . . . . . . . . . . . . . . . 91
Bumper unit
Replacing . . . . . . . . . . . . . . . . . . . . . 81
E
Explanation
Abbreviations . . . . . . . . . . . . . . . . . 10
C Symbols . . . . . . . . . . . . . . . . . . . . . . 10
Cables and lines . . . . . . . . . . . . . . . . . . 54 Explanation of abbreviations . . . . . . . 10
Changes . . . . . . . . . . . . . . . . . . . . . . . . . 21 Explanation of symbols . . . . . . . . . . . . 10
Changing
Gearbox oil . . . . . . . . . . . . . . . . . . . 74
Checking
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Delivery . . . . . . . . . . . . . . . . . . . . . . 38
F
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 110 Fastening . . . . . . . . . . . . . . . . . . . . . . . . 38
Cleaning agents . . . . . . . . . . . . . . . . . . . 61 Felt insert
Commissioning . . . . . . . . . . . . . . . . . . . 34 Preparing . . . . . . . . . . . . . . . . . . . . . 84
Connecting Final tasks . . . . . . . . . . . . . . . . . . . . . . . 90
Profiles . . . . . . . . . . . . . . . . . . . . . . . 41 Function . . . . . . . . . . . . . . . . . . . . . . . . 29
Consumables . . . . . . . . . . . . . . . . . . . . . 61 Functional check . . . . . . . . . . . . . . . . . 57
Functional description . . . . . . . . . . . . 33
118
Fundamentals of safety . . . . . . . . . . . . 27 M
Maintenance . . . . . . . . . . . . . . . . . . 59, 78
10000 hours . . . . . . . . . . . . . . . . . . 72
150 hours . . . . . . . . . . . . . . . . . . . . 67
G
2000 hours . . . . . . . . . . . . . . . . . . . 70
Gearbox 500 hours . . . . . . . . . . . . . . . . . . . . 68
Changing the oil . . . . . . . . . . . . . . . 74 Schedule . . . . . . . . . . . . . . . . . . . . . 65
Replacing . . . . . . . . . . . . . . . . .98, 101 Tasks . . . . . . . . . . . . . . . . . . . . . . . . 66
Setting the backlash . . . . . . . . . . . 102 Maintenance schedule . . . . . . . . . . . . . 65
General inspection . . . . . . . . . . . . . . . . 68 Maintenance tasks 100 hours after
General rules for occupational safety . commissioning . . . . . . . . . . . . . . . . 66
21
Marking
Greases . . . . . . . . . . . . . . . . . . . . . . . . . 63 Lubrication points . . . . . . . . . . . . . 64
Guideway Material groups . . . . . . . . . . . . . . . . . 115
Assembly . . . . . . . . . . . . . . . . . .46, 88 Measuring instruments . . . . . . . . . . . . 79
Disassembly . . . . . . . . . . . . . . . . . . . 87 Monitoring equipment . . . . . . . . . . . . 27
Lubricating . . . . . . . . . . . . . . . . . . . . 67 Motor
Replacing . . . . . . . . . . . . . . . . . . . . . 87 Assembling . . . . . . . . . . . . . . . . . . 104
Assembly . . . . . . . . . . . . . . . . . . . . . 50
Disassembly . . . . . . . . . . . . . . . . . 104
H Replacing . . . . . . . . . . . . . . . . . . . . 103
Mounting aid . . . . . . . . . . . . . . . . . . 46, 88
Hazard symbols
Manual . . . . . . . . . . . . . . . . . . . . . . . 22
Product . . . . . . . . . . . . . . . . . . . . . . . 25
O
Oil change
I Gearbox . . . . . . . . . . . . . . . . . . . . . 72
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Improper handling of cables . . . . . . . . 54
Operating personnel . . . . . . . . . . . . . . 20
Inspecting
Operation . . . . . . . . . . . . . . . . . . . . . . . 58
Rack transition . . . . . . . . . . . . . . . . 48
Optional components
Installation
Attaching . . . . . . . . . . . . . . . . . . . . . 52
Drive . . . . . . . . . . . . . . . . . . . . . . . . . 77
Options . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation instructions . . . . . . . . . . . . 21
Other documents . . . . . . . . . . . . . . . 106
L P
Labeling . . . . . . . . . . . . . . . . . . . . . . . . 110
Packing symbols . . . . . . . . . . . . . . . . . . 35
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parts list . . . . . . . . . . . . . . . . . . . . . . . 116
Load
Personnel qualifications 34, 60, 79, 107,
Attaching . . . . . . . . . . . . . . . . . . . . . 52
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112
Lubricants . . . . . . . . . . . . . . . . . . . . . . . 61
Pinion
Lubricating
Lubricating . . . . . . . . . . . . . . . . . . . 67
Guideways . . . . . . . . . . . . . . . . . . . . 67
Position drawings . . . . . . . . . . . . . . . 116
Pinions . . . . . . . . . . . . . . . . . . . . . . . 67
Preparing
Racks . . . . . . . . . . . . . . . . . . . . . . . . . 67
Felt insert . . . . . . . . . . . . . . . . . . . . 84
Lubricating pinion
Wiper . . . . . . . . . . . . . . . . . . . . . . . 83
Replacing . . . . . . . . . . . . . . . . . . . . . 70
Prerequisites . . . . . . . . . . . . . . . . . . . . 37
119
Base . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Safety equipment . . . . . . . . . . . . . . . . . 27

Lifting unit . . . . . . . . . . . . . . . . . . . . 37 safety regulations
Lines . . . . . . . . . . . . . . . . . . . . . . . . . 37 disregarding . . . . . . . . . . . . . . . . . . . 21
Maintenance, repair . . . . . . . . .66, 81 Screw locked . . . . . . . . . . . . . . . . . . . . 11
Positioning . . . . . . . . . . . . . . . . . . . . 37 Service departments . . . . . . . . . . . . . 117
Product Setting
Description . . . . . . . . . . . . . . . . . . . 17 Gear backlash . . . . . . . . . . . . . . . . 102
Designation . . . . . . . . . . . . . . . . . . . 18 Roller backlash . . . . . . . . . . . . . 90, 92
Integrating . . . . . . . . . . . . . . . . . . . . 53 Tooth flank backlash . . . . . . . . 90, 93
Positioning . . . . . . . . . . . . . . . . . . . . 40 Setting the roller backlash . . . . . . . . . 92
Safety . . . . . . . . . . . . . . . . . . . . . . . . 20 Setting the tooth flank backlash . . . . 93
Product-specific hazards . . . . . . . . . . . 27 Setup . . . . . . . . . . . . . . . . . . . . . . . . 37, 38
Profiles Shutdown . . . . . . . . . . . . . . . . . . . . . . 109
Connecting . . . . . . . . . . . . . . . . . . . 41 Slings
Protective measures . . . . . . . . . . . . . . 21 Attaching . . . . . . . . . . . . . . 39, 76, 100
Purpose of the document . . . . . . . . . . . 9 Spare part supply . . . . . . . . . . . . . . . . 116
Spare parts list . . . . . . . . . . . . . . . . . . 116
Explanation of symbols . . . . . . . . 116
Explanations . . . . . . . . . . . . . . . . . 116
R Special symbols . . . . . . . . . . . . . . . . . . 25
Rack Special tools . . . . . . . . . . . . . . . . . . . . . 79
Inspecting transition . . . . . . . . . . . . 48 Storage . . . . . . . . . . . . . . . . . . . . . . . . 107
Lubricating . . . . . . . . . . . . . . . . . . . . 67 Storage conditions . . . . . . . . . . . . . . 108
Recommissioning . . . . . . . . . . . . . . . . 111 Symbols
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Special symbols . . . . . . . . . . . . . . . 25
Replacing Warning symbols . . . . . . . . . . . . . . 23
Bumper unit . . . . . . . . . . . . . . . . . . . 81
Coupling . . . . . . . . . . . . . . . . . . . . . 103
Gearbox . . . . . . . . . . . . . . . . . .98, 101
Guideway . . . . . . . . . . . . . . . . . . . . . 84 T
Guideways . . . . . . . . . . . . . . . . . . . . 87 Target readership . . . . . . . . . . . . . . . . 10
Lubricating pinion . . . . . . . . . . . . . . 70 Technical data . . . . . . . . . . . . . . . . . . . 19
Motor . . . . . . . . . . . . . . . . . . . . . . . 103 Temperature ranges . . . . . . . . . . . . . . 19
Roller . . . . . . . . . . . . . . . . . . . . . . . . 84 Testing instruments . . . . . . . . . . . . . . 79
Residual danger . . . . . . . . . . . . . . . . . . 20 Thread rolling screws . . . . . . . . . . . . . 16
Robot Tightening torques
Mounting . . . . . . . . . . . . . . . . . . . . . 53 Gearbox screws . . . . . . . . . . . 76, 100
Roller backlash HV sets . . . . . . . . . . . . . . . . . . . . . . 13
Setting . . . . . . . . . . . . . . . . . . . . . . . . 90 Roller holders . . . . . . . . . . . . . . . . . 14
Roller holder Roller support . . . . . . . . . . . . . . . . 15
Arrangement . . . . . . . . . . . . . . . . . . 85 Screws . . . . . . . . . . . . . . . . . . . . . . . 11
Installation types . . . . . . . . . . . . . . . 84 Tooth flank backlash
D003125
Roller holder installation types . . . . . 84 Checking . . . . . . . . . . . . . . . . . . . . . 95

Rust-proofing . . . . . . . . . . . . . . . . . . . 110 Setting . . . . . . . . . . . . . . . . . . . . . . . 90
Torque tables . . . . . . . . . . . . . . . . . . . . 11
Training of operating personnel . . . . 58
Transport . . . . . . . . . . . . . . . . . . . . . . . 35
S Transport securing devices . . . . 56, 110
Safety . . . . . . . . .20, 34, 60, 78, 107, 112 Type plate . . . . . . . . . . . . . . . . . . . . . . . 18
Safety data sheets . . . . . . . . . . . . . . . . 28
120
U
Unpacking . . . . . . . . . . . . . . . . . . . . . . . 37
Use
Improper . . . . . . . . . . . . . . . . . . . . . 17
Intended . . . . . . . . . . . . . . . . . . . . . 17
Purpose . . . . . . . . . . . . . . . . . . . . . . 17
W
Warning symbols . . . . . . . . . . . . . . . . . 23
Waste management compliant assemblies 113
Wiper
Preparing . . . . . . . . . . . . . . . . . . . . . 83
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121
OPERATING MANUAL TMF Appendix
13 Appendix
The appendix of this operating manual contains the following documents:
• Hazard analysis / Risk analysis

• Layout
• Additional technical data
• Options
• Third-party products
• Spare parts list
D003125
122
OPERATING MANUAL TMF Hazard analysis / Risk analysis
Hazard analysis / Risk analysis

D003125
123
Customer:
Machine type: all modules without control system Risk assessment/safety goals/protective measures/residual risks1)
Project no.: Hazard analysis / risk assessment Solution suggested to the customer (cursive, Times New Roman)
Document no.: Güdel solution (Arial)
Special operating modes
Risk assessment (<=3; 4-8; 9-20; >20)

Probability of
Extent of the
occurrence
damage
F Commissioning at the customer
Corresponding operating mode
Safety requirement fulfilled [Y/N]

J Troubleshooting and repair
E Assembly at the customer
Category / PLr (SIL) minimal

G Training at the customer
Event
B Internal commissioning
Safety goal
C Internal disassembly
Source of danger Triggering factor Protective measures
Affected person(s)
H Setup/changeover
A Internal assembly
(Worst case) Residual risks

(negation of the event)
(Without protective measures) (existing protective measures)
Operating manual
Normal operation
K Maintenance
L Disassembly
D Transport
I Cleaning
Frequent
M Disposal
Medium
Hazard no.
Severe
Often
Rare
Light
The following should be prevented:
10
1
4
1
2
3
A Güdel device is only used to bring objects to a
specific position, hold them there or to move
simultaneously with other machine movements.
Processing of hazardous materials. If the intended use is modified, hazards can
No hazardous (e.g. poisonous or explosive) objects
Fire and danger of explosion results that are not covered by the safety
1.1 x x x x x x x x x x x x x x All Noncompliance with the intended use Persons are injured or killed x x 10 3/d Intended use of the product. may be moved. A Güdel device may not be x J
Thermal factors concept.
operated in a potentially explosive area. The
ambient temperature during operation must be
between 12° and 40 °C.
Technicians
Commissio Person is surprised by unexpected movement and injured or killed as Use appropriate lifting equipment. Wear protective
1.2 x x x x x x x x Suspended loads Improper use of lifting equipment x x 10 3/d No persons may be injured by falling parts. Do not walk under suspended loads. x J
ning a result. clothing. Keep a safe distance.
technicians
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. In normal operation, all protective hoods
Safety shutdown situation: must be closed, removable protective hoods
The areas of movement must be secured The vacuum system remains active in a de-energized must be screwed securely.
Movement of the axes. Operator
Maintenance
Gripper problems so that neither operating personnel nor state. Required behavior:
Suspended loads
1.3 x personnel Defective motor brake Person is surprised by vertical movement and injured as a result. x x 20 3/d third parties can reach or walk into the Inspect the protective hoods before starting x J
(Z-axis and workpieces)
General problems in the drive train hazardous locations where automatic Door elements: when opening the danger area, a safety normal operation.
movements are performed. shutdown is performed for at least the drives that pose a Safety shutdown situation: do not walk
hazard in this area. under suspended workpieces and Z-axes.
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.
Insertion or ejection axes may only be moved in jog Extra attention is required of the operator at
It must be ensured that neither operating mode or with two-hand operation. The drive manual workstations.
Manual workstations Person is surprised by the automation, body parts are crushed and personnel nor third parties are injured configuration is such that at the maximum speed of the Only perform movements if no other person
1.4 x Operator Automatic movements at the manual workstation x x 20 3/d x J
injuries result. during manual insertion and ejection of the drive motor only a slow axis speed is achieved. The is in the danger area and none of your own
workpieces. operating elements for insertion and ejection must be body parts are in the line of danger of the
configured so that the operator has a clear view onto corresponding axis
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.
Mechanical guards must be placed in the possible flight In normal operation, all protective hoods
Operator It must be ensured that neither operating path of parts that could fly off. must be closed, removable protective hoods
Parts clamped improperly
1.5 x Parts that are flung out Third Person is surprised by parts flying away and injured as a result x x 10 3/d personnel nor third parties are injured by Safety devices are inspected using calculations and must be screwed securely. x J
Breakage of rotating tools
parties parts that become loose and fly off. trials. Required behavior: Inspect the protective
hoods before starting normal operation.
Only contact-protected components are to be used.
Before working on electrical installations, always
Operator
Touching the machine disconnect the system (plug/main switch) and
Maintenance It must be ensured that neither operating
personnel Defective insulation double check.
1.6 x x x x x x x Electrical hazard Person suffers an electric shock and is injured or killed as a result. x x 10 3/d personnel nor third parties are injured by Work on electrical installations requires x J
Technicians Improper el. installation Work on electrical installations, switch cabinets and
direct or indirect electrical contact. expertise and extra care.
Unsuitable components devices may only be performed by authorized
specialists.
Control cabinet fuses
The movement of the drives is mechanically limited
in case the supply voltage fails (mechanical stops
Operator and holding brakes). After a crash, defective elements of the
Maintenance
The effects of a power failure must not be
The movement of the drives is braked if the supply mechanical stops cannot necessarily be
1.7 x Disruption of the energy supply personnel Power failure, lightning Person is surprised by unexpected movement and injured as a result. x x 10 3/d dangerous for the operator or for third x J
voltage fails recognized immediately. The entire bumper
parties.
The operator and third parties are outside the danger unit must always be replaced.
area.
The areas of movement are to be encompassed by

mechanical safety fences and light curtains and light
In normal operation, all protective hoods
Operator grids so that it is not possible to enter this area from any
Maintenance
The effects of a control system malfunction must be closed, removable protective hoods
side.
1.8 x Malfunction of the control system personnel Failure of control unit components Person is surprised by unexpected movement and injured as a result. x x 10 3/d must not be dangerous for the operator or must be screwed securely. x J
Movements must transition to static states as quickly as
for third parties. Required behavior: Inspect the protective
possible.
hoods before starting normal operation.
Copyright © 2009 by GÜDEL AG Process owner: M. Knuchel Version 30 / Risikobeurteilung_en.xls Page1 / 3

Customer:
Risk assessment (<=3; 4-8; 9-20; >20)

Probability of
Extent of the
occurrence
damage


Event
Safety goal
Affected person(s)
H Setup/changeover
A Internal assembly

Operating manual
Normal operation
K Maintenance
L Disassembly
D Transport
I Cleaning
Frequent
M Disposal
Medium
Hazard no.
Severe
Often
Rare
Light
10
1
4
1
2
3
Do not walk under suspended workpieces or
Operator The plant is equipped with emergency stop devices,
Maintenance
Z-axes. Only possible in setup mode.
Aging, fatigue fracture, failure due to vibration or which trigger an emergency stop of the plant. A lock-out
1.9 x x x x x Malfunction of protection measures personnel Person is surprised by unexpected situation and injured as a result. x x 10 3/d Averting an emerging hazard Permanent workstations are not permitted in x J
overloading (overview of the switch off locations) draws attention to
the direction of movement of the axes.
the switch-off devices.
Movement of the axes.

Suspended loads Removal of transport securing device without It must be ensured that suspended loads Before removing the transport securing device, support
1.1 x Technicians Person is surprised by unexpected movement and injured as a result. x x 10 3/d Do not walk under suspended loads. x J
(Z-axis and workpieces) supporting suspended loads and axes. do not fall down. the suspended loads or axis.
A start-up of the plant without the permissive button

being pressed must be prevented.
Operator Do not walk under suspended workpieces
Maintenance With the permission device pressed, moving plant parts
personnel
and
Movement of the axes. It must be ensured that an expected start can be moved in a controlled manner, even if the plant
1.11 x x x x Cleaning Unexpected start Person is surprised by unexpected situation and injured as a result. x x 10 3/d Z-axes. x J
Parts that are flung out of moving parts is prevented. is unsecured.
personnel
In confirmation mode, the operator must pay
When the permissive button is pressed, it must not be
great attention and have a high level of
possible for the operator to be endangered by an
individual responsibility.
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 In confirmation mode, the operator must pay
using a key switch. The permissive button is a "shock great attention and have a high level of
When the permissive button is pressed, it
button". individual responsibility. Only perform
must not be possible for the operator to be
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 For the permissive button to be activated, only one movements if no other person is in the x J
endangered by an automatic movement
safety door may be open and the others must be closed danger area and none of your own body
triggered by a third party.
and reset. Safety-relevant parts of the control are parts are in the line of danger of the
inspected in appropriate time intervals by the machine corresponding axis.
control system.
Grippers must remain in the de-energized state in the

clamp position.
For very frequent set-up under Z-axes, Z-axes can be
Gripper problems Do not walk under suspended workpieces or
It must be ensured that no persons can be secured redundantly with an additional brake on the
Suspended loads. Defective motor brake Z-axes. Take especial care with telescopic
endangered by Z-axes, telescopic axes pinion and the motor brake.
1.13 x (Z-axes, telescopic axes, counter balance Setters Torn belt (telescopic axis) Person is surprised by unexpected situation and injured as a result. x x 10 3/d axes. Inspect belts before every setup x J
and workpieces that fall down when the Telescopic axes: and load balancing cylinders: Special
cylinders and workpieces) Pressure drop (load balancing) procedure for cracks and tears.
permissive button is not pressed. attention is required here. The axis (for a telescopic
General problems in the drive train
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

Suspended loads. Z-axes. Take especial care with telescopic
Workpieces must not be dropped Grippers can only be operated in the storage position.
1.14 x (Z-axes, telescopic axes, counter balance Setters Inattention and/or careless operation by operator Person is surprised by unexpected situation and injured as a result. x x 10 3/d axes. Inspect belts before every setup x J
accidentally.
cylinders and workpieces) procedure for cracks and tears.
Work in this mode requires a high level of

Gripper problems individual responsibility from the operator.
Defective motor brake Only perform movements if no other person
Setters The axes can only be moved with reduced speed.
1.15 x Parts that are flung out Third parties
Torn belt (telescopic axis) Person is surprised by parts flying away and injured as a result x x 10 3/d No parts may be flung out. is in the danger area and none of your own x J
Rotating parts must be shut down securely.
Pressure drop (load balancing) body parts are in the line of danger of the
General problems in the drive train corresponding axis.
The movement of the drives is limited by

mechanical stops in case the supply voltage fails.
After a crash, defective elements of the
The effects of a power failure must not be The drives have already been switched off in case of a
mechanical stops cannot necessarily be
1.16 x x Disruption of the energy supply Setters Power failure, lightning Person is surprised by unexpected situation and injured as a result. dangerous for the operator or for third power failure (safety shutdown situation). The x J
recognized immediately. The entire bumper
parties. movement of the drives is braked in case of supply
unit must always be replaced.
voltage failure by the motor brake or holding brake in
the drive train.
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
Only drive systems are used. They comply with the state
The risk of possible hazard must be kept as create a dangerous situation by moving the
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/d of the art and the standards referenced in the machine x J
low as possible. axes.
directives.
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.

Customer:
Risk assessment (<=3; 4-8; 9-20; >20)

Probability of
Extent of the
occurrence
damage


Event
Safety goal
Affected person(s)
H Setup/changeover
A Internal assembly

Operating manual
Normal operation
K Maintenance
L Disassembly
D Transport
I Cleaning
Frequent
M Disposal
Medium
Hazard no.
Severe
Often
Rare
Light
10
1
4
1
2
3
Service
Movement of the axes. personnel The lockable main plant switch breaks all main and If motors or gearboxes are removed, vertical
1.18 x x x Cleaning
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. x J
Parts that are flung out control circuits. axes must always be secured or supported.
personnel
Avoid walking under suspended workpieces

or Z-axes. Take especial care with
telescopic axes. Inspect belts before every
Workpieces must be deposited beforehand in automatic maintenance procedure for cracks and
Unexpected start
or setup mode. tears.
Suspended loads Service Defective motor brake
Z-axes must be secured with the Z-axes device or with Workpieces must be deposited beforehand
(Z-axes, telescopic axes, counter balance personnel Torn belt (telescopic axis)
1.19 x x x Cleaning
Person is surprised by unexpected situation and injured as a result. x x 10 3/d Z-axes falling down must be prevented. the transport securing device. in automatic or setup mode. x J
cylinders and workpieces) Pressure drop (load balancing)
personnel Telescopic axes must be secured against falling down Z-axes must be secured with the
General problems in the drive train
with appropriate auxiliary means (cables, auxiliary Z-axes device or with the transport securing
Disassembly of the Z-axis motor
supports, etc.). device.
Telescopic axes must be secured against
falling down with appropriate auxiliary
means (cables, auxiliary supports, etc.).
Before a Güdel device is transported to the

location of use, unpacked, assembled and
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. x J
commissioned, the operating manual must
first be read and understood.
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.
Check the connections that are responsible
Equipment with base supports:
Tipping over or falling down of equipment for the stability of the device before starting
1.21 x x Loss of stability All Inattention and/or careless operation Machine/plant tips over x x 10 3/d The supplied screws for assembly must be used. x J
must be prevented. the plant. The operating manual must be
For the connection of the supports to the floor, the
read and understood.
anchoring suggestion according to the Güdel layout
must be taken into consideration.
Fall protection must be mounted for surface
gantries.
The device and its consumables must be

Improper disposal can cause Statewide regulations regarding disposal of the
1.22 x All Disposal regulations are not observed Environmental hazard x x 10 3/d disposed of accordingly after the end of its x J
environmental damage. plant must be observed.
service life.
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 TMF Layout
Layout
D003125
124
DATE REV. DESCRIPTION CHG CHK
11/12/2014 - Approved by Customer, Added Robot Information EMS
1/5/2015 A Revised Robot Information from M-900iA to M900iB EMS
+0.02 555
12 H7 0 THRU
APPROVAL DRAWING
DOWEL HOLES
FOR SQUARING OF
THE ROBOT
AS NOTE
M20 - TAP THRU ALL (8) HOLES APPROVED BY: DATE: AS IS

FOR FANUC M-900B/400L ROBOT
A PAINT SPECIFICATIONS
1. BEAMS: RAL 7035 SHERWIN WILLIAMS
-
420
2. CARRIAGES: RAL 2011/SW 4083 SHERWIN WILLIAMS
-
370
350 3. CONTROL PANEL: -
-
270
220
TECHNICAL INFORMATION
CENTRAL LUBRICATION
FILLED WITH H1 GREASE VELOCITY (m/s) ACCELERATION (m/s )
2
X-AXIS 1.00 1.00

FRONT OF ROBOT Y-AXIS N/A N/A
Z-AXIS N/A N/A
0 1200 LOAD 3550 Kg. (Includes Load and End Effector)
MTG PATTERN
WARRANTY SUBJECT TO CATALOG SPECIFICATIONS AND APPLICATION ANALYSIS
75
220
270
600
350
370
1027.3 40.4
O.A. HEIGHT
MTG PATTERN 597 23.5

17.5 48
M20 - 6H 37 TOP of CARRIAGE/
RISER MTG.
10-12 DEEP
(11) HOLES
875
506
380
230
200
235
270
340
1450
DETAIL B
A SCALE 1 : 5
1034
1209 47.6 O.A. WIDTH

VIEW A-A
SCALE 1 : 10
2200
MTG PATTERN MTG PATTERN X-AXIS GEARBOX AE120 i=13.33 FOR

FANUC MOTOR # αis30/4000
(MOTOR SUPPLIED BY CUSTOMER)
22300
300 2480
B
R30
300
CABLE PORT
10237 E-Chain Mounting
24000 944.9 E-CHAIN GUIDE O.A.LENGTH

1180
25460.97 O.A. LENGTH A

X-AXIS E-CHAIN
22300 MAX X-AXIS STROKE 1450 CARRIAGE PLATE 105 IGUS# H4-56-30-300-0
75 O.T. 300 2480 75 O.T. (146) LINKS PER CARRIAGE.
DIVIDERS EVERY OTHER LINK
R300
150
17.5 32 17.5
400 R20 400
180 180 A
1200 1200 1200 1200 1200 1200 400 1200 1200 1200 1200 1200 1200 400 1200 1200 1200 1200 1200 1200 400
23960 O.A. FRAME LENGTH 1467
300 CABLE PORT
409 403 56.1 421-75 402
2 7 9
56
1 3 4 6
5 8 GUDEL: JACKSCREW: M56x3
HEXNUT: M56x3
BASE PLATE: 140 X 20
(ANCHOR SUPPLIED BY CUSTOMER)
45 57 32
41
Position Description Ø [inch]
1 Aux Power 1.11 129
2 Ground 0.31 30 all dimensions are Letzte Änderung / Last revision Gewicht ca. Material
Weight approx. Material
Dieses Dokument ist Eigentum der Firma Güdel AG und darf ohne schrift-
This document is property of Güdel AG and should not be reproduced nor

3 Motor Power 1.39
liche Genehmigung weder vervielfältigt noch irgendwelchen Drittpersonen

A/05.01.15/erisch
METRIC 7210.63 kg Ursprung
4 Motor Power 1.39 third angle projection except where noted Änd. Nr/Rev.ID. Origin
5 Air 0.78 Massstab/Scale Gezeichnet
distributed to any third party without prior written consent.

20 JMP Automotive 14-1898 Detailed 10/20/14 197us
6 Feedback 1.13 1:20 Geprüft
7 Lube I/O 0.27
oder Drittfirmen zugänglich gemacht werden.

bei / for Roll 60 Checked
8 Aux Encoder 0.5 140

TMF-4 Assembly
Blätter / Sheets BUS Nr.
BUS No.
9 Ethernet 0.26 1/1 Artikel-Nr.
DETAIL C Article No.
END VIEW OF X-AXIS E-CHAIN SCALE 1 : 5
IGUS E4-42-30-350-0
SCALE 1:2 60-00141898-001 A
OPERATING MANUAL TMF Additional technical data
Additional technical data

D003125
125
EP-1/ZP-1 EP-2/ZP-2 EP-3/ZP-3/FP-3 EP-4/ZP-4/FP-4 EP-5/ZP-5/FP-5 EP-6/ZP-6/(FP-6 Y&Z-Axes)
25.00 pinion functional pitch dia. 31.83 pinion functional pitch dia. 31.83 pinion functional pitch dia. 47.75 pinion functional pitch dia. 63.66 pinion functional pitch dia. 84.88 pinion functional pitch dia.
25.00 pinion setup pitch dia. 31.83 pinion setup pitch dia. 31.83 pinion setup pitch dia. 47.75 pinion setup pitch dia. 63.66 pinion setup pitch dia. 84.88 pinion setup pitch dia.
25 tooth pinion 20 tooth pinion 20 tooth pinion 20 tooth pinion 20 tooth pinion 20 tooth pinion
Gearbox Ratio Travel per Rev Gearbox Ratio Travel per Rev Gearbox Ratio Travel per Rev Gearbox Ratio Travel per Rev Gearbox Ratio Travel per Rev Gearbox Ratio Travel per Rev
2:1 39.27 2:1 50 2:1 50 2:1 75 2:1 100 2:1 133.33
3:1 26.18 3:1 33.33 3:1 33.33 3:1 50 3:1 66.67 3:1 88.89
4:1 19.63 4:1 25 4:1 25 4:1 37.5 4:1 50 4:1 66.67
5:1 15.71 5:1 20 5:1 20 5:1 30 5:1 40 5:1 53.33
6:1 13.09 6:1 16.67 6:1 16.67 6:1 25 6:1 33.33 6:1 44.44
8:1 9.82 8:1 12.5 8:1 12.5 8:1 18.75 8:1 25 8:1 33.33
10:1 7.85 10:1 10 10:1 10 10:1 15 10:1 20 10:1 26.67
13.33:1 5.89 13.33:1 7.5 13.33:1 7.5 13.33:1 11.25 13.33:1 15 13.33:1 20.01
16:1 4.91 16:1 6.25 16:1 6.25 16:1 9.38 16:1 12.5 16:1 16.67
24:1 3.27 24:1 4.17 24:1 4.17 24:1 6.25 24:1 8.33 24:1 11.11
TMF-1 TMF-2 TMF-3 TMF-4 EP-7/ZP-7/FP-7 (Y-Axis) ZP-7/FP-7 (Z-Axis)

2:1 80 2:1 80 2:1 106.67 2:1 133.33 2:1 133.33 2:1 200
3:1 53.33 3:1 53.33 3:1 71.11 3:1 88.89 3:1 88.89 3:1 133.33
4:1 40 4:1 40 4:1 53.33 4:1 66.67 4:1 66.67 4:1 100
5:1 32 5:1 32 5:1 42.67 5:1 53.33 5:1 53.33 5:1 80
6:1 26.67 6:1 26.67 6:1 35.56 6:1 44.44 6:1 44.44 6:1 66.67
8:1 20 8:1 20 8:1 26.67 8:1 33.33 8:1 33.33 8:1 50
10:1 16 10:1 16 10:1 21.33 10:1 26.67 10:1 26.67 10:1 40
13.33:1 12 13.33:1 12 13.33:1 16 13.33:1 20.01 13.33:1 20.01 13.33:1 30.01
16:1 10 16:1 10 16:1 13.33 16:1 16.67 16:1 16.67 16:1 25
24:1 6.67 24:1 6.67 24:1 8.89 24:1 11.11 24:1 11.11 24:1 16.67
TMF-40 TMF-52 TMF-72 TMF-90 FP-6 (X-Axis Only) FP-7 (X-Axis Only)
2:1 70 2:1 70 2:1 125 2:1 160 2:1 125 2:1 160
3:1 46.67 3:1 46.67 3:1 83.33 3:1 106.67 3:1 83.33 3:1 106.67
4:1 35 4:1 35 4:1 62.5 4:1 80 4:1 62.5 4:1 80
5:1 28 5:1 28 5:1 50 5:1 64 5:1 50 5:1 64
6:1 23.33 6:1 23.33 6:1 41.67 6:1 53.33 6:1 41.67 6:1 53.33
8:1 17.5 8:1 17.5 8:1 31.25 8:1 40 8:1 31.25 8:1 40
10:1 14 10:1 14 10:1 25 10:1 32 10:1 25 10:1 32
13.33:1 10.5 13.33:1 10.5 13.33:1 18.75 13.33:1 24.01 13.33:1 18.75 13.33:1 24.01
16:1 8.75 16:1 8.75 16:1 15.63 16:1 20 16:1 15.63 16:1 20
24:1 5.83 24:1 5.83 24:1 10.42 24:1 13.33 24:1 10.42 24:1 13.33
OPERATING MANUAL TMF Options
Options
D003125
126
OPERATING MANUAL TMF Third-party products
Third-party products
D003125
127
OPERATING MANUAL TMF Spare parts list
Spare parts list

D003125
128
1/16/2015 / Page 1 of 5
BUS033209 M-TMF-0004 TMF-4 Track Motion Module
Position Item nr. Text Drawing Quantity Unit Spare/wear part

6001719 TMF-4 X-Axis Assembly 60-00141898-002 1 EA
6001720 TMF-4 Carriage Assembly 60-00141898-003 1 EA
30 6001722 TMF-4 E-Chain Assembly 60-00141898-005 1 EA E
35 E4.560.30.12PZB IGUS Bracket Set For E4.560.30.12PZB 1 EA E
40 6001721 TMF-4 Gearbox Assembly 60-00141898-004 1 EA
0927208 Zero Marks TMF-3/4 8158-029 1 EA

6000329 TM Robot Adapter Plate, R-2000 6000-017 0 EA
6001794 TMF Cable Assy for M-900 ,18m - 1 EA
6001748 E-Chain Separator Set DN M900 60-00141846-501 73 EA
50 0927004 Automatic lubrication system 8590-037 1 EA
FlexxPump 404DLS
SSHE044X Sherwin Williams Polyurethane Enamel F63TXA11931_4318 1 EA
SSHE234X SW 4083 Polane T 1 EA

902284 Rack Assembly Segment For Modul 4.0 8102-038b 1 EA
Helical Rack
6000114 Güdel Serial No. Tag 4'' x 2'' 6000-005 (6-000101) 1 EA
6001059 Robot Adapter Plate M900iB 60-00006000-045 2 EA
6001159 Robot Adapter Plate M900iB 60-00006000-046 2 EA
1/16/2015 / Page 2 of 5
BUS033598 6001719 TMF-4 X-Axis Assembly 60-00141898-002

0206211 TMF-4 Frame, 8m 8158-233c 3 EA
902455 Floor levelling kit M56x3 8590-014a 48 EA
120 0193035 Rack modul 4.0/A/1000mm/B 8102-091b 2 EA E
121 0193036 Rack modul 4.0/A/2000mm/B 8102-091b 11 EA E
130 903700 S3547/2000mm Guideway 8103-113A 24 EA E
0184608 Rack Cover 4x70x1998 (TMF) 11495-009c 12 EA
0184613 TMF-3/4 Bumper Block 11495-010 GUS 2 EA
200 0140172 Bumper, Ø63 x 262 DF 1-042-082-E 2 EA E
6001268 High Cable Tray Dwg L=2400 8119-007B (6-900900) 20 EA
0118067 Cable Chain Support Rails, 1200mm 8119-011A (6-901400) 20 EA

Long (Mat'l is Black UHMWPE)
0118066 Cable Tray Alignment Plate 8119-010 (6-901300) 18 EA
0119024 Connecting plate for Cable Tray side 8119-012 1 EA
panel 3x25x277
1/16/2015 / Page 3 of 5
BUS033216 6001720 TMF-4 Carriage Assembly 60-00141898-003

0198719 TMF-4 Carriage Plate 8158-056H 1 EA
0198657 Eccentric ring ø198x135 AE120 8158-062A 1 EA
250 904240 Roller support RB90 S3547 8158-022 4 EA
260 0926746 Feltpinion lubrication unit TMF-3/4 M4 8109-121 1 EA E
helical
265 0193926 Toothed wheel M4 Z17 B40 SL FG-04-40-02-17 1 EA V
1/16/2015 / Page 4 of 5
904240 Roller block RB90 S3547 8158-022

10 0198177 Housing RB90 S3547 10-00008158-023 1 EA
20 0926463 Roller holder 90 short to RB90 10-00008121-259 3 EA E
21 0107558 Socket head cap screw In-6kt DIN912- BN3-DIN912-ISO4762 2 EA
M6x10-8.8 zinced
30 904242 Lubricating element Polyurethan 10-00008158-019 1 EA V
RB72/90 S3547 ø70x15
40 904241 Wiper RB72/90 S3547 ø78 10-00008158-016 2 EA V
41 0101681 Wheel for M6 90° SN213912 BN1277 2 EA
42 0125556 Countersunk screw In-6kt DIN7991- BN1422-DIN7991 1 EA
M6x16-10.9 zinced
43 0185927 Countersunk screw In-6kt DIN7991- BN1422-DIN7991 1 EA
M6x30-10.9 zinced
50 0167350 Grease nipple M6 Typ K6 06.200 1 EA
51 0167351 Marking disc M6 red 1 EA
DATE REV. DESCRIPTION CHG CHK
11/12/2014 - Approved by Customer, Added Robot Information EMS
1/5/2015 A Revised Robot Information from M-900iA to M900iB EMS
+0.02 555
12 H7 0 THRU
APPROVAL DRAWING
DOWEL HOLES
FOR SQUARING OF
THE ROBOT
AS NOTE
M20 - TAP THRU ALL (8) HOLES APPROVED BY: DATE: AS IS

FOR FANUC M-900B/400L ROBOT
A PAINT SPECIFICATIONS
1. BEAMS: RAL 7035 SHERWIN WILLIAMS
-
420
2. CARRIAGES: RAL 2011/SW 4083 SHERWIN WILLIAMS
-
370
350 3. CONTROL PANEL: -
-
270
220
TECHNICAL INFORMATION
CENTRAL LUBRICATION
FILLED WITH H1 GREASE VELOCITY (m/s) ACCELERATION (m/s )
2
X-AXIS 1.00 1.00

FRONT OF ROBOT Y-AXIS N/A N/A
Z-AXIS N/A N/A
0 1200 LOAD 3550 Kg. (Includes Load and End Effector)
MTG PATTERN
WARRANTY SUBJECT TO CATALOG SPECIFICATIONS AND APPLICATION ANALYSIS
75
220
270
600
350
370
1027.3 40.4
O.A. HEIGHT
MTG PATTERN 597 23.5

17.5 48
M20 - 6H 37 TOP of CARRIAGE/
RISER MTG.
10-12 DEEP
(11) HOLES
875
506
380
230
200
235
270
340
1450
DETAIL B
A SCALE 1 : 5
1034
1209 47.6 O.A. WIDTH

VIEW A-A
SCALE 1 : 10
2200
MTG PATTERN MTG PATTERN X-AXIS GEARBOX AE120 i=13.33 FOR

FANUC MOTOR # αis30/4000
(MOTOR SUPPLIED BY CUSTOMER)
22300
300 2480
B
R30
300
CABLE PORT
10237 E-Chain Mounting
24000 944.9 E-CHAIN GUIDE O.A.LENGTH

1180
25460.97 O.A. LENGTH A

X-AXIS E-CHAIN
22300 MAX X-AXIS STROKE 1450 CARRIAGE PLATE 105 IGUS# H4-56-30-300-0
75 O.T. 300 2480 75 O.T. (146) LINKS PER CARRIAGE.
DIVIDERS EVERY OTHER LINK
R300
150
17.5 32 17.5
400 R20 400
180 180 A
1200 1200 1200 1200 1200 1200 400 1200 1200 1200 1200 1200 1200 400 1200 1200 1200 1200 1200 1200 400
23960 O.A. FRAME LENGTH 1467
300 CABLE PORT
409 403 56.1 421-75 402
2 7 9
56
1 3 4 6
5 8 GUDEL: JACKSCREW: M56x3
HEXNUT: M56x3
BASE PLATE: 140 X 20
(ANCHOR SUPPLIED BY CUSTOMER)
45 57 32
41
Position Description Ø [inch]
1 Aux Power 1.11 129
2 Ground 0.31 30 all dimensions are Letzte Änderung / Last revision Gewicht ca. Material
Weight approx. Material
Dieses Dokument ist Eigentum der Firma Güdel AG und darf ohne schrift-
This document is property of Güdel AG and should not be reproduced nor

3 Motor Power 1.39
liche Genehmigung weder vervielfältigt noch irgendwelchen Drittpersonen

A/05.01.15/erisch
METRIC 7210.63 kg Ursprung
4 Motor Power 1.39 third angle projection except where noted Änd. Nr/Rev.ID. Origin
5 Air 0.78 Massstab/Scale Gezeichnet
distributed to any third party without prior written consent.

20 JMP Automotive 14-1898 Detailed 10/20/14 197us
6 Feedback 1.13 1:20 Geprüft
7 Lube I/O 0.27
oder Drittfirmen zugänglich gemacht werden.

bei / for Roll 60 Checked
8 Aux Encoder 0.5 140

TMF-4 Assembly
Blätter / Sheets BUS Nr.
BUS No.
9 Ethernet 0.26 1/1 Artikel-Nr.
DETAIL C Article No.
END VIEW OF X-AXIS E-CHAIN SCALE 1 : 5
IGUS E4-42-30-350-0
SCALE 1:2 60-00141898-001 A
1/16/2015 / Page 5 of 5
BUS033306 6001794 TMF Cable Assy for M-900 ,18m -

1 EWS-11545-M018 M7PBE 7th Axis Pwr Ext Cbl 18m EWS-11545-XXXX 1 EA E
2 EWS-11548-M018 GE Ground Extension Cable 18m EWS-11548-XXXX 1 EA E
3 EWS-11550-M018 M1E Motor Power Extension Cable EWS-11550-XXXX 1 EA E

18m (59.05ft)
4 EWS-11551-M018 M2E Motor Power 2nd Extension Cable EWS-11551-XXXX 1 EA E
18m (59.05')
5 SPAR252X Parker 83FR-8-BLU-RL 60 FT E
6 EWS-11541-M018 F1E-Feedback Extension Cable 18 m EWS-11541-XXXX 1 EA E
7 SLUM218X Lumberg RST4-RKT4-602/20M 1 EA E

8 EWS-11544-M018 M7FE 7th Axis Feedback Extension EWS-11544-XXXX 1 EA E
Cable 18m
9 SLUM350X Ethernet M12 Patch 20M 0985 706 100/20M 1 EA E

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COMPONENTS MODULES ROBOTICS SYSTEMS

TMF Size 1-4

Translation of the original operating manual

phone +41 (0)62 916 91 91

Version Date Specification / Description

a 21.05.2012 Basic version

Tab. 0-1 Revision history

3.2 Hazard symbols and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.2.2 Hazard symbols on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.4.5 Transport securing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.3.5 Setting rollers and tooth flank backlash . . . . . . . . . . . . . . . . . . . . . . 90

9 Decommissioning, storage . . . . . . . . . . . . . . . . . . . . . . . . . 107

11 Spare part supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

11.2 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

1.1 Further applicable documentation

1.2 Purpose of the document

uct! It contains important information for your personal safety.

1.3 Target readership

1.4 Explanation of symbols/abbreviations

 For cross-reference Page

Tab. 1-1 Explanation of symbols/abbreviations

1.5 Torque tables

1.5.1 Tightening torques for screws

Tightening torque [Nm]

M3 1.1 1.7 2.0

M27 915 1304 1526

Tightening torque [Nm]

1.5.2 Tightening torques for HV sets

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

Tightening torque [Nm]

M12 100 120

Tab. 1-4 Tightening torques: HV sets

1.5.3 Tightening torques for roller holder

Fig. 1-1 Tightening torques for roller holders

A Move roller with hexagonal socket wrench (tightening torque A1)

The following tightening torques apply to roller holders:

Tightening torque [Nm]

Tab. 1-5 Tightening torques: Roller holders

1.5.4 Tightening torques for roller support

A Roller supports size 72 and 90

The following tightening torques apply to roller supports:

Tightening torque [Nm]

Tab. 1-6 Tightening torques: Roller supports

1.6 Thread rolling screws

Tightening torque [Nm]

Tab. 1-7 Tightening torques for thread rolling screws

2.1.1 Intended use

2.1.2 Non-intended use

The TMF product is not intended for:

• Movement of poisonous goods

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

Do not modify the product in any way.

2.2 Product designation

Fig. 2-1 Type plate

In the declaration of conformity and declaration of incorporation, the terms are

Fig. 2-2 Position of the type plate

2.3 Technical Data

Transport -10 to +60°C

In general, in these operating instructions the complete covering option is called

mentation in the same chapter under "Options".

3.1.1 Product safety

3.1.2 Operating personnel

3.1.3 Failure to comply with safety regulations